Yale G807 ERP 15-20 VT (ERP 30- 40VT) Service Manual - PDF DOWNLOAD by www.heydownloads.com

Maintenance

AC MOTOR REPAIR ERP15-20VT (ERP030-040VT) [G807]; ERP1620VF (ERP30-40VF) [A955]; ERC22-35VG (ERC045070VG) [A968]; ERC16-20VA (ERC030-040VA) [A969]; ERP22-35VL (ERP045-070VL) [A976]; ESC030AC, ESC035AC, ESC040AC [B883]

PART NO. 524327049

620 YRM 1385

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. • Keep the unit clean and the working area clean and orderly. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

AC Motor Repair

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883)...................................................... Discharging the Capacitors (All Other Models) ............................................................................................... Traction Motor Repair .......................................................................................................................................... For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883) ............................................................................................................................ Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Electrical Connector Repair or Replacement.............................................................................................. Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Install .......................................................................................................................................................... For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969).............. Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Electrical Connector Repair or Replacement.............................................................................................. Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Install .......................................................................................................................................................... For Lift Truck ERP2.2-3.5VL (ERP045-070VL) (A976) ................................................................................... Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Install .......................................................................................................................................................... Hydraulic Motor Repair........................................................................................................................................ For Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883) ................................................................................................................................... Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Electrical Connector Repair or Replacement.............................................................................................. Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Install .......................................................................................................................................................... For Lift Truck ERC22-35VG (ERC045-070VG) (A968).................................................................................... Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Electrical Connector Repair or Replacement.............................................................................................. Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Install .......................................................................................................................................................... For Lift Truck Models ERP2.2-3.5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) ............................................................................................................................................................. Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Electrical Connector Repair or Replacement..............................................................................................

1 5 6 7 7 7 8 10 10 10 10 11 14 14 14 17 17 17 18 18 18 18 18 20 20 21 21 21 21 21 22 23 24 24 25 27 28 28 29 30 31 31 32 33 34 34 34 38

Table of Contents

AC Motor Repair

TABLE OF CONTENTS (Continued) Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Install .......................................................................................................................................................... Torque Specifications .......................................................................................................................................... Traction Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) ............................................................................................................................................................. Traction Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968)and ERC16-20VA (ERC030-040VA) (A969)................................................................................................................................. Traction Motor for Lift Truck ESC030-040AC (B883)....................................................................................... Hydraulic Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955)..................................................................................................................................... Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968)........................................................... Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) ........................................................... Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969)............................................................ Hydraulic Motor for Lift Truck ESC030-040AC (B883) .................................................................................... This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]; ERC22-35VG (ERC045-070VG) [A968]; ERC16-20VA (ERC030-040VA) [A969]; ERP22-35VL (ERP045-070VL) [A976]; ESC030AC, ESC035AC, ESC040AC [B883]

38 39 39 42 44 44 44 44 44 44 44 44 44

620 YRM 1385

General

General This section contains repair and maintenance procedures for the AC motors. Additional information concerning the motors may be more closely related to other systems and included in those sections. Sections that contain information regarding the motors include:

NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag to the steering wheel and remove the key from the key switch.

Electrical System 2200 YRM 1337 for lift truck models: • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955)

Throughout this section, forward will refer to travel in the direction of the forks and left and right will be determined by sitting in the seat facing forward. See Figure 1 or Figure 2. Troubleshooting information about the traction motors is available through on-board diagnostics and may be displayed on the dash display. Refer to one of the following sections for further explanation of dash display codes concerning the motors:

Electrical System 2200 YRM 1369 for lift truck models: • ERC22-35VG (ERC045-070VG) (A968) • ERP22-35VL (ERP045-070VL) (A976) • ERC16-20VA (ERC030-040VA) (A969) Electrical System 2200 YRM 1414 for lift truck models: • ESC030-040AC (B883) Periodic Maintenance 8000 YRM 1373 for lift truck models: • ERP16-20VF (ERP30-40VF) (A955) Periodic Maintenance 8000 YRM 1339 for lift truck models: • ERP15-20VT (ERP030-040VT) (G807)

User Interface, Service-Level Functions On-Board Dash Display 2200 YRM 1417 for lift truck models: • ESC030-040AC (B883) User Interface, Service Technician 2200 YRM 1336 • ERP16-20VF (ERP30-40VF) (A955) • ERP15-20VT (ERP030-040VT) (G807) • ERC22-35VG (ERC045-070VG) (A968) • ERP22-35VL (ERP045-070VL) (A976) • ERC16-20VA (ERC030-040VA) (A969)

Periodic Maintenance 8000 YRM 1364 for lift truck models: • ERC22-35VG (ERC045-070VG) (A968) Periodic Maintenance 8000 YRM 1372 for lift truck models: • ERP22-35VL (ERP045-070VL) (A976) Periodic Maintenance 8000 YRM 1418 for lift truck models: • ESC030-040AC (B883) Periodic Maintenance 8000 YRM 1442 for lift truck models • ERC16-20VA (ERC030-040VA) (A969)

WARNING DO NOT make repairs or adjustments unless you are properly trained and have authorization to do so. Repairs and adjustments that are not correct can create dangerous operating conditions. DO

A. LEFT SIDE B. RIGHT SIDE

C. FORWARD TRAVEL

Figure 1. Truck Orientation (Three-Wheel Models)

General

620 YRM 1385

Legend for Figure 3 1. LEFT TRANSAXLE 2. TRACTION MOTOR 3. RIGHT TRANSAXLE For the following lift truck models, the hydraulic pump motor is mounted inside the counterweight: • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) • ERP22-35VL (ERP045-070VL) (A976) See Figure 4 and Figure 5.

A. LEFT SIDE B. RIGHT SIDE

C. FORWARD TRAVEL

Figure 2. Truck Orientation (Four-Wheel Models) The traction motors are mounted onto the transaxles for the following lift truck models: • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) • ERP22-35VL (ERP045-070VL) (A976)

The traction motor is mounted under the frame to the drive axle for the following lift truck models: • ERC22-35VG (ERC045-070VG) (A968) • ERC16-20VA (ERC030-040VA) (A969) See Figure 6 for lift truck models • ERC22-35VG (ERC045-070VG) (A968) See Figure 7 for lift truck models • ERC16-20VA (ERC030-040VA) (A969)

See Figure 3 for lift truck models • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) See Figure 5 for lift truck models • ERP22-35VL (ERP045-070VL) (A976)

1. HYDRAULIC PUMP MOTOR 2. COUNTERWEIGHT

Figure 3. Traction Motors for Lift Truck ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955)

Figure 4. Hydraulic Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955)

620 YRM 1385

1. LEFT TRACTION MOTOR 2. RIGHT TRACTION MOTOR 3. RIGHT TRANSMISSION

General

4. LEFT TRANSMISSION 5. HYDRAULIC PUMP AND MOTOR

Figure 5. Traction Motor and Hydraulic Pump Motor for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) The hydraulic pump motor is mounted onto the frame beside the traction motor for the following lift truck models: • ERC22-35VG (ERC045-070VG) (A968)

The hydraulic pump motor is mounted onto the frame, opposite the traction motor on the following lift truck models • ERC16-20VA (ERC030-040VA) (A969)

See Figure 6.

See Figure 7.

General

620 YRM 1385

1. HYDRAULIC PUMP MOTOR 2. TRACTION MOTOR 3. FRAME

Figure 6. Traction Motor and Hydraulic Pump Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) The traction motors are mounted onto the transaxles and the hydraulic pump motor is mounted vertically to the front wall behind the front cover for the following lift truck models: • ESC030-040AC (B883) 1. FRAME 2. TRACTION MOTOR 3. HYDRAULIC PUMP MOTOR

Figure 7. Traction Motor and Hydraulic Pump Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969)

620 YRM 1385

DISCHARGING THE CAPACITORS FOR LIFT TRUCK MODELS ESC030-040AC (B883) WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the battery. Disconnect the battery and allow the capacitors to discharge before opening any compartment covers or inspecting or repairing the electrical system. DO NOT place tools on top of the battery. If a tool causes a short circuit, the high current flow from the battery can cause personal injury or property damage. Some checks and adjustments are performed with the battery connected. DO NOT connect the battery until the procedure instructs you to do so. Never wear any metallic items on your fingers, arms, or neck. Metal items can accidentally make an electrical connection and cause injury.

General 3. Block the lift truck so the drive wheels are off the floor to prevent lift truck from moving. 4. Remove the electrical compartment cover to access the lift controller. NOTE: The lift and traction controllers are wired parallel. Connecting the resistor across the lift controller will also discharge capacitors in the traction controllers if they are properly connected. 5. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the lift controller’s negative (B ) and positive (B+) terminals. Wait at least 20 seconds to be sure that the capacitors are fully discharged. See Figure 8. 6. If necessary to discharge the traction controllers separately from the lift controller, connect a 200ohm, 2-watt resistor across the controller’s negative (B ) and positive (B+) terminals. Wait at least 20 seconds to be sure that the capacitors are fully discharged. Repeat for the other traction controller as necessary. See Figure 9.

Before performing any tests or adjustments, block the lift truck to prevent unexpected movement. The capacitor in the transistor controller(s) can hold an electrical charge after the battery is disconnected. To prevent an electrical shock and personal injury, discharge the capacitor(s) before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. 1. To avoid injury and prevent electrical shock, perform the following steps (Step 2 through Step 7 below) to discharge the capacitors before troubleshooting, making adjustments or repairs, or connecting or disconnecting a PC service tool: 2. Turn the key or keyless switch to the OFF position and DISCONNECT THE BATTERY by pushing forward on the battery disconnect lever.

1. 2. 3. 4.

B TERMINAL B+ TERMINAL JUMPER LEADS 200-OHM, 2-WATT RESISTOR

Figure 8. Lift Controller

General

620 YRM 1385 place tools on top of the battery. If a tool causes a short circuit, the high current flow from the battery can cause personal injury or property damage. Some checks and adjustments are performed with the battery connected. DO NOT connect the battery until the procedure instructs you to do so. Never wear any metallic items on your fingers, arms, or neck. Metal items can accidentally make an electrical connection and cause injury. Before performing any tests or adjustments, block the lift truck to prevent unexpected movement. The capacitors in the transistor controller(s) can hold an electrical charge for about 10 seconds after the battery is disconnected. To prevent an electrical shock and personal injury, discharge the capacitor(s) before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected. DO NOT short across the motor controller terminals with a screwdriver or jumper wire.

1. 2. 3. 4.

B+ TERMINAL B TERMINAL JUMPER LEADS 200-OHM, 2-WATT RESISTOR

Figure 9. Traction Controller 7. Remove the resistor from the controller(s) and reinstall the covers before returning the lift truck to service.

DISCHARGING THE CAPACITORS (ALL OTHER MODELS) WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the battery. Disconnect the battery and discharge the capacitors before opening any compartment covers or inspecting or repairing the electrical system. DO NOT

Make certain the Emergency-Stop Switch has not been activated. This will isolate the controller and prevent the capacitors from discharging properly. The proper way to disconnect the battery is by separating the battery connectors. 1. Ensure the capacitors are discharged by performing Step 2 through Step 6 below. 2. Turn key or keyless switch to OFF position. 3. Disconnect the battery by separating the connectors. 4. Block drive wheels to prevent lift truck from moving. 5. Make sure the Emergency-Stop Switch HAS NOT been activated. If the Emergency-Stop Switch is activated, rotate the switch to the right until it pops up. 6. Wait at least 10 seconds to be sure that the capacitors are fully discharged.

620 YRM 1385

Traction Motor Repair

Traction Motor Repair FOR LIFT TRUCK MODELS ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), AND ESC030-040AC (B883)

3. Put lift truck on blocks so that the drive tires are suspended off the floor. See one of the following sections for procedures: Periodic Maintenance 8000 YRM 1339 for lift truck models: • ERP15-20VT (ERP030-040VT) (G807)

Remove NOTE: The procedures described in this section apply to both right and left traction motors.

Periodic Maintenance 8000 YRM 1373 for lift truck models: • ERP16-20VF (ERP30-40VF) (A955)

NOTE: Step 1 does not apply to ESC030-040AC (B883). lift truck models.

Periodic Maintenance 8000 YRM 1418 for lift truck models: • ESC030-040AC (B883)

1. Disconnect manual release cable from parking brake. 2. Disconnect parking brake wire harness from main wire harness. See Figure 10.

1. 2. 3. 4. 5. 6.

TRANSAXLE PARKING BRAKE WIRE HARNESS SOCKET HEAD CAPSCREW LOCKWASHER WASHER PARKING BRAKE

4. Turn the key or keyless switch to OFF position and disconnect the battery.

7. 8. 9. 10. 11.

TRACTION MOTOR SPLINED HUB SNAP RING WOODRUFF KEY TRACTION MOTOR MOUNTING CAPSCREW

Figure 10. Transaxle Assembly

Traction Motor Repair

620 YRM 1385

5. Remove transaxle/traction motor/parking brake assembly from lift truck. See one of the following sections for removal instructions: Transaxle 1300 YRM 1330 for lift truck models: • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) Transaxle 1300 YRM 1411 for lift truck models: • ESC030-040AC (B883) 6. Move transaxle/traction motor/parking brake assembly to a bench or other suitable work surface. NOTE: Note placement and orientation of parking brake prior to removal to aid in installation. 7. Remove four socket head capscrews, lockwashers, washers and parking brake from traction motor shaft. See Figure 10. 8. Remove snap ring and splined hub from traction motor shaft; recover woodruff key. See Figure 10.

WARNING The traction motor weighs approximately 18.4 kg (40.6 lb). Make sure lifting device has enough lifting capacity to safely lift motor. NOTE: Use an approved lifting device to hold and lift traction motor during removal. 9. Remove four traction motor mounting capscrews, washers, and traction motor from transaxle. See Figure 10.

Disassemble 1. Remove four socket-head capscrews and lockwashers from brake end head and transaxle end head. See Figure 11. NOTE: Carefully tap underside of brake end head with a soft hammer to loosen brake end head from stator. 2. Remove brake end head from stator and slide brake end head off rotor shaft. See Figure 11. 3. Remove rotor from stator. See Figure 11. Place stator brake end down on workbench. NOTE: Carefully tap underside of transaxle end head with a soft hammer to loosen transaxle end head from stator. 4. Remove transaxle end head from stator. See Figure 11. 5. Remove snap ring from brake end head. See Figure 11. 6. Using bearing puller, carefully remove bearing from brake end head. See Figure 11. NOTE: Perform Step 7 and Step 8 if connection plate is damaged and must be replaced. 7. Remove temp sensor wire harness from grommet. See Figure 11. 8. Remove screws, nuts, washers, grommet, and connection plate from stator. See Figure 11.

Legend for Figure 11 1. TRANSAXLE END HEAD 2. ROTOR 3. SOCKET-HEAD CAPSCREW AND LOCKWASHER 4. STATOR, TERMINALS, AND HARDWARE 5. CONNECTION PLATE, SCREW, AND GROMMET

6. BRAKE END HEAD 7. TEMP SENSOR CONNECTOR AND WIRING HARNESS 8. SNAP RING 9. BEARING

620 YRM 1385

Traction Motor Repair

Figure 11. Traction Motor

Traction Motor Repair

Electrical Connector Repair or Replacement

620 YRM 1385 b. Place the other DMM probe on terminal V. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the cables from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the motor windings in the stator have burned open and the motor must be repaired or replaced.

1. If necessary, electric brake connector (see Figure 10) may be repaired or replaced. See Deutsch Connectors section of Wire Harness Repair 2200 YRM 1128 manual for instructions. 2. If necessary, temp sensor connector (see Figure 11) may be repaired or replaced. See AMP Superseal Connector Assemblies section of Wire Harness Repair 2200 YRM 1128 manual for instructions.

c. Place one DMM probe on terminal V. d. Place the other DMM probe on terminal W. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the cables from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the motor windings in the stator have burned open and the motor must be repaired or replaced.

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures. 1. Clean components with a clean cloth moistened with solvent and allow to thoroughly dry. DO NOT apply liquid solvent directly to stator windings.

Inspect 1. Inspect rotor and inside of stator for marks or grooves indicating contact between rotor and stator. Replace if damaged. 2. Check that the bearings roll smoothly and are not loose from excessive wear. Replace as necessary. Replace the bearings regardless of condition if motor has been subjected to thermal overload (see Step 3). In case of a catastrophic bearing failure, damage may result to other motor components and possibly to transaxle. 3. Check stator windings for signs of thermal overload. Signs of thermal overload are dark-stained, brittle, or burnt insulation. Thermal overload will shorten the life of the stator. 4. Check stator windings resistance as indicated below. To measure continuity between U, V, and W terminals of motor use a digital multi-meter (DMM) set to Ohms. a. Place one DMM probe on terminal U.

e. Place one DMM probe on terminal W. f.

Place the other DMM probe on terminal U. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the cables from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the motor windings in the stator have burned open and the motor must be repaired or replaced.

NOTE: A likely cause of motor contamination may be from a damaged input bearing seal on the transaxle. 5. Check for signs of oil or other contaminants within the motor. If contaminants are present, locate source and take corrective action.

Assemble 1. Install transaxle end head onto stator. See Figure 12. 2. Install rotor into stator with drive splines protruding through transaxle end head. See Figure 12. NOTE: Perform Step 3 through Step 5 if connection plate and hardware was removed. 3. If removed, install connection plate, grommet, washers, and nuts onto stator. See Figure 13.

620 YRM 1385

Traction Motor Repair head. See Figure 13. Tighten capscrews to 14 to 16 N•m (124 to 142 lbf in).

Install WARNING The traction motor weighs approximately 18.4 kg (40.6 lb). Make sure lifting device has enough lifting capacity to safely lift motor. NOTE: Use an approved lifting device to lift and hold traction motor during install. Use caution when installing motor to transaxle not to damage transaxle shaft seal.

1. 2. 3. 4.

TRANSAXLE END HEAD STATOR ROTOR DRIVE SPLINES

Figure 12. Transaxle End Head, Stator and Rotor NOTE: Terminal studs are located on top of connection plate. 4. Hold lower nut of terminal stud to prevent it from turning and tighten upper nut to 12 N•m (106 lbf in). See Figure 14. 5. Insert temp sensor wire harness into grommet. See Figure 13.

CAUTION Use an arbor press and a proper size driver when installing bearings to avoid damage to bearings and/or end shields. Press only on the outer race of the bearing. 6. Carefully install bearing into brake end head. See Figure 13. 7. Install snap ring into brake end head. See Figure 13. 8. Install brake end head onto rotor shaft and stator. See Figure 13. 9. Install four lockwashers and socket-head capscrews onto transaxle end head and brake end

1. Apply Dexron III transmission fluid to drive splines of traction motor and install traction motor onto transaxle. 2. Apply Loctite® 271 to four traction motor mounting capscrews. 3. Install four washers and traction motor mounting capscrews into traction motor and transaxle. See Figure 15. Tighten capscrews to 48 N•m (35 lbf ft). 4. Install splined hub and woodruff key (with counterbore facing up) onto traction motor shaft. See Figure 15. 5. Install snap ring onto traction motor shaft. See Figure 15. NOTE: Close clearances require parking brake to be installed after traction motor is installed to transaxle. Parking brake mechanical release arm must be in vertical position when installed. 6. Install parking brake onto splined hub. See Figure 15. 7. Install four washers, lockwashers, and socket-head capscrews into parking brake and brake end head of traction motor. See Figure 15. 8. Connect parking brake wire harness to main wiring harness. See Figure 15. NOTE: Step 9 does not apply to ESC030-040AC (B883) lift truck models. 9. Connect manual release cable to parking brake.

Traction Motor Repair

620 YRM 1385

Figure 13. Traction Motor

620 YRM 1385

Traction Motor Repair

Legend for Figure 13 1. TRANSAXLE END HEAD 2. ROTOR 3. SOCKET-HEAD CAPSCREW AND LOCKWASHER 4. STATOR, TERMINALS, AND HARDWARE 5. CONNECTION PLATE, SCREW, AND GROMMET

6. BRAKE END HEAD 7. TEMP SENSOR CONNECTOR AND WIRING HARNESS 8. SNAP RING 9. BEARING

10. Complete installation of transaxle into lift truck. See one of the following manuals for instructions: Transaxle 1300 YRM 1330 for lift truck models: • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) Transaxle 1300 YRM 1411 for lift truck models: • ESC030-040AC (B883) 11. Lower the lift truck from the blocks. Refer to one of the following manuals for procedures: Periodic Maintenance 8000 YRM 1339 for lift truck models: • ERP15-20VT (ERP030-040VT) (G807) Periodic Maintenance 8000 YRM 1373 for lift truck models: • ERP16-20VF (ERP30-40VF) (A955) Periodic Maintenance 8000 YRM 1418 for lift truck models: • ESC030-040AC (B883)

1. TERMINAL STUD 2. LOWER NUT

3. UPPER NUT

Figure 14. Terminal Studs and Nuts

12. Connect battery connector and turn key or keyless switch to the ON position. Remove the blocks from the wheels. Test for proper operation.

Traction Motor Repair

1. 2. 3. 4. 5.

620 YRM 1385

TRANSAXLE PARKING BRAKE WIRE HARNESS SOCKET-HEAD CAPSCREW LOCKWASHER WASHER

6. 7. 8. 9. 10.

PARKING BRAKE TRACTION MOTOR SPLINED HUB SNAP RING CAPSCREW

Figure 15. Transaxle Assembly

FOR LIFT TRUCK ERC22-35VG (ERC045-070VG) (A968) AND ERC16-20VA (ERC030-040VA) (A969) Remove 1. Remove traction motor from lift truck. See Frame 100 YRM 1342 for instructions.

CAUTION The traction motor can weigh as much as 136 kg (300 lb). To prevent injury, use a lifting device capable of lifting the assembly. 2. Place traction motor on level blocks on a flat surface with drive end pointing down. Remove floor jack.

Disassemble 1. Remove capscrew M6, lockwasher, and speed sensor from non-drive end head. See Figure 16.

2. Remove long socket-head capscrew, lockwasher, sensor connector cover bracket, and sensor connector tab bracket from stator housing above sensor cable outlet. See Figure 16. 3. Remove five capscrews, lockwashers, and washers from stator Z-nuts and non-drive end head. See Figure 16. 4. Gently tap under non-drive end head and remove from stator housing. See Figure 16. 5. Pull sensor cable outlet from stator housing (see Figure 16) and disconnect speed sensor and temperature sensor connectors. 6. Using a bearing puller, remove and discard proximity sensor wheel from non-drive end head. See Figure 17.

620 YRM 1385

Traction Motor Repair

A. NON-DRIVE END

B. DRIVE END

1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15.

SPEED SENSOR CAPSCREW M6 LOCKWASHER NON-DRIVE END HEAD LONG SOCKET-HEAD CAPSCREW SENSOR CONNECTOR COVER BRACKET SENSOR CONNECTOR TAB BRACKET STATOR HOUSING

SENSOR CABLE OUTLET CAPSCREW WASHER STATOR Z-NUT AMP SUPERSEAL TAB ASSEMBLY TAB CONTACT WIRE SEAL

Figure 16. Traction Motor Non-Drive End Head NOTE: When replacing one bearing, it is strongly recommended to replace both bearings. NOTE: Note orientation of bearing components during disassembly to aid in assembly. 7. Using bearing puller, remove bearing from non-drive end head. See Figure 17. 8. Remove bearing preload spring from non-drive end head. See Figure 17. 9. Remove three hex-head bolts, spring washers, terminal flags, terminal covers, terminal blocks, and special nuts from stator housing on non-drive end. See Figure 18. 10. Remove five capscrews, lockwashers, and washers from Z-nuts on stator housing and drive end head. See Figure 18.

1. PROXIMITY SENSOR WHEEL 2. NON-DRIVE END HEAD

3. BEARING 4. BEARING PRELOAD SPRING

Figure 17. Traction Motor Non-Drive End Head Bearing

Traction Motor Repair

620 YRM 1385

11. Attach approved lifting device to stator housing and slowly lift straight up, removing it from rotor assembly and drive end head. See Figure 18. 12. Screw lifting eye into threaded hole in end of rotor assembly. Attach approved lifting device and lift rotor assembly straight up from drive end head. See Figure 19.

NOTE: Note orientation of bearing components prior to disassembly to aid in assembly. 13. Using bearing puller, remove bearing from drive end head. See Figure 19. 14. Remove and discard shaft seal from drive end head. See Figure 19.

NOTE: When replacing one bearing, it is strongly recommended to replace both bearings.

1. 2. 3. 4. 5. 6. 7.

HEX-HEAD BOLT SPRING WASHER TERMINAL FLAG TERMINAL COVER TERMINAL BLOCK STATOR HOUSING CAPSCREW

8. 9. 10. 11. 12. 13.

LOCKWASHER WASHER DRIVE END HEAD ROTOR ASSEMBLY STATOR Z-NUT SPECIAL NUT

Figure 18. Traction Motor Drive End Head

620 YRM 1385

Traction Motor Repair damage may result to other motor components and possibly to transaxle. 3. Check stator windings for signs of thermal overload. Signs of thermal overload are dark-stained, brittle, or burnt insulation. Thermal overload will shorten the life of the stator. 4. Check motor windings resistance as indicated below. To measure continuity between U, V, and W terminals of motor use a digital multi-meter (DMM) set to Ohms. a. Place one DMM probe on terminal U. b. Place the other DMM probe on terminal V.

1. SHAFT SEAL 2. ROTOR ASSEMBLY

Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the cables from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the motor windings in the stator have burned open and the motor must be repaired or replaced.

3. DRIVE END HEAD 4. BEARING

Figure 19. Traction Motor Rotor Assembly and Drive End Head

Electrical Connector Repair or Replacement 1. If necessary, AMP Superseal tab assembly, tab contact, and wire seal (see Figure 16) may be repaired or replaced. See AMP Superseal Connector Assemblies section of Wire Harness Repair 2200 YRM 1128 manual for instructions.

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures. 1. Clean components with a clean cloth moistened with solvent and allow to air dry. DO NOT apply liquid solvent directly to components.

Inspect 1. Inspect rotor assembly and inside of stator housing for marks or grooves indicating contact between rotor and stator. Replace if damaged. 2. Check that the bearings roll smoothly and are not loose from excessive wear. Replace as necessary. Replace the bearings regardless of condition if motor has been subjected to thermal overload (see Step 3). In case of a catastrophic bearing failure,

e. Place one DMM probe on terminal W. f.

5. Check terminal flags for cracks or other damage. Replace if damaged. 6. Check for signs of oil or other contaminants within motor. If necessary, locate source of contaminants and take corrective action. 7. Inspect all other components and replace as necessary.

Traction Motor Repair

Assemble 1. Using a seal driver, install new shaft seal into drive end head. See Figure 19.

CAUTION Use an arbor press and a proper size driver when installing bearings to avoid damage to bearings and/or end shields. Press only on the outer race of the bearing. Always replace bearings in sets. 2. Install bearing into drive end head as noted during disassembly. See Figure 19. 3. Screw lifting eye into threaded hole in the end of rotor assembly. Attach approved lifting device and lower rotor assembly onto drive end head. Ensure bearing is fully seated against drive end head. See Figure 19. 4. Remove lifting device and lifting eye from rotor assembly. NOTE: Make sure holes for stator Z-nuts are aligned with capscrew holes. 5. Using approved lifting device, lower stator housing onto drive end head. See Figure 18. 6. Install five washers, lockwashers, and capscrews into drive end head and stator Z-nuts on stator housing. See Figure 18. Tighten capscrews to 25 to 30 N•m (18 to 22 lbf ft). 7. Install three special nuts, terminal blocks, terminal covers, terminal flags, spring washers, and hexhead bolts onto stator housing, non-drive end. See Figure 18. 8. Install bearing preload spring into non-drive end head. See Figure 17. 9. Install bearing into non-drive end head as noted during disassembly. See Figure 17. 10. Install new proximity sensor wheel into non-drive end head. See Figure 17. 11. Place sensor cable outlet into position on stator housing (see Figure 16). Connect proximity sensor and temperature sensor connectors to sensor cable outlet.

620 YRM 1385 12. Install non-drive end head onto stator housing. See Figure 16. 13. Install five washers, lockwashers, and capscrews into non-drive end head and stator Z-nuts on stator housing. See Figure 16. Tighten capscrews to 25 to 30 N•m (18 to 22 lbf ft). 14. Install sensor connector tab bracket, sensor connector cover bracket, lockwasher, and long sockethead capscrew onto stator housing over sensor cable outlet. See Figure 16. 15. Install speed sensor, lockwasher, and capscrew M6 onto non-drive end head and stator housing. See Figure 16.

Install 1. Install traction motor onto drive axle. See Frame 100 YRM 1342 for installation instructions.

FOR LIFT TRUCK ERP2.2-3.5VL (ERP045-070VL) (A976) Remove NOTE: The procedures described in this section apply to both right and left traction motors. 1. Remove transaxle assembly from lift truck. See Transaxle 1300 YRM 1370 for instructions. 2. Remove service and parking brake components from traction motor housings. See Transaxle 1300 YRM 1370 for instructions. 3. Remove the AC motor to be repaired from the output housing. See Transaxle 1300 YRM 1370 for instructions.

Disassemble 1. Remove nine nuts and washers from terminals on connection plate. See Figure 20. 2. Remove two screws and connection plate from stator housing. See Figure 20. 3. Remove and discard front shaft seal from brake end bell. See Figure 20.

620 YRM 1385

1. 2. 3. 4. 5. 6. 7. 8.

TERMINAL NUT WASHER CONNECTION PLATE SCREW FRONT SHAFT SEAL REAR SHAFT SEAL SNAP RING

Traction Motor Repair

9. 10. 11. 12. 13. 14. 15. 16.

BRAKE END BELL O-RING BEARING ROTOR STATOR WAVE WASHER STATOR HOUSING DOWEL PINS

Figure 20. Traction Motor

Traction Motor Repair

620 YRM 1385

4. Remove and discard rear shaft seal from stator housing. See Figure 20. 5. Remove snap ring from rotor at brake end bell. See Figure 20. NOTE: Use threaded holes on the brake end bell to move the end bell away from the stator housing. 6. Remove six screws, dowel pins if present, and brake end bell from stator housing. Remove and discard O-ring. See Figure 20. 7. Remove snap ring from inside brake end bell. See Figure 20. 8. Carefully remove bearing from brake end bell. See Figure 20.

Step 3). In case of a catastrophic bearing failure, damage may result to other motor components and possibly to transaxle. 3. Check stator windings for signs of thermal overload. Signs of thermal overload are dark-stained, brittle, or burnt insulation. Thermal overload will shorten the life of the stator. 4. Check motor windings resistance as indicated below. To measure continuity between U, V, and W terminals of motor use a digital multi-meter (DMM) set to Ohms. a. Place one DMM probe on terminal U. b. Place the other DMM probe on terminal V. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the cables from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the motor windings in the stator have burned open and the motor must be repaired or replaced.

NOTE: Bearing will remain with rotor during removal. 9. Remove rotor from stator housing. See Figure 20. 10. Carefully remove bearing from rotor. ure 20.

See Fig-

11. Carefully remove stator from stator housing. See Figure 20. Take care not to damage power leads.

c. Place one DMM probe on terminal V. d. Place the other DMM probe on terminal W.

12. Remove wave washer from stator housing. See Figure 20.

e. Place one DMM probe on terminal W. f.

620 YRM 1385

Hydraulic Motor Repair

Assemble NOTE: The procedures described in this section apply to both right and left traction motors. 1. Install wave washer in stator housing. See Figure 20. 2. Carefully install stator into stator housing. See Figure 20. Take care not to damage power leads.

CAUTION Use an arbor press and a proper size driver when installing bearings to rotor to avoid damage to bearing. Press only on the INNER race of the bearing. Always replace bearings in sets. 3. Install bearing onto rotor. See Figure 20. 4. Install rotor into stator and stator housing. See Figure 20.

CAUTION Use an arbor press and a proper size driver when installing bearings to avoid damage to bearing. Press only on the OUTER race of the bearing. Always replace bearings in sets. 5. Install bearing into brake end bell. See Figure 20. 6. Install snap ring on inside brake end bell. See Figure 20. 7. Install new O-ring on the brake end bell. Install the brake end bell dowel pins and six screws into

stator housing. Tighten the six screws to 23 N•m (204 lbf in). See Figure 20. 8. Install snap ring on rotor at brake end bell. See Figure 20. 9. Install new rear shaft seal into stator housing. See Figure 20. 10. Install new front shaft seal into brake end bell. See Figure 20. 11. Using two screws, install connection plate on stator housing. Tighten screws to 3 N•m (27 lbf in). See Figure 20. 12. Install nine nuts and washers on terminals on connection plate. Tighten bottom nuts to 8 N•m (71 lbf in). See Figure 20.

Install NOTE: The procedures described in this section apply to both right and left traction motors. 1. Install repaired AC motor onto output housing. See Transaxle 1300 YRM 1370 for instructions. 2. Install parking brake and service brake components onto traction motor housings. See Transaxle 1300 YRM 1370 for instructions. 3. Install transaxle assembly onto lift truck. Transaxle 1300 YRM 1370 for instructions.

See

Hydraulic Motor Repair FOR LIFT TRUCKS ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), AND ESC030-040AC (B883) Remove 1. Remove hydraulic pump and motor assembly from lift truck. See one of the following manuals for removal instructions: Hydraulic System 1900 YRM 1333 for models: • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955)

Hydraulic System 1900 YRM 1413 for models: • ESC030-040AC (B883) 2. Place hydraulic pump and motor assembly on a clean work bench or other suitable surface. 3. Remove two capscrews and drive end bracket from hydraulic pump and motor assembly. See Figure 21. 4. Remove two capscrews and terminal end bracket from hydraulic pump and motor assembly. See Figure 21.

Hydraulic Motor Repair

620 YRM 1385 5. Remove non-drive end shield from stator housing. See Figure 23. 6. Using bearing puller, remove non-drive ball bearing from non-drive end shield. See Figure 23. 7. Remove waved spring washer from non-drive end shield. See Figure 23. 8. Remove stator housing from drive end shield and rotor. See Figure 23. 9. Remove shaft sealing ring from drive end shield and rotor. See Figure 23.

1. 2. 3. 4.

CAPSCREWS DRIVE END BRACKET TERMINAL END BRACKET HYDRAULIC PUMP AND MOTOR ASSEMBLY

Figure 21. Hydraulic Pump and Motor Mounting 5. Remove two capscrews retaining hydraulic pump to hydraulic motor. See Figure 22. 6. Remove hydraulic pump with drive coupling from hydraulic motor.

Disassemble

10. Remove rotor from drive end shield. See Figure 23. 11. Remove snap ring from drive end of rotor shaft. See Figure 23. 12. Using bearing puller, carefully remove drive end ball bearing from drive end shield. See Figure 23. 13. Remove locking ring from drive end shield. See Figure 23. 14. Remove cap from non-drive end shield. See Figure 23.

1. Place hydraulic motor in a vise with terminal posts on top and carefully clamp vise onto stator housing. 2. Remove hex nuts and disconnect power leads from terminal posts. See Figure 23. 3. Remove two capscrews, terminal posts, and terminal post bracket from stator housing. See Figure 23. 4. Remove four tie rods holding non-drive end shield and drive end shield to stator housing. See Figure 23.

1. CAPSCREWS 2. HYDRAULIC PUMP 3. HYDRAULIC MOTOR

Figure 22. Hydraulic Pump to Hydraulic Motor

620 YRM 1385

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Hydraulic Motor Repair

SHAFT SEALING RING DRIVE END SHIELD DRIVE BALL BEARING LOCKING RING TERMINAL POST CAPSCREW SNAP RING ROTOR NON-DRIVE BALL BEARING WAVED SPRING WASHER

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

NON-DRIVE END SHIELD SENSOR SCREW SPEED SENSOR TIE ROD CAP STATOR HOUSING TERMINAL POST BRACKET SPRING WASHER HEX NUT POWER LEAD

Figure 23. Hydraulic Motor Components

Electrical Connector Repair or Replacement 1. If necessary, speed sensor connector and/or thermal sensor connector may be repaired or replaced. See Figure 24. See AMP Superseal Connector Assemblies section of Wire Harness Repair 2200 YRM 1128 manual for instructions.

Legend for Figure 24 1. SPEED SENSOR CONNECTOR 2. THERMAL SENSOR CONNECTOR

Figure 24. Electrical Connectors

Hydraulic Motor Repair

620 YRM 1385

2. Wire connections for speed sensor connector are shown in Table 1.

Table 1. Speed Sensor Connector Pin

Wire Color

Description

Red

Blue

Signal B

White

Signal A

Black

Ground

24V

0/+5

3. Wire connections for thermal sensor connector are shown in Table 2.

2. Bearings should fit snugly where they ride on the shaft. If there is excessive wear, replace the bearing. 3. Check bearings for smooth operation. If a clean bearing does not roll smoothly, it must be replaced. 4. Check rotor windings for signs of thermal overload. Signs of thermal overload are dark-stained, brittle, or burnt insulation. Thermal overload will shorten the life of the stator housing. 5. Check motor windings resistance as indicated below. To measure continuity between U, V, and W terminals of motor use a digital multi-meter (DMM) set to Ohms.

Table 2. Thermal Sensor Connector

a. Place one DMM probe on terminal U.

Wire Color

Description

b. Place the other DMM probe on terminal V.

Red

Positive

White

Negative

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

1. Clean components with a clean cloth moistened with solvent and allow to air dry. DO NOT apply liquid solvent directly to components. 2. Check for signs of oil or other contaminants within motor. If necessary, locate source of contaminants and take corrective action. 3. Clean all joints, remove all foreign matter ad contaminants such as release agents, grease, oil, dust, water, protective coatings, old adhesives or sealants, and other substances which could affect silicone seal adhesion.

Inspect 1. Inspect rotor and inside of motor case for marks or grooves indicating contact between rotor and motor case. Replace if damaged.

e. Place one DMM probe on terminal W. f.

620 YRM 1385

Assemble 1. Install cap into non-drive end shield. See Figure 25. 2. Install locking ring into drive end shield. See Figure 25.

CAUTION Use an arbor press and a proper size driver when installing bearings to avoid damage to bearings and/or end shields. Press only on the outer race of the bearing. Always replace bearings in sets. 3. Carefully install drive end ball bearing into drive end shield. See Figure 25. 4. Install snap ring onto drive end of rotor shaft. See Figure 25. 5. Install rotor into drive end shield. See Figure 25. 6. Install shaft sealing ring onto rotor and drive end shield. See Figure 25. 7. Install stator housing onto rotor and drive end shield. See Figure 25. 8. Install waved spring washer into non-drive end shield. See Figure 25.

CAUTION Use an arbor press and a proper size driver when installing bearings to avoid damage to bearings

Hydraulic Motor Repair and/or end shields. Press only on the outer race of the bearing. Always replace bearings in sets. 9. Carefully install non-drive end ball bearing into nondrive end shield. See Figure 25. NOTE: Take care when routing power leads and thermal sensor through non-drive end shield as noted during disassembly. NOTE: Ensure waved spring washer remains in position during non-drive end shield installation. 10. Install non-drive end shield onto stator housing. See Figure 25. 11. Apply neutral curing, high temperature silicone sealant, rated for at least 260°C (500°F), between stator housing and non-drive end shield to protect power leads and thermal sensor. 12. Install four tie rods into non-drive end shield and drive end shield, holding stator housing between shields. Tighten screws to 14 to 17 N•m (124 to 150 lbf in). See Figure 25. 13. Install terminal post bracket, terminal posts and two capscrews onto stator housing. See Figure 25. 14. Connect power leads to terminal posts. 15. Install hex nuts onto terminal posts. See Figure 25. Tighten hex nuts to 15 N•m (133 lbf in).

Hydraulic Motor Repair

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

SHAFT SEALING RING DRIVE END SHIELD DRIVE BALL BEARING LOCKING RING TERMINAL POST CAPSCREW SNAP RING ROTOR NON-DRIVE BALL BEARING WAVED SPRING WASHER

620 YRM 1385

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

NON-DRIVE END SHIELD SENSOR SCREW SPEED SENSOR TIE ROD CAP STATOR HOUSING TERMINAL POST BRACKET SPRING WASHER HEX NUT POWER LEAD

Figure 25. Hydraulic Motor Components

620 YRM 1385

Hydraulic Motor Repair

Install 1. Install drive coupling onto rotor. Install hydraulic pump over coupling onto hydraulic motor. 2. Apply Loctite 271 to two capscrews and install into hydraulic pump and hydraulic motor. See Figure 26. Tighten capscrews to 47 N•m (35 lbf ft). 3. Install non-drive end bracket and two capscrews onto hydraulic pump and motor assembly. See Figure 27. 4. Install drive end bracket and two capscrews onto hydraulic pump and motor assembly. See Figure 27. 5. Install hydraulic pump and motor assembly into counterweight. See one of the following manuals for installation instructions: Hydraulic System 1900 YRM 1333 for models: • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955)

1. CAPSCREW 2. HYDRAULIC PUMP 3. HYDRAULIC MOTOR

Figure 26. Hydraulic Pump to Hydraulic Motor

Hydraulic System 1900 YRM 1413 for models: • ESC030-040AC (B883)

1. 2. 3. 4.

CAPSCREW DRIVE END BRACKET NON-DRIVE END BRACKET HYDRAULIC PUMP AND MOTOR ASSEMBLY

Figure 27. Hydraulic Pump and Motor Mounting

Hydraulic Motor Repair

FOR LIFT TRUCK ERC22-35VG (ERC045-070VG) (A968) Remove 1. Remove hydraulic pump and motor assembly from lift truck. See Hydraulic System 1900 YRM 1367 for removal instructions. 2. Place hydraulic pump and motor assembly on a clean workbench or other suitable surface. 3. Remove five capscrews and two motor mount brackets from hydraulic pump and motor assembly. See Figure 28.

620 YRM 1385

Legend for Figure 28 A. FRONT VIEW

B. REAR VIEW

1. HYDRAULIC PUMP AND MOTOR ASSEMBLY 2. MOTOR MOUNT BRACKET 3. MOTOR MOUNT CAPSCREW NOTE: Note orientation of fitting and suction adapter during removal to aid in installation. 4. Remove fitting from pump. See Figure 29. 5. Remove suction adapter from pump. ure 29.

See Fig-

NOTE: Note position of inlet and outlet ports of pump for correct alignment during installation. 6. Remove two capscrews fastening pump to motor. Carefully remove pump from motor. See Figure 29. 7. Loosen two set screws in coupling. DO NOT lose two keys between coupling and shaft. Remove coupling from motor. See Figure 29.

1. 2. 3. 4.

PUMP MOTOR COUPLING SET SCREW

5. CAPSCREW 6. FITTING 7. SUCTION ADAPTER

Figure 29. Pump and Motor Assembly

Figure 28. Motor Mount Brackets

620 YRM 1385

Hydraulic Motor Repair

Disassemble 1. Place motor in a vise with terminal posts on top and carefully clamp vise on stator housing. 2. Remove three hex nuts and spring washers from terminal posts. See Figure 30. 3. Disconnect power leads from terminal posts. See Figure 30.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

TERMINAL POST HEX NUT SPRING WASHER POWER LEAD SCREW STATOR HOUSING TIE ROD NON-DRIVE END SHIELD DRIVE END SHIELD CAP O-RING

4. Remove two screws, terminal posts, and terminal post bracket from stator housing. See Figure 30. 5. Remove four tie rods holding end shields to stator housing. See Figure 30. 6. Remove cap from non-drive end shield. Remove and discard O-ring from cap. See Figure 30.

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

NON-DRIVE END BALL BEARING O-RING SEAL WAVED SPRING WASHER TERMINAL POST BRACKET CAPSCREW SPEED SENSOR ROTOR LOCKING RING DRIVE END BALL BEARING SNAP RING WOODRUFF KEY

Figure 30. Hydraulic Motor

Hydraulic Motor Repair

620 YRM 1385

CAUTION Disposal of silicone sealant must meet local environmental regulations. NOTE: Note threading position and orientation of power leads and thermal sensor connector wire through nondrive end shield during disassembly to aid in assembly. NOTE: Silicone seal for power leads and thermal sensor connector wire must be broken prior to shield removal. 7. Remove non-drive end shield from stator housing. See Figure 30. 8. Using bearing puller, carefully remove non-drive end ball bearing from non-drive end shield. See Figure 30. 9. Remove O-ring seal from non-drive end shield. See Figure 30. 10. Remove waved spring washer from non-drive end shield. See Figure 30. 11. Remove capscrew and speed sensor non-drive end shield. See Figure 30.

from

1. SPEED SENSOR CONNECTOR 2. THERMAL SENSOR CONNECTOR

Figure 31. Electrical Connectors

12. Remove drive end shield and rotor from stator housing. See Figure 30. 13. Remove woodruff key from drive end of rotor shaft. See Figure 30. 14. Remove snap ring from drive end of rotor. See Figure 30. 15. Remove rotor from drive end shield. See Figure 30. 16. Remove locking ring from drive end shield. See Figure 30. 17. Using bearing puller, carefully remove drive end ball bearing from drive end shield. See Figure 30.

Electrical Connector Repair or Replacement 1. If necessary, speed sensor connector and/or thermal sensor connector may be repaired or replaced. See Figure 31. See AMP Superseal Connector Assemblies section of Wire Harness Repair 2200 YRM 1128 manual for instructions. 2. Connections for speed sensor connector are shown in Figure 32.

1. SUPPLY 2. SIGNAL B

3. SIGNAL A 4. GROUND

Figure 32. Speed Sensor Wire Connections 3. Connections for thermal sensor connector are shown in Figure 33.

620 YRM 1385

Hydraulic Motor Repair 2. Bearings should fit snugly where they ride on the shaft. If there is excessive wear, replace bearing and/or shaft. 3. Check bearings for smooth operation. If a clean bearing does not roll smoothly, it must be replaced. 4. Check rotor windings for signs of thermal overload. Signs of thermal overload are dark-stained, brittle, or burnt insulation. Thermal overload will shorten the life of the stator housing. 5. Check motor windings resistance as indicated below. To measure continuity between U, V, and W terminals of motor use a digital multi-meter (DMM) set to Ohms. a. Place one DMM probe on terminal U. b. Place the other DMM probe on terminal V.

1. GROUND

2. POSITIVE

Figure 33. Thermal Sensor Wire Connections c. Place one DMM probe on terminal V.

Clean

d. Place the other DMM probe on terminal W.

WARNING

Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures. 1. Clean components with a clean cloth moistened with solvent and allow to thoroughly dry. DO NOT apply liquid solvent directly to rotor windings. 2. Check for signs of oil or other contaminants within the motor. If necessary, locate source of contaminants and take corrective action. 3. Clean all joints, remove all foreign matter and contaminants such as release agents, grease, oil, dust, water, protective coatings, old adhesives or sealants, and other substances which could affect silicone seal adhesion.

e. Place one DMM probe on terminal W. f.

Inspect 1. Inspect rotor and inside motor case for marks or grooves indicating contact between rotor and motor case. Replace if damaged.

Hydraulic Motor Repair

620 YRM 1385

Assemble

2. Install locking ring into drive end shield. See Figure 34.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

TERMINAL POST HEX NUT SPRING WASHER POWER LEAD SCREW STATOR HOUSING TIE ROD NON-DRIVE END SHIELD DRIVE END SHIELD CAP O-RING

3. Install rotor into drive end shield. See Figure 34. 4. Install snap ring on drive end of rotor. See Figure 34. 5. Install woodruff key into drive end of rotor shaft. See Figure 34. 6. Install rotor and drive end shield into stator housing. See Figure 34.

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

NON-DRIVE END BALL BEARING O-RING SEAL WAVED SPRING WASHER TERMINAL POST BRACKET CAPSCREW SPEED SENSOR ROTOR LOCKING RING DRIVE END BALL BEARING SNAP RING WOODRUFF KEY

Figure 34. Hydraulic Motor

620 YRM 1385 7. Install speed sensor and capscrew onto non-drive end shield. See Figure 34. 8. Install waved spring washer into non-drive end shield. See Figure 34. 9. Install O-ring seal into non-drive end shield. See Figure 34.

CAUTION Use an arbor press and a proper size driver when installing bearings to avoid damage to bearings and/or end shields. Press only on the outer race of the bearing. Always replace bearings in sets. 10. Carefully install non-drive end ball bearing into nondrive end shield. See Figure 34. 11. Install non-drive end shield onto stator housing. See Figure 34. 12. Apply neutral curing, high temperature silicone sealant (rated for at least 260°C (500°F)) between stator housing and non-drive end shield to protect power leads and thermal sensor.

Hydraulic Motor Repair 3. Make sure the halves of the coupling are correctly engaged. Make sure set screws that fasten coupling to shafts are 180° opposed. See Figure 35. Tighten set screws to 11 to 13 N•m (97 to 115 lbf in). 4. Make sure pump is aligned to motor as marked during removal. Install two capscrews fastening pump to motor. See Figure 35. Tighten capscrews to 25 N•m (221 lbf in). NOTE: Remove plugs from pump openings and install plugs into suction adapter and fitting after installation. 5. Install suction adapter onto hydraulic pump as noted during removal. See Figure 35. Tighten adapter to 91 to 100 N•m (67 to 74 lbf ft). 6. Install fitting onto hydraulic pump. See Figure 35. Tighten fitting to 49 to 59 N•m (36 to 44 lbf ft). 7. Install hydraulic pump and motor assembly into lift truck. See Hydraulic System 1900 YRM 1367 for instructions.

13. Install new O-ring onto cap. Install cap into nondrive end shield. See Figure 34. 14. Install four tie rods to hold end shields to stator housing. See Figure 34. 15. Install terminal post bracket, terminal posts, and two screws onto stator housing. See Figure 34. 16. Connect power leads to terminal posts. See Figure 34. 17. Install three spring washers and hex nuts on terminal posts. See Figure 34. Tighten hex nuts to 24 N•m (212 lbf in). 18. Carefully remove motor from vise and place on suitable work surface.

Install

1. 2. 3. 4.

PUMP MOTOR COUPLING SET SCREW

5. CAPSCREW 6. FITTING 7. SUCTION ADAPTER

Figure 35. Pump and Motor Assembly

1. Install keys onto motor shaft. 2. Install coupling onto pump shaft and motor shaft. See Figure 35.

Hydraulic Motor Repair

FOR LIFT TRUCK MODELS ERP2.2-3.5VL (ERP045-070VL) (A976) AND ERC16-20VA (ERC030-040VA) (A969) Remove 1. Remove hydraulic pump and motor assembly from lift truck. See Hydraulic System 1900 YRM 1367 for removal instructions.

620 YRM 1385 7. Remove four tie rods holding end shields to stator housing. See Figure 36 for lift truck models • ERP2.2-3.5VL (ERP045-070VL) (A976) See Figure 37 for lift truck models • ERC16-20VA (ERC030-040VA) (A969)

CAUTION 2. Place hydraulic pump and motor assembly on a clean workbench or other suitable surface.

Disposal of silicone sealant must meet local environmental regulations.

3. Remove the hydraulic pump and motor brackets. See Hydraulic System 1900 YRM 1367 for removal instructions.

NOTE: during the performance of the following step, remove only a sufficient amount of sealing material to allow removal of the non-drive end shield

Disassemble

8. Carefully remove silicone seal material from the non-drive end shield

1. Place motor in a vise with terminal posts on top and carefully clamp vise on stator housing. 2. Remove three hex nuts and lockwashers from terminal posts. See Figure 36 for lift truck models • ERP2.2-3.5VL (ERP045-070VL) (A976) See Figure 37 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 3. Disconnect power leads from terminal posts. See Figure 36 for lift truck models • ERP2.2-3.5VL (ERP045-070VL) (A976) See Figure 37 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 4. Remove two screws, terminal posts, and terminal post bracket and terminal strip from stator housing. See Figure 36 for lift truck models • ERP2.2-3.5VL (ERP045-070VL) (A976) See Figure 37 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 5. Remove three socket-head capscrews and fan cover from non drive end shield. 6. Remove three socket-head capscrews and fan cover from non drive end shield on the following lift truck models only: • ERP2.2-3.5VL (ERP045-070VL) (A976)

NOTE: Note threading position and orientation of power leads and thermal sensor connector wire through nondrive end shield during disassembly to aid in assembly. 9. Remove non-drive end shield from stator housing. See Figure 36 for lift truck models • ERP2.2-3.5VL (ERP045-070VL) (A976) See Figure 37 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 10. Using bearing puller, carefully remove non-drive end ball bearing from rotor. 11. Remove wave washer, seal, retaining bushing and fan from the non-drive end shield. Discard the seal. See Figure 36 for lift truck models • ERP2.2-3.5VL (ERP045-070VL) (A976) See Figure 37 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 12. Remove capscrew and non-drive end shield.

speed

sensor

from

13. Remove drive end shield and rotor from stator housing. See Figure 36 for lift truck models • ERP2.2-3.5VL (ERP045-070VL) (A976) See Figure 37 for lift truck models • ERC16-20VA (ERC030-040VA) (A969)

620 YRM 1385

Hydraulic Motor Repair

Figure 36. Hydraulic Motor, Lift Truck Models ERP2.2-3.5VL (ERP045-070VL) (A976)

Hydraulic Motor Repair

620 YRM 1385

Legend for Figure 36 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

SEAL LOCK RING DRIVE END SHIELD BEARING SNAP RING STATOR HOUSING THERMAL SENSOR CONNECTOR TERMINAL STRIP TERMINAL POST BRACKET TERMINAL POST LOCKWASHER HEX NUT

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

See Figure 37 for lift truck models • ERC16-20VA (ERC030-040VA) (A969)

14. Remove and discard seal from the drive end shield. See Figure 36 for lift truck models • ERP2.2-3.5VL (ERP045-070VL) (A976) See Figure 37 for lift truck models • ERC16-20VA (ERC030-040VA) (A969)

SCREW ROTOR WAVE WASHER SEAL FAN RETAINING BUSHING SPACER NON-DRIVE END SHIELD SPEED SENSOR SOCKET-HEAD CAPSCREW TIE ROD WASHER FAN COVER

16. Using bearing puller, carefully remove drive end ball bearing from the rotor. See Figure 36 for lift truck models • ERP2.2-3.5VL (ERP045-070VL) (A976)

15. Remove lock ring, snap ring and drive end shield from the rotor.

See Figure 37 for lift truck models • ERC16-20VA (ERC030-040VA) (A969)

See Figure 36 for lift truck models • ERP2.2-3.5VL (ERP045-070VL) (A976)

Legend for Figure 37 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

SEAL LOCK RING DRIVE END SHIELD BEARING SNAP RING STATOR HOUSING THERMAL SENSOR CONNECTOR TERMINAL STRIP TERMINAL POST BRACKET TERMINAL POST LOCKWASHER

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

HEX NUT SCREW ROTOR WAVE WASHER SEAL FAN RETAINING BUSHING SPACER NON-DRIVE END SHIELD SPEED SENSOR SOCKET-HEAD CAPSCREW TIE ROD

620 YRM 1385

Hydraulic Motor Repair

Figure 37. Hydraulic Motor, Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)

Hydraulic Motor Repair

620 YRM 1385

Electrical Connector Repair or Replacement 1. If necessary, speed sensor connector and/or thermal sensor connector may be repaired or replaced. See Figure 38. See AMP Superseal Connector Assemblies section of Wire Harness Repair 2200 YRM 1128 manual for instructions. 2. Connections for speed sensor connector are shown in Figure 39. 3. Connections for thermal sensor connector are shown in Figure 40.

1. SUPPLY 2. SIGNAL B

3. SIGNAL A 4. GROUND

Figure 39. Speed Sensor Wire Connections

1. SPEED SENSOR CONNECTOR 2. THERMAL SENSOR CONNECTOR

Figure 38. Electrical Connectors

1. GROUND

2. POSITIVE

Figure 40. Thermal Sensor Wire Connections

620 YRM 1385 2. Check for signs of oil or other contaminants within the motor. If necessary, locate source of contaminants and take corrective action. 3. Clean all joints, remove all foreign matter and contaminants such as release agents, grease, oil, dust, water, protective coatings, old adhesives or sealants, and other substances which could affect silicone seal adhesion.

Inspect 1. Inspect rotor and inside motor case for marks or grooves indicating contact between rotor and motor case. Replace if damaged.

Hydraulic Motor Repair e. Place one DMM probe on terminal W. f.

Assemble CAUTION

2. Bearings should fit snugly where they ride on the shaft. If there is excessive wear, replace bearing and/or shaft.

Use an arbor press and a proper size driver when installing bearings to avoid damage to bearings and/or rotor. Press only on the INNER race of the bearing. Always replace bearings in sets.

3. Check bearings for smooth operation. If a clean bearing does not roll smoothly, it must be replaced.

1. Using a press, carefully Install drive end ball bearing onto the rotor.

4. Check rotor windings for signs of thermal overload. Signs of thermal overload are dark-stained, brittle, or burnt insulation. Thermal overload will shorten the life of the stator housing. 5. Check motor windings resistance as indicated below. To measure continuity between U, V, and W terminals of motor use a digital multi-meter (DMM) set to Ohms. a. Place one DMM probe on terminal U. b. Place the other DMM probe on terminal V. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the cables from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the motor windings in the stator have burned open and the motor must be repaired or replaced. c. Place one DMM probe on terminal V. d. Place the other DMM probe on terminal W. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the cables from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the motor windings in the stator have burned open and the motor must be repaired or replaced.

See Figure 41 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 42 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 2. Install drive end shield, snap ring, and lock ring on the rotor. See Figure 41 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 42 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 3. Install a new seal in the drive end shield. See Figure 41 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 42 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 4. Install drive end shield and rotor into stator housing. See Figure 41 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 42 for lift truck models • ERC16-20VA (ERC030-040VA) (A969)

Hydraulic Motor Repair

620 YRM 1385

See Figure 41 for lift truck models • ERP22-35VL (ERP045-070VL) (A976)

11. Install fan cover and three socket-head capscrews on non drive end shield on the following lift truck models only: • ERP2.2-3.5VL (ERP045-070VL) (A976) See Figure 41.

See Figure 42 for lift truck models • ERC16-20VA (ERC030-040VA) (A969)

12. Using two screws, install terminal strip, terminal post bracket, terminal posts onto stator housing.

5. Install speed sensor and capscrew into non-drive end shield.

6. Install new seal, wave washer, fan, and retaining bushing into the non-drive end shield. Discard the seal. See Figure 41 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 42 for lift truck models • ERC16-20VA (ERC030-040VA) (A969)

CAUTION Use an arbor press and a proper size driver when installing bearings to avoid damage to bearings and/or rotor. Press only on the INNER race of the bearing. Always replace bearings in sets. 7. Using a press, install non-drive end ball bearing onto the rotor.

See Figure 41 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 42 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 13. Check torque of the nuts located on the terminal posts. Tighten to 15 N•m (133 lbf in). 14. Check torque of the nuts located on the terminal posts. Tighten to 15 N•m (133 lbf in) for lift truck models: • ERP2.2-3.5VL (ERP045-070VL) (A976) Tighten to 14 to 16 N•m (124 to 142 lbf in) for lift truck models: • ERC16-20VA (ERC030-040VA) (A969) 15. Connect power leads from terminal posts.

See Figure 41 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 42 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 8. Install non-drive end shield onto stator housing and place power leads and thermal sensor in the orientation and position as noted during removal. See Figure 41 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 42 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 9. Install four tie rods holding end shields to stator housing.

See Figure 41 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 42 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 16. Install three lockwashers and hex nuts onto terminal posts. Tighten to 24 N•m (212 lbf in). See Figure 41. 17. Install three lockwashers and hex nuts onto terminal posts. Tighten hex nuts to 24 N•m (212 lbf in) for lift truck models: • ERP2.2-3.5VL (ERP045-070VL) (A976) See Figure 41.

See Figure 41 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 42 for lift truck models • ERC16-20VA (ERC030-040VA) (A969)

Tighten hex nuts to 14 to 16 N•m (124 to 142 lbf in) for lift truck models: • ERC16-20VA (ERC030-040VA) (A969) See Figure 42.

10. Install fan cover and three socket-head capscrews on non drive end shield. See Figure 41.

620 YRM 1385

Hydraulic Motor Repair

Figure 41. Hydraulic Motor, Lift Truck Models ERP2.2-3.5VL (ERP045-070VL) (A976)

Hydraulic Motor Repair

620 YRM 1385

Legend for Figure 41 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

SEAL LOCK RING DRIVE END SHIELD BEARING SNAP RING STATOR HOUSING THERMAL SENSOR CONNECTOR TERMINAL STRIP TERMINAL POST BRACKET TERMINAL POST LOCKWASHER HEX NUT

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

18. Fill the area around the power leads and thermal sensor located on the non-drive end shield with neutral curing, high temperature silicone sealant (rated for at least 260°C (500°F).

Install

SCREW ROTOR WAVE WASHER SEAL FAN RETAINING BUSHING SPACER NON-DRIVE END SHIELD SPEED SENSOR SOCKET-HEAD CAPSCREW TIE ROD WASHER FAN COVER

2. Install the hydraulic pump and motor brackets. See Hydraulic System 1900 YRM 1367 for installation instructions. 3. Install hydraulic pump and motor assembly on the lift truck. See Hydraulic System 1900 YRM 1367 for installation instructions.

1. Place hydraulic motor assembly on a clean workbench or other suitable work surface.

Legend for Figure 42 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

SEAL LOCK RING DRIVE END SHIELD BEARING SNAP RING STATOR HOUSING THERMAL SENSOR CONNECTOR TERMINAL STRIP TERMINAL POST BRACKET TERMINAL POST LOCKWASHER

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

HEX NUT SCREW ROTOR WAVE WASHER SEAL FAN RETAINING BUSHING SPACER NON-DRIVE END SHIELD SPEED SENSOR SOCKET-HEAD CAPSCREW TIE ROD

620 YRM 1385

Hydraulic Motor Repair

Figure 42. Hydraulic Motor, Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)

Torque Specifications

620 YRM 1385

Torque Specifications TRACTION MOTOR FOR LIFT TRUCKS ERP15-20VT (ERP030-040VT) (G807) AND ERP16-20VF (ERP30-40VF) (A955) Terminal Post Hex Nuts 12 N•m (106 lbf in) Socket-Head Capscrews 14 to 16 N•m (124 to 142 lbf in) Mounting Capscrews 48 N•m (35 lbf ft)

TRACTION MOTOR FOR LIFT TRUCK ERC22-35VG (ERC045-070VG) (A968)AND ERC16-20VA (ERC030-040VA) (A969)

HYDRAULIC MOTOR FOR LIFT TRUCK ERC22-35VG (ERC045-070VG) (A968) Terminal Post Hex Nuts 24 N•m (212 lbf in) Set Screws 11 to 13 N•m (97 to 115 lbf in) Pump to Motor Capscrews 25 N•m (221 lbf in) Suction Adapter 91 to 100 N•m (67 to 74 lbf ft) Fitting 49 to 59 N•m (36 to 44 lbf ft)

End Head to Stator Housing Capscrews 25 to 30 N•m (18 to 22 lbf ft)

HYDRAULIC MOTOR FOR LIFT TRUCK ERP22-35VG (ERP045-070VG) (A976)

TRACTION MOTOR FOR LIFT TRUCK ESC030-040AC (B883)

Terminal Post Hex Nuts (Lower) 15 N•m (133 lbf in)

Terminal Post Hex Nut 12 N•m (106 lbf in)

Terminal Post Hex Nuts (Upper) 24 N•m (212 lbf in)

Socket-Head Capscrews 14 to 16 N•m (124 to 142 lbf in)

HYDRAULIC MOTOR FOR LIFT TRUCK ERC16-20VA (ERC030-040VA) (A969)

Mounting Capscrews 48 N•m (35 lbf ft)

Terminal Post Hex Nuts (Lower) 14 to 16 N•m (124 to 142 lbf in)

HYDRAULIC MOTOR FOR LIFT TRUCKS ERP15-20VT (ERP030-040VT) (G807) AND ERP16-20VF (ERP30-40VF) (A955)

Terminal Post Hex Nuts (Upper) 14 to 16 N•m (124 to 142 lbf in)

Tie Bar Screws 14 to 17 N•m (124 to 150 lbf in) Terminal Post Hex Nuts 15 N•m (133 lbf in) Pump to Motor Capscrews 47 N•m (35 lbf ft)

HYDRAULIC MOTOR FOR LIFT TRUCK ESC030-040AC (B883) Tie Bar Screws 14 to 17 N•m (124 to 150 lbf in) Terminal Post Hex Nuts 15 N•m (133 lbf in) Pump to Motor Capscrews 47 N•m (35 lbf ft)

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

620 YRM 1385

1/11 (4/10)(2/10)(12/09)(9/09)(12/08)(7/08) Printed in U.S.A.

Maintenance

BRAKE SYSTEM ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

PART NO. 524295632

1800 YRM 1332

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Brake System

Table of Contents

1 1 2 2 2 3 4 4 5 5 5 7 7 7 7 7 8 9 9 10 10 10 10 11 11

This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

1800 YRM 1332

Introduction

Introduction GENERAL This section contains the description and replacement procedures for the brake system. Components covered are the brake pedal assembly, the spring-applied, electrically-released parking brakes, and the master cylinder system. Some parts associated with the brake system are not covered in this section because they are more closely associated with other systems. See the following list for information not included in this section: • See the section Electrical System 2200 YRM 1337 for information on brake lights and parking brake wiring. • See the section Transaxle 1300 YRM 1330 for information on the internal, wet brake system. Throughout this section, forward will refer to travel in the direction of the forks and left and right determined by an operator sitting in the seat facing forward. See Figure 1 and Figure 2.

A. LEFT SIDE B. RIGHT SIDE C. FORWARD TRAVEL

Figure 1. Truck Orientation (Three-Wheel Trucks)

Figure 2. Truck Orientation (Four-Wheel Trucks)

Brake Pedal Assembly Repair

1800 YRM 1332 personal injury, discharge the capacitors before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Make certain the Emergency Disconnect Switch has not been activated. This will isolate the controller and prevent the capacitors from discharging properly. The proper way to disconnect the battery is by separating the battery connectors. 1. Ensure the capacitors are discharged by performing Step 2 through Step 5 below. 2. Turn the key or keyless switch to the OFF position and disconnect the battery by separating the connectors. 3. Block load wheels to prevent lift truck from moving. 4. Make sure the Emergency Disconnect Switch HAS NOT been activated. If the Emergency Disconnect Switch is activated, rotate the switch to the right until it pops up. 5. Wait at least 10 seconds to be sure the capacitors are completely discharged.

The capacitors in the transistor controllers can hold an electrical charge after the battery is disconnected. To prevent an electrical shock and

Brake Pedal Assembly Repair REMOVE

2. Remove floor mat and floor covers.

It is not always necessary to remove the brake pedal assembly to disassemble certain components. Parts of the brake pedal assembly may be removed without removing the assembly from the lift truck. The entire removal procedure is outlined below. Evaluate the required service to determine if the entire brake assembly should be removed. Perform only the steps necessary to safely complete the required service.

3. Tag and disconnect transducer and fluid sensor wiring.

1. Turn the key switch to the OFF position and disconnect the battery.

NOTE: Position a catch can or a cloth to contain the brake fluid spilled when the line is disconnected. 4. Remove the clamp and disconnect the main pressure line from the elbow fitting on top of the master cylinder. Cap or plug the lines and fittings to minimize spills and prevent contamination to the brake system. See Figure 3.

1800 YRM 1332

Brake Pedal Assembly Repair c. Remove nut, then slide bolt from assembly. See Figure 3 and Figure 4. d. Lift pedal from assembly. Recover washer and sleeve from pedal. See Figure 5. e. Remove bushings from pedal if necessary.

1. CLAMP 2. MAIN PRESSURE LINE 3. ELBOW FITTING 4. TRANSDUCER 5. MASTER CYLINDER

6. 7. 8. 9.

BRACKET BOLT NUT MOUNTING CAPSCREWS AND NUTS 10. PEDAL

1. 2. 3. 4.

PEDAL RETURN SPRING WASHER CLEVIS PIN

5. COTTER PIN 6. CLEVIS 7. BOLT

Figure 4. Pedal Assembly and Linkage

Figure 3. Pedal Retaining Nut 5. Remove three mounting capscrews and nuts securing bracket to frame. 6. Lift brake pedal assembly from the lift truck.

DISASSEMBLE For the following procedures, see Figure 3, Figure 4, and Figure 5. 1. Remove master cylinder if necessary. See Master Cylinder Repair, in this section. 2. Remove brake pedal: a. Remove the return spring. See Figure 4. b. Pull the cotter pin and remove clevis pin and washer from the clevis if the master cylinder has not been removed. Discard the cotter pin.

1. WASHER 2. BUSHING 3. SLEEVE

4. BUSHING 5. PEDAL

Figure 5. Pedal Bushings

Brake Pedal Assembly Repair

1800 YRM 1332

ASSEMBLE

b. Loosen locknuts and adjust capscrew so pedal is within the proper distance from the bracket.

For the following procedures, see Figure 4, and Figure 5. 1. Install brake pedal: a. Install new bushings into pedal if removed. Install sleeve into bushings. See Figure 5. b. Position pedal and washer into bracket and align holes. Make sure clevis is positioned properly if the master cylinder was not removed.

c. Retighten locknuts to secure capscrew in place. 7. Adjust the master cylinder linkage. See Adjust Linkage in this section. 8. Connect the battery and test for proper operation. 9. Install the floor covers and the floor mat.

c. Install bolt through washer, pedal, and bracket and secure with nut. Tighten to 165 to 206 N•m (122 to 152 lbf ft). See Figure 4. 2. Install pedal return spring. 3. Install master cylinder if removed. Cylinder Repair in this section.

See Master

4. Install clevis to pedal using clevis pin and washer. Install new cotter pin to secure. See Figure 4.

INSTALL 1. Place brake pedal assembly in position and align the bracket with the mounting holes in the frame. 2. Install three capscrews and nuts securing bracket to frame. 3. Connect transducer and fluid sensor wiring as removed. 4. Connect the main pressure line to the elbow fitting on top of the master cylinder. 5. Bleed air from the brake system. See Master Cylinder Repair - Bleed the Brake System in this section. 6. Adjust the brake pedal to the proper height: a. Measure distance from the top of the bracket to the foot pedal as shown in Figure 6.

1. 2. 3. 4. 5.

PEDAL BRACKET MASTER CYLINDER LINKAGE LOCKNUTS CAPSCREW

Figure 6. Pedal Adjustment

1800 YRM 1332

Master Cylinder Repair

Master Cylinder Repair REMOVE WARNING Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling Dexron III. Thoroughly wash exposed areas of skin as soon as possible.

CAUTION Protect the brake system from dirt and contaminants during servicing procedures. 1. Turn the key switch to the OFF position and disconnect the battery. 2. Remove the floor mat and floor plates. 3. Disconnect the brake pressure line from the elbow fitting on top of the master cylinder. Cap hose and fitting to minimize spills and prevent contamination. 4. Disconnect the transducer and the fluid sensor wiring.

1. 2. 3. 4. 5. 6.

PEDAL RETURN SPRING WASHER CLEVIS PIN COTTER PIN CLEVIS

7. CAPSCREWS 8. NUTS 9. CYLINDER HOUSING 10. BRAKE PRESSURE LINE

Figure 7. Master Cylinder Mounting 5. Pull the cotter pin from the clevis pin and remove the clevis pin and washer connecting the clevis to the pedal. Discard the cotter pin. 6. Remove capscrews and nuts securing master cylinder to bracket. 7. Remove master cylinder from bracket. See Figure 7.

DISASSEMBLE 1. Remove master cylinder assembly from the truck. See Remove. 2. Remove the brake switch by unscrewing it from the cylinder housing. See Figure 8. 3. Remove the elbow fitting from the cylinder housing. 4. Loosen the clamp and remove the reservoir from the cylinder housing. See Figure 9.

1. 2. 3. 4. 5.

MAIN BRAKE LINE ELBOW FITTING MASTER CYLINDER HOUSING TRANSDUCER (BRAKE PRESSURE) BRACKET

Figure 8. Brake Switch 5. Pull the push rod out of the boot. Remove the boot from the cylinder housing. See Figure 9.

Master Cylinder Repair

1. 2. 3. 4. 5. 6. 7.

CYLINDER HOUSING PISTON ASSEMBLY CUP PISTON SPACER CUP RETAINER

1800 YRM 1332

8. 9. 10. 11. 12. 13. 14.

SPRING RETAINING RING BOOT PUSH ROD NUT CLEVIS PIN CLEVIS

Figure 9. Master Cylinder

15. 16. 17. 18. 19. 20.

WASHER COTTER PIN CLAMP RESERVOIR GASKET CAP

1800 YRM 1332

Master Cylinder Repair

6. Loosen the nut and remove the clevis and nut from the push rod if necessary.

8. Install master cylinder assembly to the truck. See Install.

7. Remove the retaining ring and extract the piston assembly from the cylinder housing.

INSTALL

CLEAN AND INSPECT Clean the inside of the master cylinder housing with a clean cloth and solvent. Inspect the inside of the housing for grooves, wear, or scarring. If the housing shows any visible damage, replace the master cylinder.

ASSEMBLE CAUTION The brake system uses Dexron III (same as used in the transaxle). Use of other fluids can damage the brake system. NOTE: Lightly lubricate the piston assembly components with Dexron III prior to installation.

CAUTION The brake system uses Dexron III (same as used in the transaxle). Use of other fluids can damage the brake system. 1. Position master cylinder to bracket and align mounting holes. 2. Install capscrews and nuts securing master cylinder to bracket. Tighten to 19 to 23 N•m (14 to 17 lbf ft). 3. Install the main pressure line to the elbow fitting on top of the master cylinder. 4. Connect transducer and fluid sensor wiring as removed.

1. Install the piston assembly into the cylinder housing:

5. Attach the clevis to the pedal using the clevis pin and washer. Secure in place with a new cotter pin. Adjust linkage as necessary. See Adjustments, Adjust Linkage.

a. Carefully install the piston assembly into the cylinder housing (spring first) and hold in position.

6. Bleed air from the brake system. See Adjustments, Bleed the Brake System.

b. Install the retaining ring into the cylinder housing against the cup. Ensure that the retaining ring is securely seated in the groove of the cylinder housing. 2. Install the transducer by screwing it into the cylinder housing. Tighten to 23 to 28 N•m (17 to 21 lbf ft). 3. Install the elbow fitting into the cylinder housing. Orient as removed. 4. Install the reservoir onto the cylinder housing. Tighten the clamp to secure in position. 5. Install the boot to the housing. 6. Install nut onto rod and then install clevis onto rod as removed. Wait to tighten nut until linkage has been adjusted. NOTE: Lightly lubricate the push rod with Dexron III to ease in installation. 7. Install the push rod through the hole in the boot into the cylinder housing.

ADJUSTMENTS Bleed the Brake System CAUTION The brake system uses Dexron III (same as used in the transaxle). Use of other fluids can damage the brake system. When the brake system is operating properly, the brake pedal will have back pressure that will stop the pedal before it can be pressed to the end of its mechanical travel limit. A brake system that has air present may have some back pressure but not enough to stop the pedal before reaching its mechanical travel limit. The pedal may feel soft and inconsistent (spongy) and must be bled before operating the lift truck. NOTE: Bleeding air from the brake system requires two technicians. One technician must sit in the seat and operate the brake pedal while the other opens and closes the brake bleed valve located on the transaxle housing.

Master Cylinder Repair To bleed air from the brake system: 1. Remove the floor plates and check that the master cylinder reservoir is full of oil. 2. One technician must sit in the seat and repeatedly press and release (pump) the brake pedal to increase the back pressure. The brake pedal may become harder to press as this occurs. 3. When back pressure seems to be at the maximum, the technician must press and hold the pedal as far as it will go. 4. The second technician must slowly loosen the bleed valve on one of the transaxle housings between the wheel and the frame. Air and oil should bubble from the valve until the pedal is pressed to its mechanical travel limit.

1800 YRM 1332 NOTE: Do not allow the boot to be twisted while adjusting the push rod length. 3. Turn the push rod to counterclockwise (as viewed from rear of truck) to remove all slack between the master cylinder and the brake pedal. 4. Turn the push rod 1/8 clockwise (as viewed from rear of truck) to allow the master cylinder to fully return when the brake pedal is released. 5. Hold the push rod in position, and tighten the locknut on the push rod against the clevis to secure in place.

5. The pedal should be held in this position while the valve is retightened. 6. Repeat Step 2 through Step 5 until oil with no air (bubbles) flows from the valve. Check the oil level in the master cylinder every cycle and fill reservoir as necessary. 7. Perform Step 2 through Step 5 on the other transaxle until all air has been bled from the system.

Adjust Linkage To adjust the master cylinder linkage: 1. Check that the pedal is adjusted properly before adjusting the master cylinder linkage. Refer to Brake Pedal Assembly Repair section for procedures. 2. Loosen the lock nut on the push rod. See Figure 10.

1. 2. 3. 4. 5.

SPRING BRAKE PEDAL WASHER CLEVIS PIN COTTER PIN

6. 7. 8. 9.

CLEVIS LOCKNUT PUSH ROD BOOT

Figure 10. Linkage Adjustment

1800 YRM 1332

Brake Lines

Brake Lines WARNING

4. Bleed the brake lines. Refer to Bleed the Brake System in this section.

Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling oil. Thoroughly wash oil from exposed areas of skin as soon as possible. Never check for leaks by putting hands on pressurized lines or components under pressure. Pressurized oil can be injected into the skin. Pressure is transferred from the master cylinder to the transaxles through brake lines. These are metal tubes filled with oil connected by hydraulic fittings. Brake lines run below the floor plates, from the master cylinder to a tee fitting located near the front of the frame. They continue from there as separate left-hand (LH) and righthand (RH) lines through the frame to a fitting on each transaxle. The drive wheel may be removed to access this connection. See Figure 11.

BRAKE LINE REPLACEMENT 1. Clean around the component(s) to be replaced to reduce the risk of contaminating the brake system.

CAUTION Disposal of fluids must meet local environmental regulations. 2. Disconnect the brake line component(s) which need replacement at both ends. Drain oil from brake lines into a suitable container.

1. CLAMP 2. MAIN PRESSURE LINE 3. FITTING 4. LH LINE

5. TEE FITTING 6. CAPSCREW 7. RH LINE

Figure 11. Brake Lines

NOTE: Clean up any spilled oil. 3. Remove the component(s) and install the new component(s) as necessary.

Parking Brake

1800 YRM 1332

Parking Brake The parking brake consists of two identical spring-applied, electrically-released brakes mounted directly to the drive motors. The controller breaks the power supply to the brake coils, engaging the parking brake when the truck is stopped. Pressing the emergency disconnect will apply the parking brake immediately in any mode of operation. The parking brakes may be released for towing by removing the floor plate from the operator compartment and pulling the manual release lever. This lever and cable assembly manually releases the parking brakes for towing. The following procedures detail the repair procedures for the lever and cable assembly and removal and installation procedures for the parking brakes.

MANUAL RELEASE LEVER Adjust Cable The manual release mechanism should be adjusted so that the brake is fully engaged when the lever is down, but is fully released when the lever has been pulled up.

CAUTION If the cable is adjusted too tight, damage to the cable may occur when the manual release lever is used. Make sure the cable is adjusted so there is 2 to 4 mm (0.08 to 0.16 in.) extra travel available between the parking brake actuators when the manual release lever is UP.

1. 2. 3. 4. 5. 6. 7.

MANUAL RELEASE LEVER CABLE NUTS PARKING BRAKE ACTUATORS TRACTION MOTOR (LEFT) PARKING BRAKE ASSEMBLIES TRACTION MOTOR (RIGHT)

Figure 12. Manual Release Components

Replace Cable

1. Check the adjustment of the manual release lever by placing the lever in the UP position and checking the tension on the parking brake actuators. See Figure 12.

1. Remove the floor mat and floor plates. The manual release lever must be in the down position.

2. If the parking brake actuators have more than 2 to 4 mm (0.08 to 0.16 in.) of free travel available, adjust the nuts to tighten the cable and check free travel again.

3. Press the parking brake actuators together so the cable can be removed from the parking brake actuators.

3. If the parking brake actuators have less than 2 to 4 mm (0.08 to 0.16 in.) of free travel, adjust the nuts to loosen cable and check free travel again.

5. Install the new cable to the manual release lever.

4. When the adjustment is within specification, tighten the nuts, lower the manual release lever and test for proper operation.

2. Loosen the hardware securing the cable in place.

4. Disconnect the cable from the manual release lever.

6. Secure the cable in position with hardware as removed. 7. Press the parking brake actuators together and install the cable to the parking brake actuators.

1800 YRM 1332

Parking Brake

8. Adjust the cable. See Adjust Cable.

5. Install brake wiring harness.

REMOVE

6. Install the manual release cable to the parking brakes. Refer to Replace Cable.

1. Raise and safety chain the mast to prevent unexpected movement while working under the mast. See the section Periodic Maintenance 8000 YRM 1373 for lift truck models ERP16-20VF (ERP3040VF) (A955) or Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15-20VT (ERP030040VT) (G807) for instructions on properly safety chaining the mast.

7. Remove safety chains from the mast. See the section Periodic Maintenance 8000 YRM 1373 for lift truck models ERP16-20VF (ERP30-40VF) (A955) or Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15-20VT (ERP030-040VT) (G807) for instructions on properly removing safety chains from the mast.

2. Turn the key switch to the OFF position and disconnect the battery. 3. Block the wheels of the truck to prevent unexpected movement.

8. Remove blocks from the wheels. 9. Connect the battery, sit in the seat and turn the key switch to the ON position. Listen for the parking brakes to release. Check for proper operation.

4. Disconnect the parking brake wiring harness near the parking brake assembly. 5. Disconnect the manual release cable from the parking brakes. Refer to Replace Cable. 6. Remove the four capscrews, lockwashers, and washers securing the brake assembly to the drive motor. See Figure 13. 7. Slide brake assembly from the hub. 8. Remove the retaining ring securing the hub to the motor shaft. Slide the hub off the motor shaft. Recover the Woodruff key.

INSTALL 1. Install the Woodruff key to the motor shaft. See Figure 13. 2. Install the hub onto the motor shaft with key groove aligned with the Woodruff key in the motor shaft. 3. Install the snap ring into the groove in the motor shaft to secure hub in place.

1. 2. 3. 4. 5.

TRACTION MOTOR SHAFT WOODRUFF KEY SNAP RING HUB

6. 7. 8. 9. 10.

BRAKE WIRING BRAKE ASSEMBLY WASHER LOCKWASHER CAPSCREW

Figure 13. Parking Brake

4. Position the brake assembly onto the hub and secure to the motor housing using four capscrews, lockwashers, and washers.

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

1800 YRM 1332

12/10 (2/10)(1/09)(7/08) Printed in U.S.A.

Maintenance

CAPACITIES AND SPECIFICATIONS ERP15-20VT (ERP030-040VT) [G807]

PART NO. 524306565

8000 YRM 1340

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Capacities and Specifications

Table of Contents

1 1 2 2 3 5 5 5 5 5 5 5 6 11 11 12 12 14

This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]

8000 YRM 1340

Lubrication Specifications

General European Model

Wheel Base

Grade Clearance

Turning Radius

Right Angle Aisle Clearance 1

ERP15-16VT

1290.0 mm (50.8 in.)

31%

1476.0 mm (58.1 in.)

3130.0 mm (123.2 in.)

ERP16-20VT

1385.0 mm (54.5 in.)

29%

1575.0 mm (62.0 in.)

3230.0 mm (127.2 in.)

ERP16-20VT

1495.0 mm (58.9 in.)

27%

1676.0 mm (66.0 in.)

3332.0 mm (132.2 in.)

Equipped with two-stage mast and carrying a 1000 mm (39.4 in.) long × 1200 mm (47.2 in.) wide load.

U.S.

Model

Wheel Base

Grade Clearance

Turning Radius

Right Angle Aisle Clearance 1

ERP030VT

1290.0 mm (50.8 in.)

31%

1476.0 mm (58.1 in.)

3130.0 mm (123.2 in.)

ERP035040VT

1385.0 mm (54.5 in.)

29%

1575.0 mm (62.0 in.)

3230.0 mm (127.2 in.)

Equipped with two-stage mast and carrying a 1000 mm (39.4 in.) long × 1200 mm (47.2 in.) wide load.

Specifications Maximum Gross Vehicle Weight (w/Battery Unladen)

3700 kg (8157 lb)

Counterweight

690 kg (1521 lb)

Maximum Load US

1814 kg (4000 lb)

Maximum Load European

2000 kg (4410 lb)

Lubrication Specifications Lubrication Area

Application Standard

Freezer/Food Processing

Hydraulic System

ISO VG 46 Antiwear Hydraulic Oil

Oil Freezer Exxon Univis (HVI-26) or Equivalent

Brake Master Cylinder

DEXRON III Transmission Fluid

Steering System Fluid

ISO VG 46 Antiwear Hydraulic Oil (Drawn from Hydraulic Tank)

Oil Freezer Exxon Univis (HVI-26) or Equivalent (Drawn from Hydraulic Tank)

Grease

Multipurpose (Lithium Complex) Grease with 2 to 4% Molybdenum Disulfide

Lift Chains and Sheaves

SAE 10W-30

Operator Controls

Silicone Spray Lubricant

Steering System

8000 YRM 1340

Hydraulic System Hydraulic Pump Displacement

17.5 cc/rev

Operating Temperature

0 to 80°C (32 to 176°F)

Filtration

10 Micron Nominal

Max Pressure

18.1 MPa (2611 psi)

Max Peak Pressure

20.6 MPa (2902 psi)

Hydraulic Lift Motor

36/48 Volt AC Motor

Power

12 kW (16 hp)

Speed

600-3000 RPM

Thermal Rating

S3 = 15%

Insulation Hydraulic System

Class "F" Manual Hydraulic Valve

Electric Hydraulic Valve

Main Relief Pressure

18.0 ±0.52 MPa (2610 ±75 psi)

17.9 ±0.52 MPa (2596 ±75 psi)

Secondary Relief Pressure

18.0 ±0.52 MPa (2610 ±75 psi)

15.5 ±0.52 MPa (2248 ±75 psi)

Tank Capacity (To Full Mark)

17.9 liter (19 qt)

System Capacity

19.0 liter (20.0 qt)

Steering System System Specifications Steering System Normal Operating Temperature

Min

Max

30°C ( 22°F)

90°C (194°F)

Steer Tire Angle

0° straight travel 90° left and right for a total of 180°

No. of Turns on Steering Wheel, Steering Lock to Lock

4 1/2 36V

48V

20A ±5A

15A ±5A

Open Center Pressure

0.2 ±0.1 MPa (30 ±15 psi)

0.35 ±0.1 MPa (50 ±15 psi)

Open Center Current

1.2A ±0.75A

1.8A ±0.75A

Steering Relief Current

Steering Control Unit Displacement Relief Valve

70 cc 7.5 ±0.25 MPa (1100 ±36 psi)

8000 YRM 1340

Tire Sizes

System Specifications *Hydraulic Pump Motor Voltage

36 Volts AC

48 Volts AC

Speed

2100 RPM

1850 RPM

Output

0.80 kW (1.07 HP)

Steering Actuator Max Torque

66.7 N•m (49.2 lbf ft)

Oil Pressure (Max Torque)

6.1 MPa (885 psi) 180°

Range of Motion

*Hydraulic pump motor provides fluid flow for steering demands for lift trucks covered in this service manual.

Tire Sizes European Drive Tire

Model

Wheel

Size

Description

Quantity

Size

Description

Quantity

18 × 7 - 8

Snap-On Solid Pneumatic

4.33R-8

SIT

18 × 7 - 8

Snap-On Solid Pneumatic Non-Marking

4.33R-8

SIT

200/50-10

Snap-On Solid Pneumatic

6.50F-10

SIT

200/50-10

Snap-On Solid Pneumatic Non-Marking

6.50F-10

SIT

ERP15-18VT

ERP20VT

European Steer Model

Tires

Wheel

Size

Description

Quantity

Size

Description

Quantity

15 × 4.5 - 8

Snap-On Solid Pneumatic

3.00D-8

SIT

15 × 4.5 - 8

Snap-On Solid Pneumatic Non-marking

3.00D-8

SIT

ERP15-20VT

Tire Sizes

8000 YRM 1340

U.S. Drive Tire

Model

Wheel

Size

Description

Quantity

Size

Description

Quantity

18 × 7 - 8

Solid Pneumatic

4.33R-8

Locking Ring Wheel

18 × 7 - 8

Solid Pnuematic Non-marking

4.33R-8

200/50-10

Solid Pneumatic

6.50F-10

200/50-10

Solid Pneumatic Non-marking

6.50F-10

Locking Ring Wheel

ERP030-040VT

18 x 7 x 12.125

Cushion

Cast Wheel

ERP030-040VT

18 x 7 x 12.125

Cushion Non-marking

Cast Wheel

ERP030-035VT

ERP040VT

Locking Ring Wheel Locking Ring Wheel

U.S. Steer Model

Tires Size

Description

Quantity

Size

Description

Quantity

15 × 4.5 - 8

Solid Pneumatic

4.33R-8

Locking Ring Wheel

15 × 4.5 - 8

Solid Pneumatic Non-Marking

4.33R-8

Locking Ring Wheel

ERP030-040VT

15 x 4 x 11.25

Cushion

Cast Wheel

ERP030-040VT

15 x 4 x 11.25

Cushion Non-marking

Cast Wheel

ERP030-040VT

Wheel

8000 YRM 1340

Torque Specifications

Torque Specifications FRAME

Steer Tire Wheel Nuts 81 N•m (60 lbf ft)

Screws - Overhead Guard Grab Handle 224 N•m (165 lbf ft)

HYDRAULIC SYSTEM

Front Nuts - Overhead Guard 122 N•m (90 lbf ft)

Hydraulic Pump Fittings (Supply) 98 to 110 N•m (72 to 81 lbf ft)

Overhead Guard Leg Capscrews- Front 66 N•m (49 lbf ft)

Hydraulic Pump Fitting (Return) 151 to 166 N•m (111 to 122 lbf ft)

Overhead Guard Leg Capscrews- Rear 66 N•m (49 lbf ft)

E-HYDRAULIC CONTROL VALVE

ELECTRICAL

Tie Rod Nuts 19 to 22 N•m (14 to 16 lbf ft)

Load Weight Sensor 37 N•m (27 lbf ft)

Jam Nuts 7 to 11 N•m (5 to 8 lbf ft)

Motor Controller Power Cables 13 to 15 N•m (115 to 133 lbf in)

Fitting, Inlet Section 16 N•m (12 lbf ft)

STEERING SYSTEM

Compensator Plug 47 N•m (35 lbf ft)

Steering Disc 41 to 54 N•m (30 to 40 lbf ft) Capscrews- Rotary Actuator to Frame 63 N•m (46 lbf ft) Capscrews- Power Steering Pump Body 34 to 40 N•m (25 to 30 lbf ft) Capscrews - Hydraulic Steering Motor 5 to 8 N•m (4 to 6 lbf ft) Capscrews - Flange Cover (6 places) 30 to 36 N•m (22 to 27 lbf ft) Capscrews - End Cover (6 places) 30 to 36 N•m (22 to 27 lbf ft) Capscrews - Steering Control Unit to Steering Column 19 N•m (14 lbf ft) Capscrews - Steering Motor Assembly Upper Mounting Brackets 52 N•m (38 lbf ft) Capscrews - Steering Motor Assembly Lower Mounting Brackets 34 N•m (25 lbf ft) Capscrews - Gear Housing 84 N•m (62 lbf ft) Hydraulic Fittings - Steering Pump 24.9 to 29.4 N•m (18 to 22 lbf ft)

Main Relief Valve 27 N•m (20 lbf ft) Pilot Cartridge 65 N•m (48 lbf ft) Plug, Lift Section 27 N•m (20 lbf ft) Manual Lowering Valve 54 N•m (40 lbf ft) Port Option Plug 54 N•m (40 lbf ft) Plug, Tilt Section 27 N•m (20 lbf ft) Tilt Relief Valve 27 N•m (20 lbf ft)

TRANSAXLE Transaxle to Frame 220 N•m (162 lbf ft) Fixing Plate and Disc Carrier to Spur Gear 70 N•m (52 lbf ft) Wheel Lug Nuts 170 N•m (125 lbf ft)(Lubed)

Mast Speeds

8000 YRM 1340

Ring Gear to Transaxle Housing 70 N•m (52 lbf ft)

Oil Check Plug 22 N•m (16 lbf ft)

Oil Fill Plug 22 N•m (16 lbf ft)

Brake Line Port Fitting 12 to 16 N•m (9 to 12 lbf ft)

Oil Drain Plug 22 N•m (16 lbf ft)

Retainer Cap Bolts 35 N•m (26 lbf ft)

Mast Speeds European Lowering M/Sec (F/Min) Model

Voltage

Mast

No Load

Rated Load

No Load

Rated Load

ERP15VT

48V

Two-Stage LFL (A270)

N/A

Two-Stage FFL (A272)

N/A

Three-Stage FFL (A271)

0.50 m (98 ft)

0.53 m (104 ft)

0.58 m (114 ft)

0.45 m (89 ft)

Two-Stage LFL (A270)

N/A

Two-Stage FFL (A272)

N/A

Three-Stage FFL (A271)

0.50 m (98 ft)

0.53 m (104 ft)

0.58 m (114 ft)

0.45 m (89 ft)

Two-Stage LFL (A270)

N/A

Two-Stage FFL (A272)

N/A

Three-Stage FFL (A271)

N/A

ERP16VT

48V

ERP18VT

48V

LFL = Limited Free Lift FFL = Full-Free Lift N/A = Not Available Mast with Serial Numbers A270, A271, and A272 Are High Visibility Mast Oil temperature 43 to 54°C (110 to 130°F). Freezer truck lift speed to be checked at temperature -18 to -29°C (0 to -20°F). Lifting and lowering speeds with valve fully open ± 3% acceptable.

Lifting M/Sec (F/Min)

8000 YRM 1340

Mast Speeds

European Lowering M/Sec (F/Min) Model

Voltage

ERP20VT

48V

Lifting M/Sec (F/Min)

Mast

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL (A270)

N/A

Two-Stage FFL (A272)

N/A

Three-Stage FFL (A271)

N/A

European and U.S. Lowering M/Sec (F/Min)

Lifting M/Sec (F/Min)

Model

Voltage

Mast

No Load

Rated Load

No Load

Rated Load

ERP15VT

48V

Two-Stage LFL (C661)

N/A

Two-Stage FFL (C663)

N/A

Three-Stage FFL (C662)

N/A

Two-Stage LFL (A270)

N/A

Two-Stage FFL (A272)

N/A

Three-Stage FFL (A271)

0.50 m (98 ft)

0.53 m (104 ft)

0.58 m (114 ft)

0.45 m (89 ft)

LFL = Limited Free Lift FFL = Full-Free Lift N/A = Not Available Mast with Serial Numbers A270, A271, and A272 Are High Visibility Mast Mast with Serial Numbers C661, C662, and C663 are Heavy Duty Mast Oil temperature 43 to 54°C (110 to 130°F). Freezer truck lift speed to be checked at temperature -18 to -29°C (0 to -20°F). Lifting and lowering speeds with valve fully open ± 3% acceptable.

Mast Speeds

8000 YRM 1340

European and U.S. Lowering M/Sec (F/Min) Model

Voltage

36V

ERP16VT (ERP030VT)

48V

Mast

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL (C661)

N/A

Two-Stage FFL (C663)

N/A

Three-Stage FFL (C662)

0.50 m (0.98 ft)

0.53 m (104 ft)

0.58 m (114 ft)

0.45 m (0.89 ft)

Two-Stage LFL (A270)

N/A

Two-Stage FFL (A272)

N/A

Three-Stage FFL (A271)

0.50 m (0.98 ft)

0.53 m (104 ft)

0.58 m (114 ft)

0.45 m (0.89 ft)

Two-Stage LFL (C661)

N/A

Two-Stage FFL (C663)

N/A

Three-Stage FFL (C662)

0.50 m (98 ft)

0.53 m (104 ft)

0.58 m (114 ft)

0.45 m (89 ft)

Two-Stage LFL (A270)

N/A

Two-Stage FFL (A272)

N/A

Three-Stage FFL (A271)

0.50 m (98 ft)

0.53 m (104 ft)

0.58 m (114 ft)

0.45 m (89 ft)

Lifting M/Sec (F/Min)

8000 YRM 1340

Mast Speeds

European and U.S. Lowering M/Sec (F/Min) Model

Voltage

36V

ERP18VT (ERP035VT)

48V

Lifting M/Sec (F/Min)

Mast

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL (C661)

N/A

Two-Stage FFL (C663)

N/A

Three-Stage FFL (C662)

0.50 m (98 ft)

0.53 m (104 ft)

0.58 m (114 ft)

0.40 m (79 ft)

Two-Stage LFL (A270)

N/A

Two-Stage FFL (A272)

N/A

Three-Stage FFL (A271)

N/A

Two-Stage LFL (C661)

N/A

Two-Stage FFL (C663)

N/A

Three-Stage FFL (C662)

0.50 m (98 ft)

0.53 m (104 ft)

0.58 m (114 ft)

0.40 m (79 ft)

Two-Stage LFL (A270)

N/A

Two-Stage FFL (A272)

N/A

Three-Stage FFL (A271)

N/A

Mast Speeds

8000 YRM 1340

European and U.S. Lowering M/Sec (F/Min) Model

Voltage

36V

ERP20VT (ERP040VT)

48V

Mast

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL (C661)

N/A

Two-Stage FFL (C663)

N/A

Three-Stage FFL (C662)

0.50 m (98 ft)

0.53 m (104 ft)

0.58 m (114 ft)

0.40 m (79 ft)

Two-Stage LFL (A270)

N/A

Two-Stage FFL (A272)

N/A

Three-Stage FFL (A271)

N/A

Two-Stage LFL (C661)

N/A

Two-Stage FFL (C663)

N/A

Three-Stage FFL (C662)

0.50 m (98 ft)

0.53 m (104 ft)

0.58 m (114 ft)

0.40 m (79 ft)

Two-Stage LFL (A270)

N/A

Two-Stage FFL (A272)

N/A

Three-Stage FFL (A271)

N/A

Lifting M/Sec (F/Min)

8000 YRM 1340

Tilt Angles

Maximum Carriage and Tilt Creep Rates Measure with mast vertical and rated load at 2.5 m (8.2 ft) high and with the lift, tilt, and auxiliary control levers in neutral position. Hydraulic Oil Temperature

Maximum Vertical Creep at Carriage

Maximum Tilt Creep Mast Angle

Cylinder Stroke

mm/Min

in/Min

Deg/Min

mm/Min

in/Min

20°C (68°F)

N/A

30°C (86°F)

N/A

40°C (104°F)

N/A

50°C (120°F)

10.0

0.375

0.50

N/A

60°C (140°F)

N/A

Tilt Angles Lift truck should be on level ground and in unloaded condition.

NOTE: Tilt speeds (all masts) with hydraulic oil at 50°C (122°F) and freezer oil at 24 ±5°C (75 ±5°F).

NOTE: Tilt drift must not exceed 0.50° in 1 minute.

Table 1. Tilt Angles Mast Type

Forward

Back

Tilt Speed (Max.) Time (Sec.)

Two-Stage LFL

*10°

5°

3.5 to 6.0

5°

2.0 to 4.0

*10°

5°

3.5 to 6.0

5°

2.0 to 4.0

*10°

5°

3.5 to 6.0

5°

2.0 to 4.0

Two-Stage FFL

Three-Stage FFL

*10° Forward is an optional feature LFL = Limited Free-Lift mast FFL = Full Free-Lift mast

Travel Speeds

8000 YRM 1340

Transaxle Assembly Function

Specification

36 Volts AC

48 Volts AC

1950 rpm

Power (S2 60 min)

4.80 kW (6.43 hp)

5.00 kW (6.71 hp)

Stator Resistance

6.10 ±0.10 ohms

10.00 ± 0.10 ohms

Traction Motor Traction Motor Speed

26.6:1

Gear Ratio Drive Wheel Load

2860 kg (6305 lb)

Fluid Type

Dexron III Transmission Fluid

Fluid Capacity

0.60 liter (0.63 qt)

Brake Specifications Torque at Axle

2200 N•m (1623 lbf ft)

Hold on Grade (Rated Load)

15% Grade

Travel Speeds European Maximum Travel Speed Model

Voltage

ERP15-1.6VT

ERP18VT

ERP20VT

Extended Shift

No Load

Full Load

kph

mph

kph

mph

14.5

9.0

14.5

9.0

OFF

16.0

9.9

16.0

9.9

14.5

9.0

14.5

9.0

OFF

16.0

9.9

16.0

9.9

14.5

9.0

14.5

9.0

OFF

16.0

9.9

16.0

9.9

8000 YRM 1340

Travel Speeds

U.S. Maximum Travel Speed Model

Voltage

36 ERP030VT 48

36 ERP035VT 48

36 ERP040VT 48

Extended Shift

No Load

Full Load

kph

mph

kph

mph

N/A

OFF

N/A

14.5

9.0

14.5

9.0

OFF

16.0

9.9

16.0

9.9

N/A

OFF

N/A

14.5

9.0

14.5

9.0

OFF

16.0

9.9

16.0

9.9

N/A

OFF

N/A

14.5

9.0

14.5

9.0

OFF

16.0

9.9

16.0

9.9

N/A = Not Available.

Battery

8000 YRM 1340

Battery

Figure 1. Battery Compartment Dimensions Battery Compartment Dimensions (European) Height (Z) Model

Wheel Base

Width (X)

Length (Y)

NMHG Custom Battery

DIN Drop-in Battery

DIN Side REM Battery

ERP15-16VT

1290.0 mm (50.4 in.)

991 mm (39 in.)

546.0 mm (21.5 in.)

677.0 mm (26.7 in.)

643.0 mm (25.3 in.)

ERP16-20VT

1385.0 mm (54.5 in.)

991 mm (39 in.)

642.0 mm (25.2 in.)

677.0 mm (26.7 in.)

643.0 mm (25.3 in.)

ERP16-20VT

1495.0 mm (58.9 in.)

991 mm (39 in.)

750.0 mm (29.5 in.)

677.0 mm (26.7 in.)

643.0 mm (25.3 in.)

Measurement with acid plate and appropriate counterweight/spacer installed.

Battery Compartment Dimensions (U.S.) Height (Z)

Model

Wheel Base

Width (X)

Length (Y)

ERP030VT

1290.0 mm (50.4 in.)

991 mm (39 in.)

ERP035VT

1385.0 mm (54.5 in.)

ERP040VT

1385.0 mm (54.5 in.)

OPT Battery

STD Battery

Side REM Battery

546.0 mm (21.5 in.)

663.0 mm (26.1 in.)

587.00 mm (23.12 in.)

587.00 mm (23.1 in.)

991 mm (39 in.)

642.0 mm (25.2 in.)

663.0 mm (26.1 in.)

587.00 mm (23.12 in.)

587.00 mm (23.1 in.)

991 mm (39 in.)

642.0 mm (25.2 in.)

663.0 mm (26.1 in.)

587.00 mm (23.12 in.)

587.00 mm (23.1 in.)

Measurement with acid plate and appropriate counterweight/spacer installed.

8000 YRM 1340

Battery

Battery Discharge Rate (European.) 1 Model

ERP15-16VT

ERP18VT

ERP20VT

Wheel Base

Max Amp Hours

Max kW Hours

48 V

DIN

420

20.2

DIN

460

22.1

DIN

500

24.0

NMHG custom

595

28.6

NMHG custom

700

336

DIN

575

27.6

DIN

625

30.0

NMHG custom

625

30.0

NMHG custom

750

36.0

DIN

690

33.1

DIN

750

36.0

NMHG custom

690

33.1

NMHG custom

750

36.0

Type

1290.0 mm (50.8 in.)

1385.0 mm (54.5 in.)

1495.0 mm (58.9 in.)

Calculated using 5-hour rate. Battery Discharge Rate (U.S.) 1 Model

Max Amp Hours

Max kW Hours

36 V

48 V

36 V

48 V

ERP030VT

880

660

30.9

ERP035VT

1100

770

38.6

36.0

ERP40VT

1100

770

38.6

36.0

Calculated using 6-hour rate.

Battery

8000 YRM 1340

Figure 2. Battery Dimensions Battery Specifications (European) Model

Type (48 V)

Wheel Base

NMHG Custom

ERP15-16VT

DIN Drop-In

DIN Side REM 1

1290.0 mm (50.8 in.)

Weight MIN

800 kg (1765 lb)

MAX

1100 kg (2425 lb)

MIN

673 kg (1480 lb)

MAX

743 kg (1640 lb)

MIN

673 kg (1480 lb)

MAX

743 kg (1640 lb)

Used with acid plate and appropriate counterweight/spacer installed.

Width (X)

Length (Y)

Height (Z)

980.0 mm (38.6 in.) MIN

537.0 mm (21.1 in.) MIN

664.0 mm (26.1 in.) MAX

830.0 mm (32.7 in.) MAX

522.0 mm (20.6 in.) MAX

630.0 mm (24.8 in.) MAX

8000 YRM 1340

Battery

Battery Specifications (European) Model

Type (48 V)

Wheel Base

NMHG Custom

ERP16VT

DIN Drop-In

1385.0 mm (54.5 in.)

DIN Side REM

NMHG Custom

ERP18VT

DIN Drop-In

1385.0 mm (54.5 in.)

DIN Side REM

NMHG Custom

ERP20VT

DIN Drop-In

DIN Side REM 1

1385.0 mm (54.5 in.)

Weight MIN

1000 kg (2205 lb)

MAX

1200 kg (2646 lb)

MIN

813 kg (1790 lb)

MAX

899 kg (1980 lb)

MIN

813 kg (1790 lb)

MAX

899 kg (1980 lb)

MIN

1000 kg (2205 lb)

MAX

1200 kg (2646 lb)

MIN

813 kg (1792 lb)

MAX

899 kg (1982 lb)

MIN

813 kg (1792 lb)

MAX

899 kg (1982 lb)

MIN

1225 kg (2700 lb)

MAX

1300 kg (2866 lb)

MIN

813 kg (1792 lb)

MAX

899 kg (1982 lb)

MIN

813 kg (1792 lb)

MAX

899 kg (1982 lb)

Width (X)

Length (Y)

Height (Z)

980.0 mm (38.6 in.)

632.0 mm (24.9 in.)

664.0 mm (26.1 in.) MAX

830.0 mm (32.7 in.) MAX

630.0 mm (24.8 in.) MAX

980.0 mm (38.6 in.)

632.0 mm (24.9 in.)

664.0 mm (26.1 in.) MAX

830.0 mm (32.7 in.) MAX

630.0 mm (24.8 in.)

980.0 mm (36.8 in.)

632.0 mm (24.9 in.)

664.0 mm (26.1 in.)

830.0 mm (32.7 in.)

630.0 mm (24.8 in.)

Used with acid plate and appropriate counterweight/spacer installed.

Battery

8000 YRM 1340

Battery Specifications (European) Model

Type (48 V)

Wheel Base

NMHG Custom

ERP16VT

DIN Drop-In

1495.0 mm (58.9 in.)

DIN Side REM

NMHG Custom

ERP18VT

DIN Drop-In

1495.0 mm (58.9 in.)

DIN Side REM

NMHG Custom

ERP20VT

DIN Drop-In

DIN Side REM 1

1495.0 mm (58.9 in.)

Weight MIN

1000 kg (2205 lb)

MAX

1300 kg (2866 lb)

MIN

962 kg (2121 lb)

MAX

1064 kg (2346 lb)

MIN

962 kg (2121 lb)

MAX

1064 kg (2346 lb)

MIN

1000 kg (2200 lb)

MAX

1300 kg (2866 lb)

MIN

962 kg (2121 lb)

MAX

1064 kg (2346 lb)

MIN

962 kg (2121 lb)

MAX

1064 kg (2346 lb)

MIN

1000 kg (2200 lb)

MAX

1300 kg (2865 lb)

MIN

962 kg (2120 lb)

MAX

1064 kg (2350 lb)

MIN

962 kg (2120 lb)

MAX

1064 kg (2350 lb)

Used with acid plate and appropriate counterweight/spacer installed.

Width (X)

Length (Y)

Height (Z)

980.0 mm (38.6 in.)

742.0 mm (29.2 in.)

664.0 mm (26.1 in.)

830.0 mm (32.7 in.)

738.0 mm (29.1 in.)

630.0 mm (24.8 in.)

980.0 mm (38.6 in.)

742.0 mm (29.2 in.)

664.0 mm (26.1 in.)

830.0 mm (32.7 in.)

738.0 mm (29.1 in.)

630.0 mm (24.8 in.)

980.0 mm (38.6 in.) MAX

742.0 mm (29.2 in.)

664.0 mm (26.1 in.) MAX

830.0 mm (32.7 in.) MAX

738.0 mm (29.1 in.)

630.0 mm (24.8 in.) MAX

8000 YRM 1340

Battery

Battery Specifications (U.S.) Model

Wheel Base

Type (36/48 V)

Weight (approximate)

ERP030VT

771 kg (1700 lb)

970.0 mm (38.2 in.)

508.0 mm (20.0 in.)

MAX

998 kg (2200 lb)

986.0 mm (38.8 in.)

539.0 mm (21.2 in.)

MIN

907 kg (2000 lb)

970.0 mm (38.2 in.)

508.0 mm (20.0 in.)

MAX

1134 kg (2500 lb)

986.0 mm (38.8 in.)

539.0 mm (21.2 in.)

MIN

771 kg (1700 lb)

970.0 mm (38.2 in.)

508.0 mm (20.0 in.)

MAX

998 kg (2200 lb)

986.0 mm (38.8 in.)

539.0 mm (21.2 in.)

MIN

953 kg (2100 lb)

975.0 mm (38.2 in.)

597.0 mm (23.5 in.)

MAX

1089 kg (2400 lb)

986.0 mm (38.8 in.)

635.0 mm (25.0 in.)

MIN

1134 kg (2500 lb)

975.0 mm (38.2 in.)

597.0 mm (23.5 in.)

MAX

1270 kg (2800 lb)

986.0 mm (38.8 in.)

635.0 mm (25.0 in.)

MIN

953 kg (2100 lb)

975.0 mm (38.2 in.)

597.0 mm (23.5 in.)

MAX

1089 kg (2400 lb)

986.0 mm (38.8 in.)

635.0 mm (25.0 in.)

MIN

953 kg (2100 lb)

975.0 mm (38.2 in.)

597.0 mm (23.5 in.)

MAX

1089 kg (2400 lb)

986.0 mm (38.8 in.)

635.0 mm (25.0 in.)

MIN

1134 kg (2500 lb)

975.0 mm (38.2 in.)

597.0 mm (23.5 in.)

MAX

1270 kg (2800 lb)

986.0 mm (38.8 in.)

635.0 mm (25.0 in.)

MIN

953 kg (2100 lb)

975.0 mm (38.2 in.)

597.0 mm (23.5 in.)

MAX

1089 kg (2400 lb)

986.0 mm (38.8 in.)

635.0 mm (25.0 in.)

OPT

Side REM

STD

ERP035VT

1385.0 mm (54.5 in.)

OPT

Side REM

STD

ERP040VT

1385.0 mm (54.5 in.)

OPT

Side REM

Length (Y)

MIN STD

1290.0 mm (50.4 in.)

Width (X)

Height (Z)

579.0 mm (22.8 in.) MAX

655.0 mm (25.8 in.) MAX

579.0 mm (22.8 in.) MAX

579.0 mm (22.8 in.)

655.0 mm (25.8 in.)

579.0 mm (22.8 in.)

655.0 mm (25.8 in.)

579.0 mm (22.8 in.)

Used with acid plate and appropriate counterweight/spacer installed.

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

8000 YRM 1340

7/11 (11/10)(2/10)(8/08) Printed in U.S.A.

Maintenance

CYLINDER REPAIR ERC22-35VG (ERC045-070VG) [A968]; ERP22-25VL (ERP045-070VL) [A976]; ERP15-20VT (ERP030-040VT) [G807]; ERP15-20VF (ERP30-40VF) [A955]; ESC030-40AC [B883]

PART NO. 524319496

2100 YRM 1382

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Cylinder Repair

Table of Contents

TABLE OF CONTENTS Safety Procedures When Working Near Mast ..................................................................................................... General................................................................................................................................................................ Description .......................................................................................................................................................... Tilt Cylinder Repair for Lift Trucks ERC22-35VG (ERC045-070VG) (A968) ERP22-25VL (ERP045-070VL) (A976) ..................................................................................................................................... Remove ........................................................................................................................................................... Disassemble.................................................................................................................................................... Inspect............................................................................................................................................................. Clean............................................................................................................................................................... Assemble ........................................................................................................................................................ Install............................................................................................................................................................... Tilt Cylinders, Adjust ....................................................................................................................................... Tilt Cylinder Leak Check ................................................................................................................................. Tilt Cylinder Repair for Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-40AC (B883) ..................................................................................................................... Remove ........................................................................................................................................................... Disassemble.................................................................................................................................................... Inspect............................................................................................................................................................. Clean............................................................................................................................................................... Assemble ........................................................................................................................................................ Install............................................................................................................................................................... Tilt Cylinders, Adjust ....................................................................................................................................... Tilt Cylinders Leak Check ............................................................................................................................... Lift Cylinder Repair for Lift Trucks ERC22-35VG (ERC045-070VG) (A968) ERP22-25VL (ERP045-070VL) (A976) ..................................................................................................................................... Main Lift Cylinders........................................................................................................................................... Remove....................................................................................................................................................... Two-Stage FFL ....................................................................................................................................... Three-Stage FFL .................................................................................................................................... Four-Stage FFL ...................................................................................................................................... Two-Stage LFL ....................................................................................................................................... Disassemble ............................................................................................................................................... Two-Stage FFL ....................................................................................................................................... Three-Stage FFL .................................................................................................................................... Four-Stage FFL ...................................................................................................................................... Two-Stage LFL ....................................................................................................................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Two-Stage FFL ....................................................................................................................................... Three-Stage FFL .................................................................................................................................... Four-Stage FFL ...................................................................................................................................... Two-Stage LFL ....................................................................................................................................... Install .......................................................................................................................................................... Two-Stage FFL ....................................................................................................................................... System Air Bleed Procedures................................................................................................................. Three-Stage FFL .................................................................................................................................... Four-Stage FFL ...................................................................................................................................... Two-Stage LFL ....................................................................................................................................... Lift Cylinder Repair for Lift Truck ERP15VT (G807) ............................................................................................ Main Lift Cylinder ............................................................................................................................................

1 3 4 4 4 5 6 6 6 6 7 8 9 9 10 11 12 12 12 13 13 14 14 14 14 14 16 16 16 16 18 18 20 20 21 21 21 21 22 22 23 23 23 23 24 24 25 25

Table of Contents

Cylinder Repair

TABLE OF CONTENTS (Continued) Remove....................................................................................................................................................... Main Lift Cylinders - Two-Stage FFL Mast.............................................................................................. Left-Hand Main Lift Cylinder - Three-Stage FFL Mast............................................................................ Right-Hand Main Lift Cylinder - Three-Stage FFL Mast ......................................................................... Main Lift Cylinder - Two-Stage LFL Mast................................................................................................ Disassemble ............................................................................................................................................... Main Lift Cylinders - Two-Stage FFL Mast.............................................................................................. Main Lift Cylinder - Three-Stage FFL Mast ............................................................................................ Main Lift Cylinder - Two-Stage LFL Mast................................................................................................ Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Main Lift Cylinder - Two-Stage FFL Mast ............................................................................................... Main Lift Cylinder - Three-Stage FFL Mast ............................................................................................ Main Lift Cylinder - Two-Stage LFL Mast................................................................................................ Install .......................................................................................................................................................... Main Lift Cylinder - Two-Stage FFL Mast ............................................................................................... Left-Hand Main Lift Cylinder - Three-Stage FFL Mast............................................................................ Right-Hand Main Lift Cylinder - Three-Stage FFL Mast ......................................................................... Main Lift Cylinder - Two-Stage LFL Mast................................................................................................ System Air Bleed Procedures................................................................................................................. All Main Lift Cylinders ............................................................................................................................. Lift Cylinder Repair for Lift Trucks ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-40AC (B883) ..................................................................................................................... Main Lift Cylinder ............................................................................................................................................ Remove....................................................................................................................................................... Two-Stage FFL ....................................................................................................................................... Three-Stage FFL .................................................................................................................................... Two-Stage LFL ....................................................................................................................................... Four-Stage FFL ...................................................................................................................................... Disassemble ............................................................................................................................................... Two-Stage FFL ....................................................................................................................................... Three-Stage FFL .................................................................................................................................... Two-Stage LFL ....................................................................................................................................... Four-Stage FFL ...................................................................................................................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Two-Stage FFL ....................................................................................................................................... Three-Stage FFL .................................................................................................................................... Two-Stage LFL ....................................................................................................................................... Four-Stage FFL ...................................................................................................................................... Install .......................................................................................................................................................... Two-Stage FFL ....................................................................................................................................... System Air Bleed Procedures................................................................................................................. Three-Stage FFL Mast ........................................................................................................................... Two-Stage LFL ....................................................................................................................................... Four-Stage FFL ...................................................................................................................................... Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL........................... Mast and Carriage Installation for Four-Stage FFL ................................................................................

25 25 27 31 31 33 33 35 35 36 36 36 36 37 37 37 38 38 39 40 40 40 41 41 41 41 42 42 44 46 46 47 48 48 50 51 51 51 52 52 52 53 54 54 54 55 55 56 56

Cylinder Repair

Table of Contents

TABLE OF CONTENTS (Continued) Free-Lift Cylinder Repair for Lift Trucks ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) ..................................................................................................................................... Free-Lift Cylinder............................................................................................................................................. Remove....................................................................................................................................................... Two and Three-Stage FFL Mast ............................................................................................................. Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968)............................................... Disassemble ............................................................................................................................................... Two and Three-Stage FFL Mast ............................................................................................................. Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) ....................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Two and Three-Stage FFL Mast ............................................................................................................. Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) ....................................... Install .......................................................................................................................................................... Two and Three-Stage FFL Mast ............................................................................................................. Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) ......................................... Free Lift Cylinder Repair for Lift Truck ERP15VT (G807) .................................................................................... Free-Lift Cylinder............................................................................................................................................. Remove....................................................................................................................................................... Three-Stage FFL Mast ........................................................................................................................... Disassemble ............................................................................................................................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Install .......................................................................................................................................................... Free Lift Cylinder Repair for Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-40AC (B883)............................................................................................. Free-Lift Cylinder............................................................................................................................................. Remove....................................................................................................................................................... Two and Three-Stage FFL Mast ............................................................................................................. Four-Stage FFL Mast ............................................................................................................................. Disassemble ............................................................................................................................................... Two-Stage and Three-Stage FFL Masts................................................................................................. Four Stage FFL Mast.............................................................................................................................. Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Two-Stage and Three-Stage FFL Masts................................................................................................. Four-Stage FFL Mast ............................................................................................................................. Install .......................................................................................................................................................... Two-Stage and Three-Stage FFL Masts................................................................................................. Four-Stage FFL Mast ............................................................................................................................. All Masts ................................................................................................................................................. Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) ..................................................................................................................................... Tilt Cylinders ................................................................................................................................................... Piston Rod Nut............................................................................................................................................ Gland .......................................................................................................................................................... Tilt Cylinder Mounting Capscrew ................................................................................................................ Tilt Cylinder Rod End Capscrew .................................................................................................................

56 56 56 56 57 59 59 60 60 61 61 61 61 62 62 62 63 63 63 63 64 65 65 65 66 66 66 66 66 68 71 71 71 72 72 73 73 73 73 73 74 76 76 76 76 76 76 76

iii

Table of Contents

Cylinder Repair

TABLE OF CONTENTS (Continued) Main and Free-Lift Cylinder ............................................................................................................................. Torque Specifications for Lift Truck Model ERP15VT (G807) .............................................................................. Tilt Cylinders ................................................................................................................................................... Main and Free-Lift Cylinders ........................................................................................................................... Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-40AC (B883) ............................................................................................. Tilt Cylinders ................................................................................................................................................... Main and Free-Lift Cylinders ........................................................................................................................... This section is for the following models: ERC22-35VG (ERC045-070VG) [A968]; ERP22-25VL (ERP045-070VL) [A976]; ERP15-20VT (ERP030-040VT) [G807]; ERP15-20VF (ERP30-40VF) [A955]; ESC030-40AC [B883]

76 77 77 77 78 78 78

2100 YRM 1382

Safety Procedures When Working Near Mast

Safety Procedures When Working Near Mast The following procedures MUST be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage. • Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed. Also make sure that the power is OFF and the key is removed. Put a DO NOT OPERATE tag in the operator’s compartment. Disconnect the battery and put a tag or lock on the battery connector. • Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury. • DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast. • DO NOT use blocks to support the mast weldments nor to restrain their movement. • Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in this section. WHEN WORKING NEAR THE MAST ALWAYS: • Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered. OR • If parts of the mast must be in a raised position, install a safety chain to restrain the moving parts

of the mast. Connect moving parts to a part that does not move. Follow these procedures: 1. Put mast in vertical position. 2. Raise mast to align bottom crossmember of weldment that moves in outer weldment with crossmember on outer weldment. On the two-stage and freelift mast, the moving part is the inner weldment. On the three-stage mast, it is the intermediate weldment. On the four-stage mast, it is the first intermediate weldment. See Figure 1. 3. Use a 3/8-inch (minimum) safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Put hook on back side of mast. Make sure hook is completely engaged with a link in the chain. Make sure safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast. 4. Lower mast until there is tension in safety chain and free-lift cylinder (two-stage full free-lift, three-stage, and four-stage) is completely retracted. If running, turn the power OFF. Apply the parking brake. Install a DO NOT REMOVE tag on the safety chain(s). 5. Install another safety chain (3/8-in. minimum) between the top or bottom crossmember of the carriage bar and a crossmember on the outer weldment. 6. After lowering or restraining the mast, shut off the power, and remove key. NOTE: Place a DO NOT OPERATE tag in the operator’s compartment. 7. Disconnect battery and put a tag or lock on battery connector.

Safety Procedures When Working Near Mast

2100 YRM 1382

A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST

C. THREE-STAGE FFL MAST D. FOUR-STAGE FFL MAST

1. 2. 3. 4.

5. 6. 7. 8.

OUTER WELDMENT INNER WELDMENT INTERMEDIATE WELDMENT HOOK

FREE-LIFT CYLINDER CARRIAGE BAR CROSSMEMBER FIRST INTERMEDIATE WELDMENT

Figure 1. Safety Chaining the Mast (Sit-Down Lift Trucks)

2100 YRM 1382

General

NOTE: TWO-STAGE MASTS SHOWN. FOR THREE-STAGE MAST, ALIGN THE CROSSEMEMBER OF INTERMEDIATE WELDMENT ALONG WITH INNER AND OUTER WELDMENTS WHEN CHAINING THE MAST. A. LIMITED FREE-LIFT MAST

B. FULL FREE-LIFT MAST

1. SAFETY CHAIN AND HOOK 2. MAST CROSSMEMBERS ALIGNED 3. INNER WELDMENT

4. CARRIAGE (TOP BAR) 5. FREE-LIFT CYLINDER 6. OUTER WELDMENT

Figure 2. Safety Chaining the Masts (Stand-Up Lift Trucks)

General This section contains repair procedures for tilt cylinders, main lift cylinder, and free-lift cylinders. The number

and the design of the parts can be different, but the operation of the cylinders is the same.

Tilt Cylinder Repair

2100 YRM 1382

Description This manual covers many different types of cylinders. Each cylinder will be described in detail.

single external lowering control valve is connected by tubing and hoses to all the lift cylinders.

Tilt cylinders are fastened between the frame of the lift truck and the outer weldment of the mast to change the angle of the mast and forks.

NOTE: On lift truck models ERC22-35VG (ERC045070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) there are two free-lift chains and chain sheaves.

Two single-stage main lift cylinders and a free-lift cylinder are used to raise the carriage and extend the mast weldments.

On lift truck models ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883) there is one free-lift chain and chain sheave. The description below applies to all trucks.

The two main lift cylinders are installed at the back of the outer mast. The base of each lift cylinder sits on a mount at the bottom crossmember of the outer mast. The top of each main lift cylinder rod fits into a guide on the top crossmember of the inner mast. The freelift cylinder is installed in the inner mast. Each of the lift cylinders has an internal lowering control valve. A

The free-lift chains connect at one end of the mid-crossmember of the inner mast. Chain sheaves are installed on a crosshead on the rod of the free-lift cylinder. The chains then go over sheaves on the crosshead and connect to the carriage.

Tilt Cylinder Repair for Lift Trucks ERC22-35VG (ERC045-070VG) (A968) ERP22-25VL (ERP045-070VL) (A976) REMOVE WARNING Before removing the tilt cylinder(s), tilt the mast forward. Use a chain to hold the mast to the frame and prevent the mast from moving forward.

WARNING DO NOT push the anchor pins out of the rod end with your fingers. DO NOT permit the tilt cylinders to drop and cause damage. 1. At the mast, remove capscrew and retainer from anchor pin. Using a drift pin or similar tool, push anchor pin out of rod end. See Figure 3.

2. Stroke tilt cylinder to the full back tilt position. 3. Disconnect hydraulic line at tilt cylinder. Install cap on hydraulic line and in cylinder port. 4. Use a lifting device to hold tilt cylinder. Remove capscrew and retainer from anchor pin. Using a drift pin or similar tool, push anchor pin out of lift truck frame. 5. Using lifting device, remove tilt cylinder from lift truck. 6. If necessary, repeat Step 1 through Step 5 for opposite tilt cylinder.

2100 YRM 1382

Tilt Cylinder Repair

NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY. 1. CAPSCREW 2. RETAINER

3. LUBRICATION FITTING 4. ANCHOR PIN

5. TILT SPACER

Figure 3. Tilt Cylinder Removal

DISASSEMBLE NOTE: The following steps have detailed disassembly instructions. Perform only those steps required to repair the tilt cylinder. NOTE: Note position of rod end and number of turns used to remove it from rod. 1. Place tilt cylinder in a soft jaw vise. Remove rod end and, if equipped, tilt spacer from rod. 2. Using a pin-type spanner wrench, remove gland from rod and shell. Remove rod and piston assembly from shell. NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 3. Remove and discard O-ring, backup ring, seal, and rod wiper from gland. See Figure 4. 1. 2. 3. 4. 5. 6.

SHELL GLAND ROD ROD WIPER SEAL BACKUP RING

7. 8. 9. 10. 11.

O-RING PISTON PISTON SEAL NUT BUSHING

Figure 4. Tilt Cylinder

Tilt Cylinder Repair

2100 YRM 1382

NOTE: Perform Step 4 only if piston or rod has been damaged.

1. Install new piston seal and O-ring on the piston. See Figure 4.

4. Place rod in a soft-jaw vise and remove nut and piston from rod. See Figure 4.

NOTE: Perform Step 2 only if piston was removed from rod.

5. Remove and discard O-ring and piston seal from piston. See Figure 4.

2. Place rod in a soft-jaw vise and lube the threads of the nut with hydraulic oil. Install piston on rod and tighten nut to:

INSPECT Inspect gland for damage to threads and seal surfaces. If damaged, replace gland. Inspect piston for any damage to seal surfaces. If damaged, replace piston. Inspect rod for damage to rod surface and ensure that rod is not bent. If damaged, replace rod. Inspect inner surface of cylinder tube for damage. If damaged, replace tilt cylinder assembly. Inspect bushings for damage. These bushings are in the frame and mast tilt cylinder connection points. If damaged, replace bushings.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION DO NOT allow cleaning solvent to come in contact with rubber components, as it will damage those components. Clean all metal parts in solvent and dry with compressed air.

ASSEMBLE NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings. NOTE: Lubricate new seals, O-rings, and rings with clean hydraulic oil before installation.

170 to 220 N•m (125 to 162 lbf ft) on lift truck models • ERC22-25VG (ERC045-055VG) (A968) • ERP22-25VL (ERP045-050VL) (A976) 320 to 400 N•m (236 to 295 lbf ft) on lift truck models • ERC30-35VG (ERC060-070VG) (A968) • ERP30-35VL (ERP060-070VL) (A976) 3. Install new rod wiper, seal, backup ring, and O-ring on gland. See Figure 4. 4. Install rod and piston assembly into shell. Using a pin-type spanner, install gland onto rod in shell. Tighten gland to: 170 to 237 N•m (125 to 175 lbf ft) for lift truck models • ERC30-35VG (ERC045-055VG) (A968) • ERP30-35VL (ERP060-070VL) (A976) 400 to 500 N•m (295 to 370 lbf ft) for lift truck models • ERC30-35VG (ERC060-070VG) (A968) • ERP30-35VL (ERP060-070VL) (A976) 5. Place cylinder in a soft-jaw vise and install tilt spacer, if equipped, and rod end on rod as noted during removal. Lubricate threads on capscrew with lubricant, Yale Part No. 504234269. Install capscrew in rod end so that capscrew head is on the inboard side of rod end. Install washer and nut on capscrew. Washer and nut must be on the outboard side of rod end. See Figure 5. Tighten nut to 105 N•m (77 lbf ft). 6. Repeat above steps for other tilt cylinder.

INSTALL 1. Using a lifting device, place cylinder in mounting position on lift truck frame. Install anchor pin. Install retainer and capscrew. See Figure 3. Lubricate threads on bolt that secures rod end to piston with lubricant, Yale Part No. 504234269. Install washer and nut on bolt that secures the rod end. Tighten nut to 38 N•m (28 lbf ft).

2100 YRM 1382

Tilt Cylinder Repair tilt too much and cause an accident or serious injury. Check tilt cylinder stroke by slowly tilting mast fully forward and backward several times. Both tilt cylinders must stop their stroke at the same time. Adjust rod ends as shown in Figure 6. There must be no twist in mast weldments.

NOTE: LEFT TILT CYLINDER SHOWN. A. OUTBOARD SIDE OF ROD END 1. 2. 3. 4. 5. 6.

B. INBOARD SIDE OF ROD END

CAPSCREW NUT WASHER TILT SPACER ROD END MAST END MOUNT Figure 5. Rod End Installation

2. Connect hydraulic lines to tilt cylinder. Slowly stroke cylinders until rod holes line up with mast tilt anchor holes. 3. Install anchor pin and retainer on tilt anchor.

A. DIMENSION A = 15 mm (0.60 in.) 1. MAST 2. ROD END 3. SHIMS

4. TILT LIMIT SPACER 5. TILT CYLINDER

4. Repeat above steps for remaining tilt cylinder.

Figure 6. Tilt Cylinder Adjustments

5. Remove chain holding mast to lift truck frame.

1. Adjust the stroke of the tilt cylinders WITHOUT tilt limit spacers as follows:

WARNING DO NOT put hands between the cylinder rod end and the mast. Serious injury can occur. 6. Operate tilt cylinders. Check for correct operation and leakage. Adjust tilt cylinders.

TILT CYLINDERS, ADJUST WARNING When the tilt cylinders have tilt limit spacers, make sure they are installed during installation procedures. Without the tilt limit spacers, the mast can

a. Adjust rod ends to 15 mm (0.6 in.). b. Slowly tilt mast backward until one cylinder rod stops. On the opposite cylinder, loosen capscrews on rod end. Measure the distance from the end of the cylinder to the back end of the rod end. Use a wrench and turn the cylinder rod IN until the dimension starts to decrease, then stop. Repeat this procedure until both cylinder rods stop at the same position within 0.5 mm (0.02 in.). After the adjustments are complete, tighten nuts on rod ends to 105 N•m (77 lbf ft).

Tilt Cylinder Repair

2100 YRM 1382

c. Tilt mast fully backward and measure tilt angle. See the Nameplate for tilt angles. If necessary, adjust both rod ends equally for the correct angle. NOTE: Dimension A cannot exceed 20 mm (0.60 in.). 2. Adjust the stroke of the tilt cylinders WITH tilt limit spacers as follows: a. Adjust rod ends to 15 mm (0.6 in.) for all tilt cylinders as shown in Figure 6. b. Slowly tilt mast forward until one cylinder rod stops. On the opposite cylinder, loosen capscrews on rod end. Use a wrench and turn the cylinder rod IN as necessary. Repeat this procedure until both cylinder rods stop at the same position within 0.5 mm (0.02 in.). c. Slowly tilt mast backward until one rod end just contacts the spacer. Add shims to fill the gap at the opposite rod end until both rod ends contact the spacers within 0.5 mm (0.02 in.). d. After adjustments are complete, tighten nuts on rod ends to 105 N•m (77 lbf ft). e. Tilt mast fully backward and measure the tilt angle. See the nameplate for tilt angles. If necessary, add an equal number of shims to both rods for the correct angle. NOTE: Dimension A cannot exceed 0.5 mm (0.02 in.).

TILT CYLINDER LEAK CHECK WARNING Never allow anyone under a raised carriage. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the key switch or keyless switch is turned OFF. DO NOT try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by the pressure. 1. Put a capacity load on the forks. Use a safety chain to hold the load to the carriage. Raise the load approximately 2.5 m (8 ft). Put the mast in a vertical position. 2. Measure the distance that the tilt cylinder rod extends from the shell. Check the distance the rod moves in five or ten minutes. See Table 1. 3. If the tilt rate is greater than the specifications, lower the mast and remove the load from the forks. Install a valve between the port at the front of the tilt cylinder and the hydraulic line. The valve must be able to completely shut off the flow of hydraulic oil. Put the load on the forks again. Close the valve. Tilt the mast forward just past the vertical position. If the mast continues to tilt SLOWLY forward, the seals on the piston are leaking. 4. If the mast does not move, open the valve and check the movement again. If the mast moves forward when the gate valve is open, check for leaks in the hydraulic lines and fittings. If no leaks are found, the main control valve may be worn or damaged. Remove the load from the forks when the checks are complete.

Table 1. Movement Rates (Maximum) for Tilt Cylinders, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) Hydraulic Oil Temperature/Mast Tilt Rate 20 C (68 F)

30 C (86 F)

40 C (104 F)

50 C (122 F)

60 C (140 F)

mm/min

in./min

mm/min

in./min

mm/min

in./min

mm/min

in./min

mm/min

in./min

0.88

0.035

1.32

0.05

2.56

0.10

4.14

0.16

5.99

0.24

2100 YRM 1382

Tilt Cylinder Repair

Tilt Cylinder Repair for Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-40AC (B883) REMOVE

WARNING

WARNING Before removing the tilt cylinder(s), tilt the mast forward. Use a chain to hold the mast to the frame and prevent the mast from moving forward.

DO NOT push the anchor pins out of the rod end with your fingers. DO NOT permit the tilt cylinder(s) to drop and cause damage. 1. At the mast, remove capscrew, lock washer, and special washer. Using drift pin or similar tool remove rod end pin from rod end and tilt anchor. See Figure 7 or Figure 8.

NOTE: RIGHT-HAND TILT CYLINDER FOR ERP16-20VT (ERP030-040VT) (G807) AND ERP16-20VF (ERP3040VF) (A955) SHOWN. 1. 2. 3. 4. 5. 6.

ROD END PIN SPECIAL WASHER WASHER CAPSCREW ROD END COTTER PIN

7. 8. 9. 10. 11. 12.

LUBE FITTING BUSHING MOUNTING PLATE FRONT CROSSMEMBER ANCHOR PIN LOCK WASHER EXTERNAL TOOTH

Figure 7. Tilt Cylinder Connections

Tilt Cylinder Repair

2100 YRM 1382 8. Repeat Step 1 through Step 7 for opposite tilt cylinder.

DISASSEMBLE NOTE: The following steps have detailed disassembly instructions. Perform only those steps required to repair tilt cylinder. NOTE: Note position of rod end and number of turns used to remove it from rod. 1. Place tilt cylinder in a soft jaw vise. Remove nut, washer, capscrew, and rod end. See Figure 9. If equipped, remove tilt spacer from rod. See Figure 10. 2. Using a pin-type spanner wrench, remove gland from tilt cylinder. Remove rod and piston assembly from shell. See Figure 10. NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 3. Remove and discard rod wiper, rod seal, backup ring, and O-ring from gland. See Figure 10. NOTE: RIGHT-HAND TILT CYLINDER FOR FOR LIFT TRUCKS ESC030-40AC (B883) SHOWN.

4. Place rod in a soft jawed vise and remove lock nut and piston from rod. See Figure 10.

1. 2. 3. 4. 5. 6.

MOUNTING PLATE (FRAME) ANCHOR PIN (WITH GREASE FITTING) SHIMS COTTER PIN ROD END CAPSCREW, LOCKWASHER, AND SPECIAL WASHER 7. ROD END PIN (WITH GREASE FITTING) 8. TILT MOUNTING FLANGE (MAST) Figure 8. Tilt Cylinder Connections 2. Stroke tilt cylinder to the full back tilt position. 3. Disconnect hydraulic line at tilt cylinder. Install cap on hydraulic line and in cylinder port. 4. Remove cotter pin and two washers from anchor pin. Discard cotter pin. See Figure 7. 5. Remove anchor pin and washer using drift pin or similar tool from rod end and mounting plate. See Figure 7. 6. Using a lifting device, remove tilt cylinder from lift truck. 7. Remove washer. See Figure 7.

A. OUTBOARD SIDE OF ROD END

B. INBOARD SIDE OF ROD END

1. NUT 2. WASHER

3. CAPSCREW 4. ROD END Figure 9. Rod End

2100 YRM 1382

1. 2. 3. 4. 5. 6.

Tilt Cylinder Repair

7. 8. 9. 10. 11.

SHELL GLAND ROD ROD WIPER ROD SEAL BACKUP RING

O-RING LOCK NUT PISTON PISTON SEAL SPACER

Figure 10. Tilt Cylinder 5. Remove and discard O-ring and piston seal from piston. See Figure 10.

Inspect rod for damage to rod surface and ensure rod is not bent. If damaged, replace rod.

6. Remove spacer from rod. See Figure 10.

Inspect inner surface of shell for damage. If damaged, replace tilt cylinder.

INSPECT Inspect gland for damage to threads and seal surfaces. If damaged, replace gland.

Inspect bushings for damage. These bushings are in the frame and mast tilt cylinder connection points. If damaged, replace bushings.

Inspect piston for any damage to seal surfaces. If damaged, replace piston.

Tilt Cylinder Repair

CAUTION DO NOT allow cleaning solvent to come in contact with rubber components, as it will damage those components. Clean all metal parts in solvent and dry with compressed air.

2100 YRM 1382 tilt cylinder. Tighten gland to 163-190 N•m (120-140 lbf ft). 6. Place cylinder in a soft-jaw vise and install tilt spacer, if equipped, and rod end on rod as noted during removal. Lubricate threads on capscrew with lubricant, Yale Part No. 504234269. Install capscrew in rod end so that capscrew head is on the inboard side of rod end. Install washer and nut on capscrew. Washer and nut must be on the outboard side of rod end. See Figure 9. Tighten nut to 105 N•m (77 lbf ft). 7. Repeat above steps for remaining tilt cylinder.

INSTALL 1. Using lifting device, place tilt cylinder in mounting position on lift truck frame. 2. Install washer and rod end onto mounting plate. See Figure 7.

ASSEMBLE

3. Install washer on anchor pin. Install anchor pin into rod end and mounting plate. See Figure 7.

NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings.

4. Install two washers and new cotter pin onto anchor pin. See Figure 7.

NOTE: Lubricate new rod seal, piston seal, O-rings, and backup ring with clean hydraulic oil before installation.

5. Connect hydraulic lines to tilt cylinder. Slowly stroke cylinder until rod holes line up with mast tilt anchor holes.

1. Install new piston seal and O-ring on piston. See Figure 10. 2. Place rod in a soft jaw vise and install spacer onto rod. See Figure 10. NOTE: Perform following step only if piston was removed from rod. 3. With rod still in soft jaw vise, lube the threads of the lock nut with hydraulic oil. Install piston and lock nut onto rod and tighten lock nut to 163-190 N•m (120-140 lbf ft). See Figure 10. 4. Install new rod wiper, rod seal, backup ring, and O-ring on gland. See Figure 10. 5. Install rod and piston assembly into shell. Using pin-type spanner wrench, install gland onto

6. Position rod end pin head to outboard side of lift truck. Install special washer, rod end pin, washer, and capscrew to rod end and tilt anchor. See Figure 7. Tighten capscrew to 38 N•m (28 lbf ft) 7. Repeat above steps for remaining tilt cylinder. 8. Remove chain holding mast to lift truck frame.

WARNING DO NOT put hands between cylinder rod end and mast. Serious injury can occur. 9. Operate tilt cylinders. Check for correct operation and leakage. Adjust tilt cylinders.

2100 YRM 1382

Tilt Cylinder Repair

TILT CYLINDERS, ADJUST WARNING When tilt cylinders have tilt limit spacers, make sure they are installed during installation procedures. Without the tilt limit spacers, the mast can tilt too much and cause an accident or serious injury. Check the tilt cylinder stroke by SLOWLY tilting the mast fully forward and backward several times. Both tilt cylinders must stop their stroke at the same time. Adjust the rod ends as shown in Figure 11. There must be no twist in mast weldments.

end of the rod end. Use a wrench to turn the cylinder rod IN until the dimension start to decrease, then stop. Repeat this procedure until both cylinder rods stop at the same position within 1 mm (0.04 in.). After adjustments are complete, tighten nuts on rod end to 105 N•m (77 lbf ft). c. Tilt mast fully backward and measure tilt angle. See the Nameplate for tilt angles. If necessary, adjust both rod ends equally for the correct angle.

TILT CYLINDERS LEAK CHECK WARNING Never allow anyone under a raised carriage. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the key switch or keyless switch is turned OFF. DO NOT try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by the pressure. 1. Put a capacity load on the forks. If the mast slowly tilts forward when the control valve is in the NEUTRAL position, there are leaks inside the hydraulic system. The maximum speed that the mast is allowed to tilt forward when there are internal leaks in the lift system is 0.50 degree in one minute. The maximum speed is measured when the hydraulic oil is 49 C (120 F).

A. 32 mm (1.25 in.) 1. MAST 2. ROD END

3. TILT CYLINDER

Figure 11. Tilt Cylinder Adjustments 1. Adjust the stroke of tilt cylinders WITHOUT tilt limit spacers as follows: a. Adjust the rod ends to 32 mm (1.25 in.). See Figure 11. b. Slowly tilt the mast backward until one cylinder rod stops. On the opposite cylinder, loosen the capscrew on the rod end. Measure the distance from the end of the cylinder to the back

2. If the leak rate is greater than these specifications, remove the load from the mast. Install a gate valve between the port at the front of the tilt cylinder and the hydraulic line. Put the load on the forks again. Close the gate valve. If the mast tilts forward faster than 0.5 degrees per minute, the cylinder seals are leaking. Be sure to check both tilt cylinders. 3. If the mast does not move, open the gate valve and check for movement again. If the mast moves forward when the gate valve is open, check for leaks in the hydraulic lines or fittings. If no leaks are found, the main control valve may have a defect. Remove the load from the forks.

Lift Cylinder Repair

2100 YRM 1382

Lift Cylinder Repair for Lift Trucks ERC22-35VG (ERC045-070VG) (A968) ERP22-25VL (ERP045-070VL) (A976) MAIN LIFT CYLINDERS Remove WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast. NOTE: The following procedures are for the removal of lift cylinders with the mast installed on lift truck. NOTE: Except as noted, the following procedures are for removal of both lift cylinders. 1. Remove the carriage as described in the carriage removal procedures located in the section Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338. Two-Stage FFL 1. Raise and chain the mast as instructed in Safety Procedures When Working Near Mast section. The mast must be chained before proceeding to the next step in this procedure.

WARNING

NOTE: After the cylinder has been completely disconnected from the mast, the mast needs to be raised high enough for the bottom of the cylinder to clear the crossmember on the outer mast weldment. The cylinder being removed needs to have the rod retracted into the cylinder. 5. Using a lifting device, remove main lift cylinder from mast. Three-Stage FFL 1. Raise and chain the mast as instructed in Safety Procedures When Working Near Mast section. The mast must be chained before proceeding to the next step in this procedure.

Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool.

4. Remove nut, washer, capscrew and spacer at mounting plate. See Figure 12.

3. Put a drain pan under the area of the hydraulic fittings. Disconnect hydraulic lines at lift cylinder and drain oil. See Figure 12. Cap hydraulic lines and cylinder ports.

NOTE: Raise the mast high enough for the bottom of the cylinder to clear the crossmember on the outer mast weldment and push the rod back into the cylinder being removed.

4. Remove nut, washer, capscrew, and spacer at mounting plate. See Figure 12.

6. Using a lifting device, remove lift cylinder from mast.

5. Disconnect main lift chain at mount.

2100 YRM 1382

Lift Cylinder Repair

NOTE: BALANCE LINE IS USED ON FOUR-STAGE FFL MAST ONLY. MASTS REMOVED FOR CLARITY. A. TWO AND THREE-STAGE FFL. TYPICAL FOR BOTH RIGHT-HAND AND LEFT-HAND CYLINDERS ON TWO AND THREE-STAGE MASTS. B. FOUR-STAGE FFL 1. 2. 3. 4. 5. 6. 7. 8.

SNAP RING SHIM HYDRAULIC LINE CYLINDER PORT NUT WASHER CAPSCREW SPACER

9. 10. 11. 12. 13. 14. 15.

MOUNTING PLATE LEFT-HAND MAIN LIFT CYLINDER RIGHT-HAND MAIN LIFT CYLINDER TUBE ASSEMBLY STRAIGHT FITTING BALANCE LINE KEEPER

Figure 12. Main Lift Cylinders Installation

Lift Cylinder Repair Four-Stage FFL 1. Raise and chain the mast as instructed in Safety Procedures When Working Near Mast section. The mast must be chained before proceeding to the next step in this procedure.

WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool. 3. Put a drain pan under the area of the hydraulic fittings. Disconnect hydraulic lines at lift cylinders and drain oil. See Figure 12. Cap hydraulic lines and cylinder ports. 4. On right-hand lift cylinder, disconnect tube assembly from straight fitting at top of cylinder. See Figure 12. Cap tube assembly. 5. On right-hand lift cylinder, remove nut, keeper, capscrew, and washer from cylinder mount of intermediate mast section. See Figure 12. 6. Disconnect balance line from both cylinders. See Figure 12. 7. Remove nut, washer, capscrew, and spacer at mounting plate. See Figure 12 NOTE: Raise the mast high enough for the bottom of the cylinder to clear the crossmember on the outer mast weldment and push the rod back into the cylinder being removed. 8. Using a lifting device, remove lift cylinder from mast. Keep shims from top of left-hand cylinder with cylinder. Two-Stage LFL 1. Raise and chain the mast as instructed in Safety Procedures When Working Near Mast section.

2100 YRM 1382

Disassemble Two-Stage FFL 1. Loosen gland with spanner wrench. 2. Remove gland from rod and shell. See Figure 13. 3. Remove rod and piston assembly from shell. See Figure 13. Drain any remaining hydraulic oil into drain pan. NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 4. Remove and discard rod wiper, rod seal, backup ring, and O-ring from gland. See Figure 13. 5. Remove spacer, if installed, from rod. See Figure 13.

2100 YRM 1382

Lift Cylinder Repair

A. LEFT-HAND CYLINDER

B. RIGHT-HAND CYLINDER

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13. 14.

SHELL ROD GLAND ROD WIPER ROD SEAL BACKUP RING O-RING

SPACER WEAR RING PISTON RING (R. H. ONLY) CAPSCREW WASHER-SEAL LEFT-HAND PISTON RIGHT-HAND PISTON

Figure 13. Main Lift Cylinder - RH/LH Two-Stage Mast FFL NOTE: Perform Step 6 for Right-Hand Lift Cylinders. Perform Step 7 for Left-Hand Lift Cylinders.

7. Remove and discard wear ring from piston end of rod. See Figure 13.

6. Remove wear ring, and piston ring from piston end of rod. Discard wear ring. See Figure 13.

8. Remove capscrew and seal. Discard seal. See Figure 13.

Lift Cylinder Repair

2100 YRM 1382

NOTE: Perform the following step only if the piston is damaged. 9. Remove piston from rod using spanner wrench. See Figure 13. Three-Stage FFL 1. Loosen gland with spanner wrench. 2. Remove gland from rod and shell. See Figure 14.

3. Remove rod and piston assembly from shell. See Figure 14. Drain any remaining hydraulic oil into drain pan. NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 4. Remove and discard rod wiper, backup ring, rod seal, O-ring, and wear ring from gland. See Figure 14. 5. Remove spacer, if installed, from rod. See Figure 14. 6. Remove piston ring, wear ring, seal, and backup ring from piston. See Figure 14. Discard wear ring, seal and backup ring.

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. 7. Remove snap ring, washer, and check valve from piston base. Remove and discard O-ring from check valve. See Figure 14. Four-Stage FFL 1. Loosen gland with spanner wrench. 2. Remove gland from rod and shell. See Figure 15. NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 3. Remove and discard rod wiper, rod seal, and O-ring, from gland. See Figure 15. 4. Remove rod and piston assembly from shell. 1. 2. 3. 4. 5. 6. 7.

SHELL ROD GLAND SPACER CHECK VALVE WASHER SNAP RING

8. 9. 10. 11. 12. 13. 14.

ROD WIPER SEAL O-RING BACKUP RING WEAR RING ROD SEAL PISTON RING

Figure 14. Main Lift Cylinder - RH/LH Three-Stage Mast

5. Remove spacer, backup ring, rod seal, and wear ring from piston. Discard backup ring, rod seal, and wear ring. See Figure 15. NOTE: Perform Step 6 for left-hand cylinder and Step 7 for right-hand cylinder. 6. Remove piston ring from piston. See Figure 15.

2100 YRM 1382

Lift Cylinder Repair

A. LEFT-HAND CYLINDER

B. RIGHT-HAND CYLINDER

1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15.

SHELL ROD GLAND PISTON RING SNAP RING WASHER O-RING CHECK VALVE

WEAR RING ROD SEAL BACKUP RING SPACER ROD WIPER LEFT-HAND PISTON RIGHT-HAND PISTON

Figure 15. Main Lift Cylinder For Four-Stage Mast 7. Remove and discard O-ring and backup ring from piston. See Figure 15.

8. Remove piston from rod using spanner wrench. See Figure 15.

NOTE: Perform the following step only if the piston is damaged.

Lift Cylinder Repair

2100 YRM 1382 the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION DO NOT allow cleaning solvent to come in contact with rubber components, as it will damage those components. Clean all metal parts in solvent and dry with compressed air.

Two-Stage LFL 1. Loosen gland with spanner wrench. 2. Remove gland from rod and shell. See Figure 16. 3. Remove rod and piston assembly from shell. Drain any remaining hydraulic oil into drain pan. NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 4. Remove and discard rod wiper, backup ring, rod seal, O-ring, and wear ring from gland. See Figure 16. 5. Remove spacer from rod. See Figure 16. 6. Remove and discard wear ring, seal, and backup ring from piston. See Figure 16.

1. 2. 3. 4. 5. 6. 7.

SHELL ROD GLAND SPACER CHECK VALVE WASHER SNAP RING

8. 9. 10. 11. 12. 13.

ROD WIPER SEAL O-RING BACKUP RING WEAR RING ROD SEAL

Figure 16. Limited Free-Lift Cylinder Two-Stage Mast LFL

2100 YRM 1382

Inspect Inspect gland for damage to threads and seal surfaces. If damaged, replace gland. Inspect piston for damage to seal surfaces. If damaged, replace piston on two and four-stage FFL main lift cylinders, replace rod and piston assembly on three-stage FFL and two-stage LFL main lift cylinders. Inspect rod for damage to rod surface and ensure that rod is not bent. If damaged, replace rod. Inspect inner surface of cylinder tube for damage. If damaged, replace lift cylinder assembly.

Assemble Two-Stage FFL 1. Lubricate all internal parts of the lift cylinder with clean hydraulic oil. Use new O-rings, seals, and wear rings.

Lift Cylinder Repair 7. Install gland onto rod in shell. See Figure 13. Tighten gland to 340 to 410 N•m (250 to 300 lbf ft).

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer. 8. Pour 150 cc (5 oz) hydraulic oil into cylinder through the capscrew hole. This oil provides a hydraulic cushion when cylinder reaches the top of its stroke. Install washer-seal and capscrew. See Figure 13. Tighten capscrew to 6.0 to 8.0 N•m (53 to 71 lbf in) Three-Stage FFL 1. Lubricate all internal parts of lift cylinder with clean hydraulic oil. Use new O-rings, seals, and wear rings.

WARNING

2. Install piston onto rod. Tighten piston to 170 to 200 N•m (125 to 148 lbf ft).

NOTE: Perform Step 3 for Right-Hand Lift Cylinders. Perform Step 4 for Left-Hand Lift Cylinders.

NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings.

NOTE: Perform the following step if the piston was removed from the rod.

CAUTION A difficult and important step in assembling lift cylinders is the correct installation of the seals. Most lift cylinder maintenance is caused by seal leaks. DO NOT damage any parts during assembly. NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings. 3. Install spacer, new wear ring, and piston ring onto piston. See Figure 13. 4. Install spacer and new wear ring onto piston. See Figure 13. 5. Install new backup ring, O-ring, rod seal, and rod wiper on gland. See Figure 13. 6. Install rod and piston assembly into shell. See Figure 13.

2. Install new O-ring on check valve. Install check valve, washer, and snap ring into base of piston. Make sure arrow on check valve is toward piston base. See Figure 14.

CAUTION A difficult and important step in assembling lift cylinder is the correct installation of the seals. Most lift cylinder maintenance is caused by seal leaks. DO NOT damage any parts during assembly. 3. Install new backup ring, seal, wear ring, and piston ring on piston. See Figure 14. 4. Install spacer, if removed, onto rod. See Figure 14. 5. Install new wear ring, O-ring, rod seal, backup ring, and rod wiper onto gland. See Figure 14. 6. Install rod and piston assembly into shell.

NOTE: To prevent possible damage to rod and piston assembly, use care while installing gland.

Lift Cylinder Repair

2100 YRM 1382

NOTE: To prevent possible damage to rod and piston assembly, use care while installing gland.

9. Install new O-ring, rod seal, and rod wiper onto gland. See Figure 15.

7. Install gland onto rod in shell. Tighten gland to 340 to 410 N•m (250 to 300 lbf ft).

NOTE: To prevent possible damage to rod and piston assembly, use care while installing gland.

Four-Stage FFL

10. Install gland onto rod in shell. Tighten gland to 340 to 410 N•m (250 to 300 lbf ft).

1. Lubricate all internal parts of lift cylinder with clean hydraulic oil. Use new O-rings, seals, backup rings, and wear rings.

Two-Stage LFL

NOTE: Perform the following step for the right-hand cylinder only.

1. Lubricate all internal parts of the lift cylinder with clean hydraulic oil. Use new O-rings, seals, backup rings, and wear rings.

2. Install backup ring and O-ring onto piston. See Figure 15.

NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings.

NOTE: Perform the following step only if piston was removed from rod.

2. Install new O-ring on check valve. See Figure 16.

3. Install piston onto rod. Tighten piston to 170 to 200 N•m (125 to 148 lbf ft). NOTE: Perform the following step for left hand cylinder only. 4. Install piston ring onto piston. See Figure 15. NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings. 5. Install new O-ring onto check valve.

CAUTION A difficult and important step in assembling lift cylinders is the correct installation of the seals. Most lift cylinder maintenance is caused by seal leaks. DO NOT damage any parts during assembly. 7. Install wear ring, rod seal, backup ring, and spacer onto piston. See Figure 15. 8. Install rod and piston assembly into shell.

CAUTION A difficult and important step in assembling lift cylinders is the correct installation of the seals. Most lift cylinder maintenance is caused by seal leaks. DO NOT damage any parts during assembly. 4. Install backup ring, seal, and wear ring onto piston. See Figure 16. 5. Install spacer onto rod. See Figure 16. 6. Install wear ring, O-ring, rod seal, backup ring, and rod wiper onto gland. See Figure 16. 7. Install rod and piston assembly into shell. NOTE: To prevent damage to the rod and piston assembly, use care while installing gland. 8. Install gland onto rod and in shell. Tighten gland to 340 to 410 N•m (250 to 300 lbf ft). See Figure 16.

2100 YRM 1382

Install NOTE: Except as noted, the following procedures are for installation of both lift cylinders. Two-Stage FFL 1. Using lifting device, install lift cylinder in mount at bottom of outer mast. NOTE: After the cylinder has been completely disconnected from the mast, raise the mast high enough for the bottom of the cylinder to clear the crossmember on the outer mast weldment and push the rod back into the cylinder being removed. 2. Install spacer, capscrew, washer, and nut at mounting plate. See Figure 12. Tighten nut to 40 N•m (30 lbf ft). 3. Use lifting device to lower the inner mast onto lift cylinder. Connect tube assembly to top of left lift cylinder. Install shims and snap ring at top of lift cylinder. See Figure 12. 4. Uncap hydraulic lines and cylinder ports. Connect hydraulic lines to cylinder ports. See Figure 12.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 5. Dispose of drain pan contents. 6. Connect main lift chains and adjust as specified in section Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338.

Lift Cylinder Repair b. With forks unloaded, raise carriage using hydraulic control. Raise carriage 300 mm (12 in.) and then stop for 10 seconds to reduce the pressure in the cylinder. Repeat this procedure until the oil flowing from around the threads is free of air bubbles. c. Stop carriage at the top of the cylinder stroke. Tighten capscrew to 6.0 to 8.0 N•m (53 to 71 lbf in). Three-Stage FFL 1. Using lifting device, install lift cylinder in mount at the bottom of the outer mast. NOTE: Raise the mast high enough for the bottom of the cylinder to clear the crossmember on the outer mast weldment and push the rod back into the cylinder being removed. 2. Install spacer, capscrew, washer, and nut at mounting plate. See Figure 12. Tighten nut to 40 N•m (30 lbf ft). 3. Use lifting device to lower intermediate mast onto lift cylinder. Install shim and snap ring at top of lift cylinder. See Figure 12. 4. Reconnect main lift chain to chain anchor. 5. Install new cotter pin with cotter pin hole positioned toward the inside mast. Bend both legs of cotter pin against chain anchor pin to secure lift chain to chain anchor. 6. Uncap hydraulic lines and cylinder ports. Connect hydraulic lines to cylinder ports. See Figure 12.

System Air Bleed Procedures NOTE: The procedures for bleeding air out of the lift cylinders apply only to lift trucks equipped with a twostage FFL mast. Trucks equipped with a three or fourstage FFL mast or two-stage LFL mast do not need to have air bled out of the lift cylinders. 1. Remove the air from main lift cylinders as described below. See Figure 13, Two-Stage FFL shown.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 7. Dispose of drain pan contents. 8. Connect main lift chains and adjust as specified in section Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338.

a. Loosen capscrew two turns to permit oil to flow around threads of capscrew.

Lift Cylinder Repair Four-Stage FFL

2100 YRM 1382

CAUTION

1. Using lifting device, install lift cylinder in mount at the bottom of the outer mast section.

Disposal of lubricants and fluids must meet local environmental regulations.

NOTE: Raise the mast high enough for the bottom of the cylinder to clear the crossmember on the outer mast weldment and push the rod back into the cylinder being removed.

10. Dispose of drain pan contents.

2. Install spacer, capscrew, washer, and nut at mounting plate. See Figure 12. Tighten nut to 40 N•m (30 lbf ft). 3. Use lifting device to lower mast onto lift cylinder.

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. 4. On left-hand cylinder, install shim(s) and snap ring at top of cylinder. See Figure 12. 5. On right-hand cylinder, install keeper, washer, capscrew, and nut to cylinder mount of intermediate mast. See Figure 12. Tighten nut to 33 N•m (24 lbf ft). 6. Connect main lift chains and adjust as specified in section Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338. 7. On right-hand cylinder, uncap tube assembly and connect to straight fitting at top of cylinder. See Figure 12.

Two-Stage LFL 1. Using lifting device, install lift cylinder in mount at the bottom of the outer mast. NOTE: Raise the mast high enough for the bottom of the cylinder to clear the crossmember on the outer mast weldment and push the rod back into the cylinder being removed. 2. Install spacer, capscrew, washer, and nut at mounting plate. See Figure 12. Tighten nut to 40 N•m (30 lbf ft).

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

8. Uncap hydraulic lines and cylinder ports. Connect the hydraulic lines at cylinder ports. See Figure 12.

5. Dispose of drain pan contents.

9. Install balance line between main lift cylinders. See Figure 12.

6. Connect main lift chains and adjust as specified in section Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338.

2100 YRM 1382

Lift Cylinder Repair for Lift Truck ERP15VT (G807)

Lift Cylinder Repair for Lift Truck ERP15VT (G807) MAIN LIFT CYLINDER

WARNING

Before working on or near the mast, see Safety Procedures When Working Near Mast.

NOTE: The following procedures are for removal of lift cylinders with mast installed on lift truck.

2. Remove snap ring, washer, and shims at top of cylinder. See Figure 17.

Remove WARNING

NOTE: Except as noted, the following procedures are for removal of both lift cylinders. 1. Remove the carriage as described in the carriage removal procedures located in the section Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 or Mast Repair, 2, 3, And 4-Stage Heavy Duty Masts 4000 YRM 1405. 2. Raise and chain the mast as instructed in Safety Procedures When Working Near Mast section. The mast must be chained before proceeding to the next step in this procedure. Main Lift Cylinders - Two-Stage FFL Mast NOTE: Perform the following step for Right-Hand lift cylinder only. 1. Remove fitting at top of cylinder. See Figure 17.

Lift Cylinder Repair for Lift Truck ERP15VT (G807)

Figure 17. Main Lift Cylinder Installation

2100 YRM 1382

Lift Cylinder Repair for Lift Truck ERP15VT (G807) Legend for Figure 17

NOTE: CROSSMEMBER REMOVED FOR CLARITY. NOTE: TWO-STAGE FFL MAIN LIFT CYLINDER SHOWN. 1. 2. 3. 4. 5. 6. 7. 8.

LEFT-HAND MAIN LIFT CYLINDER RIGHT HAND MAIN LIFT CYLINDER FITTING WITH O-RING SNAP RING WASHER SHIMS CAPSCREW SPACER

9. 10. 11. 12. 13. 14. 15.

NUT FILL SCREW SEAL LOWERING CONTROL VALVE LOWERING CONTROL HOUSING FITTING HOSE ASSEMBLY

Left-Hand Main Lift Cylinder - Three-Stage FFL Mast

9. Remove free-lift hose from hose sheave and free-lift sheave bracket. See Figure 18.

1. Put drain pan underneath area of hydraulic fittings.

10. Remove hose sheave from free-lift sheave stubshaft. See Figure 18.

2. Remove two nuts, two capscrews, and clamp from tube mounting plate. See Figure 18.

WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool. 3. Disconnect tube assembly from the top of free-lift hose. See Figure 18. NOTE: Note position of hydraulic line, lowering control, and tube assembly prior to disconnecting hydraulic line to aid in installation. NOTE: Steps 4-11 must be performed before starting to remove the main lift cylinder to allow access to the main lift cylinder. 4. Disconnect hydraulic line at cylinder and drain oil from cylinder. Cap hydraulic line and cylinder port. 5. Move hydraulic line, lowering control, and tube assembly aside to prevent damage during lift cylinder removal. 6. Disconnect free-lift hose from free-lift cylinder fitting. Cap free-lift hose and free-lift cylinder fitting. See Figure 18. 7. Remove bottom capscrew and washer from hose sheave cover plate and cylinder mount bracket. See Figure 18.

11. Remove two nuts, two capscrews, and free-lift sheave mounting bracket from inner mast top crossmember. See Figure 18.

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. 12. Remove snap ring and washer from top of lift cylinder. See Figure 19. 13. Remove two capscrews and cylinder restraint bracket from chain anchor bracket. See Figure 19. 14. Disconnect main lift chain at chain anchor bracket. 15. Remove capscrew, nut, and clamp from cylinder port and plate. See Figure 19. 16. Using lifting device, remove lift cylinder from mast. NOTE: Note quantity of shims prior to removal to aid in installation. 17. Remove shims from top of lift cylinder. See Figure 19.

8. Remove top capscrew, washer, and hose sheave cover plate from free-lift sheave stubshaft. See Figure 18.

Lift Cylinder Repair for Lift Truck ERP15VT (G807)

Figure 18. Main Lift Cylinders, Three-Stage FFL Mast

2100 YRM 1382

Lift Cylinder Repair for Lift Truck ERP15VT (G807) Legend for Figure 18

NOTE: HEADER HOSES AND OUTER MAST CROSSMEMBERS REMOVED FOR CLARITY. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

TUBE MOUNTING PLATE NUT CAPSCREW CLAMP TUBE ASSEMBLY FREE-LIFT HOSE HYDRAULIC LINE LOWERING CONTROL FREE-LIFT CYLINDER FITTING BOTTOM CAPSCREW WASHER

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

HOSE SHEAVE COVER PLATE LEFT-HAND CYLINDER MOUNT BRACKET TOP CAPSCREW FREE-LIFT SHEAVE STUBSHAFT HOSE SHEAVE FREE-LIFT SHEAVE MOUNTING BRACKET INNER MAST TOP CROSSMEMBER CHAIN SHEAVE COVER PLATE CHAIN STUBSHAFT RIGHT-HAND CYLINDER MOUNT BRACKET

Lift Cylinder Repair for Lift Truck ERP15VT (G807)

2100 YRM 1382

Figure 19. Main Lift Cylinders Three-Stage FFL Mast for Lift Truck ERP15VT (G807)

2100 YRM 1382

Lift Cylinder Repair for Lift Truck ERP15VT (G807) Legend for Figure 19

1. 2. 3. 4. 5. 6. 7.

LEFT-HAND MAIN LIFT CYLINDER RIGHT-HAND MAIN LIFT CYLINDER SNAP RING WASHER CAPSCREW CLAMP NUT

Right-Hand Main Lift Cylinder - Three-Stage FFL Mast 1. Remove bottom capscrew and washer from chain sheave cover plate and cylinder mount bracket. See Figure 18. 2. Remove top capscrew, washer, and chain sheave cover plate from chain stubshaft. See Figure 18.

8. 9. 10. 11. 12. 13.

CYLINDER RESTRAINT BRACKET LEFT-HAND CHAIN ANCHOR BRACKET RIGHT-HAND CHAIN ANCHOR BRACKET PLATE SHIMS CYLINDER PORT

Main Lift Cylinder - Two-Stage LFL Mast 1. Remove bottom capscrew and washer from chain sheave cover plate and cylinder mount bracket. See Figure 20. 2. Remove top capscrew, washer, and chain sheave cover plate from chain stubshaft. See Figure 20.

WARNING WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool. 3. Put a drain pan underneath area of hydraulic fittings. Disconnect hydraulic line at cylinder and drain oil from cylinder. Cap hydraulic line and cylinder port.

1. BOTTOM CAPSCREW 2. WASHER 3. TOP CAPSCREW 4. LEFT-HAND CHAIN SHEAVE COVER PLATE

5. RIGHT-HAND CHAIN SHEAVE COVER PLATE 6. CYLINDER MOUNT BRACKET 7. CHAIN STUBSHAFT

Figure 20. Cover Plates Two-Stage LFL Mast for Lift Truck ERP15VT (G807)

Lift Cylinder Repair for Lift Truck ERP15VT (G807)

2100 YRM 1382

NOTE: OUTER MAST CROSSMEMBERS REMOVED FOR CLARITY. 1. 2. 3. 4. 5. 6. 7.

SNAP RING WASHER LEFT-HAND MAIN LIFT CYLINDER RIGHT-HAND MAIN LIFT CYLINDER CAPSCREW CYLINDER RESTRAINT BRACKET CHAIN ANCHOR BRACKET

8. 9. 10. 11. 12. 13.

MAIN LIFT CHAIN PLATE HYDRAULIC LINE NUT CLAMP SHIMS

Figure 21. Main Lift Cylinders Two-Stage LFL Mast for Lift Truck ERP15VT (G807)

2100 YRM 1382

WARNING

Lift Cylinder Repair for Lift Truck ERP15VT (G807) 2. Remove gland from rod and shell. See Figure 22.

Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool.

3. Remove rod and piston assembly from shell. See Figure 22. Drain any remaining hydraulic oil into drain pan.

4. Put a drain pan under the area of the hydraulic fittings. Disconnect hydraulic line at cylinder and drain oil from cylinder. Cap hydraulic line and cylinder port.

NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings.

5. Remove two capscrews and cylinder restraint bracket from chain anchor bracket. See Figure 21. 6. Disconnect main lift chain at chain anchor bracket. See Figure 21. 7. Remove capscrew, nut, and clamp from lift cylinder and plate. See Figure 21. 8. Using a lifting device, remove lift cylinder from mast. NOTE: Note number of shims prior to removal to aid in installation. 9. Remove shims from top of lift cylinder. See Figure 21. 10. Repeat Step 1 through Step 9 for opposite lift cylinder.

Disassemble Main Lift Cylinders - Two-Stage FFL Mast

4. Remove and discard rod wiper, rod seal, backup ring, and O-ring from gland. See Figure 22. 5. Remove spacer, if installed, from rod. See Figure 22. NOTE: Perform the following step for Right-Hand Main Lift Cylinder. 6. Remove and discard wear ring from piston. See Figure 22. NOTE: Perform the following step for Left-Hand Main Lift Cylinder. 7. Remove piston ring and wear ring from piston. Discard wear ring. See Figure 22. NOTE: Perform the following step only if piston is damaged. 8. Remove piston from rod. See Figure 22. 9. Remove capscrew and seal from shell. Discard seal. See Figure 22.

1. Loosen gland with spanner wrench.

Lift Cylinder Repair for Lift Truck ERP15VT (G807)

2100 YRM 1382

A. RIGHT-HAND CYLINDER

B. LEFT-HAND CYLINDER

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13. 14.

SHELL ROD GLAND SPACER ROD WIPER BACKUP RING O-RING

WEAR RING ROD SEAL CAPSCREW SEAL PISTON RING RIGHT-HAND PISTON LEFT-HAND PISTON

Figure 22. Main Lift Cylinder Two-Stage FFL Mast

2100 YRM 1382

Lift Cylinder Repair for Lift Truck ERP15VT (G807)

Main Lift Cylinder - Three-Stage FFL Mast

5. Remove spacer, if installed, from rod.

1. Loosen gland with spanner wrench. 2. Remove gland from rod and shell. See Figure 23.

6. Remove piston ring, wear ring, seal, and backup ring from piston. See Figure 23. Discard wear ring rod seal, and backup ring.

3. Remove rod and piston assembly from shell. See Figure 23. Drain any remaining hydraulic oil into drain pan.

7. Remove snap ring, washer, and check valve from piston base. Remove and discard O-ring from check valve. See Figure 23.

NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings.

Main Lift Cylinder - Two-Stage LFL Mast

4. Remove and discard rod wiper, backup ring, rod seal, O-ring, and wear ring from gland. See Figure 23.

1. 2. 3. 4. 5. 6. 7.

SHELL ROD GLAND SPACER ROD WIPER BACKUP RING O-RING

8. 9. 10. 11. 12. 13. 14.

WEAR RING ROD SEAL CHECK VALVE WASHER SNAP RING PISTON RING SEAL

Figure 23. Main Lift Cylinder Three-Stage FFL Mast

1. Loosen gland with spanner wrench. 2. Remove gland from rod and shell. See Figure 24.

1. 2. 3. 4. 5. 6. 7.

SHELL ROD GLAND ROD WIPER BACKUP RING ROD SEAL O-RING

8. 9. 10. 11. 12. 13. 14.

WEAR RING SEAL CHECK VALVE WASHER SNAP RING SPACER PISTON

Figure 24. Main Lift Cylinder Two-Stage LFL Mast

Lift Cylinder Repair for Lift Truck ERP15VT (G807) 3. Remove rod and piston assembly from shell. Remove piston assembly from the rod. See Figure 24. Drain any remaining hydraulic oil into drain pan. NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings.

2100 YRM 1382

Inspect Inspect gland for damage to threads and seal surfaces. If damaged, replace gland.

4. Remove and discard rod wiper, backup ring, rod seal, O-ring, and wear ring. See Figure 24.

Inspect piston for any damage to seal surfaces. If damaged, replace piston on two-stage FFL or rod and piston assembly on three-stage FFL and two-stage LFL main lift cylinders.

5. Remove spacer, if installed, from rod. See Figure 24.

Inspect rod for damage to rod surface and ensure that the rod is not bent. If damaged, replace rod.

6. Remove and discard backup ring, seal, and wear ring from piston. See Figure 24.

Inspect inner surface of cylinder tube for damage. If damaged, replace cylinder assembly.

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION DO NOT allow cleaning solvent to come in contact with rubber components, as it will damage those components. Clean all metal parts in solvent and dry with compressed air.

Assemble Main Lift Cylinder - Two-Stage FFL Mast 1. Lubricate all internal parts of the lift cylinder with clean hydraulic oil. Use new O-rings, seals, and wear rings for installation. NOTE: Perform the following step only if piston was removed from rod. 2. Install piston onto rod. Tighten piston to 170 to 200 N•m (125 to 148 lbf ft). NOTE: Perform the following step for Right-Hand Main Lift Cylinder. 3. Install wear ring onto piston. See Figure 22. NOTE: Perform the following step for Left-Hand Main Lift Cylinder. 4. Install wear ring and piston ring onto piston. See Figure 22. 5. Install spacer, if removed, onto rod. See Figure 22.

CAUTION A difficult and important step in assembling lift cylinders is the correct installation of the seals. Most lift cylinder maintenance is cause by seal leaks. DO NOT damage any parts during assembly. NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings. 6. Install new backup ring, O-ring, rod seal, and rod wiper onto gland. See Figure 22.

2100 YRM 1382

Lift Cylinder Repair for Lift Truck ERP15VT (G807)

7. Install rod and piston assembly into shell. See Figure 22.

NOTE: To prevent possible damage to rod and piston assembly, use care while installing gland.

8. Install gland on rod in shell. Tighten gland to 340 to 410 N•m (250 to 300 lbf ft). See Figure 23.

8. Install gland onto rod in shell. Tighten gland to 340 to 410 N•m (250 to 300 lbf ft). See Figure 22.

Main Lift Cylinder - Two-Stage LFL Mast

9. Install seal and capscrew into shell. Tighten capscrew to 6.0 to 8.0 N•m (53 to 71 lbf in). See Figure 22. Main Lift Cylinder - Three-Stage FFL Mast

1. Lubricate all internal parts of the lift cylinder with clean hydraulic oil. Use O-rings, seals, and wear rings. NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings

1. Lubricate all internal parts of the lift cylinder with clean hydraulic oil. Use new O-rings, seals, and wear rings for installation.

2. Install new O-ring on check valve. See Figure 24.

NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings.

2. Install new O-ring onto check valve. See Figure 23.

WARNING

3. Install check valve, washer, and snap ring into piston base. See Figure 24. 4. Install new backup ring, seal, and wear ring on piston. See Figure 24. 5. Install spacer, if removed, onto rod. 6. Install new O-ring, wear ring, rod seal, backup ring, and rod wiper on gland. See Figure 24. 7. Install rod and piston assembly into shell. See Figure 24. NOTE: To prevent possible damage to rod and piston assembly, use care while installing gland. 8. Install gland onto rod in shell. Tighten gland to 340 to 410 N•m (250 to 300 lbf ft). See Figure 24.

5. Install spacer, if required, onto rod. See Figure 23.

Install

6. Install new O-ring, wear ring, rod seal, backup ring, and rod wiper on gland. See Figure 23.

NOTE: Except as noted, the following procedures are for installation of both lift cylinders.

7. Install rod and piston assembly into shell. See Figure 23.

Lift Cylinder Repair for Lift Truck ERP15VT (G807) Main Lift Cylinder - Two-Stage FFL Mast

WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast. NOTE: The following procedures are for the installation of lift cylinders with the mast installed on lift truck. 1. Using a lifting device, install lift cylinder on mast. NOTE: Mast must be raised for bottom of cylinder to clear outer mast crossmember. 2. Install spacer, washer, capscrew, and nut at mounting plate. Tighten nut to 40 N•m (30 lbf ft). See Figure 17. 3. Uncap hydraulic lines and cylinder ports. Connect hydraulic lines at cylinder.

2100 YRM 1382 NOTE: The following procedures are for the installation of lift cylinders with the mast installed on lift truck. The mast must be chained before proceeding to the next step in this procedure. 1. Install shims, as noted during removal, at top of lift cylinder. See Figure 19. 2. Using a lifting device, install lift cylinder onto mast. NOTE: Mast must be raised for bottom of cylinder to clear outer mast crossmember. 3. Install clamp, capscrew, and nut onto cylinder port and plate. Tighten nut to 25 N•m (18 lbf ft). See Figure 19. 4. Connect main lift chain at chain anchor bracket. Use new cotter pin and bend both legs of cotter pin a minimum of 90 degrees against chain anchor pin to secure lift chain to chain anchor. 5. Install cylinder restraint bracket and two capscrews onto chain anchor bracket. Tighten capscrews to 52 N•m (38 lbf ft). See Figure 19.

WARNING

NOTE: One washer and one snap ring required at top of each main lift cylinder.

Be careful when removing or installing snap rings. These snap rings come loose during removal or installation with enough force to cause an injury. Always use the correct ring pliers, and wear eye and face protection during removal or installation.

4. Install shims, if removed, washer, and snap ring at top of cylinder. See Figure 17.

NOTE: One washer and snap ring required at top of each main lift cylinder.

NOTE: Perform following step for Right-Hand lift cylinder.

6. Install washer and snap ring at top of lift cylinder. See Figure 19.

5. Install fitting at top of cylinder. See Figure 17. Connect hydraulic line at fitting.

NOTE: Nut to be at top of mast crossmember.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 6. Remove drain pan from below hydraulic fitting area and dispose of contents. Left-Hand Main Lift Cylinder - Three-Stage FFL Mast

WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast.

7. Install free-lift sheave mounting bracket, two capscrews, and two nuts on inner mast top crossmember. See Figure 18. Tighten nut to 25 N•m (18 lbf ft). 8. Install hose sheave onto free-lift sheave stubshaft. See Figure 18. 9. Install free-lift hose on free-lift sheave bracket and hose sheave. See Figure 18. 10. Install hose sheave cover plate, washer and top capscrew onto free-lift sheave stubshaft. DO NOT tighten top capscrew. See Figure 18.

2100 YRM 1382

Lift Cylinder Repair for Lift Truck ERP15VT (G807)

11. Install washer and bottom capscrew onto hose sheave cover plate and cylinder mount bracket. See Figure 18.

3. Install clamp, capscrew, and nut onto cylinder port and plate. Tighten nut to 25 N•m (18 lbf ft). See Figure 19.

12. Tighten bottom capscrew to 38 N•m (28 lbf ft).

4. Connect main lift chain at chain anchor bracket. Use new cotter pin and bend both legs of cotter pin a minimum of 90 degrees against chain anchor pin to secure lift chain to chain anchor.

13. Tighten top capscrew to 38 N•m (28 lbf ft). 14. Remove caps from free-lift cylinder fitting and freelift hose. Connect free-lift hose to free-lift cylinder fitting. NOTE: Make sure tube assembly, lowering control and hydraulic line are in position, as noted during removal, prior to connecting hydraulic line. 15. Remove caps from hydraulic line and cylinder port. Connect hydraulic line to cylinder port. 16. Connect tube assembly to free-lift hose. See Figure 18. 17. Install clamp, two capscrews, and two nuts on tube mounting plate. See Figure 18. Tighten nuts to 25 N•m (18 lbf ft).

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 18. Remove drain pan from below hydraulic fitting area and dispose of contents. Right-Hand Main Lift Cylinder - Three-Stage FFL Mast

WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast. NOTE: The following procedures are for the installation of lift cylinders with the mast installed on lift truck. The mast must be chained before proceeding to the next step in this procedure. 1. Install shims, as noted during removal, at top of lift cylinder. See Figure 19. 2. Using a lifting device, install lift cylinder onto mast. NOTE: Mast must be raised for bottom of cylinder to clear outer mast crossmember.

5. Install cylinder restraint bracket and two capscrews onto chain anchor bracket. Tighten capscrews to 52 N•m (38 lbf ft). See Figure 19.

WARNING Be careful when removing or installing snap rings. These snap rings come loose during removal or installation with enough force to cause an injury. Always use the correct ring pliers, and wear eye and face protection during removal or installation. NOTE: One washer and one snap ring required at top of each main lift cylinder. 6. Install washer and snap ring at top of lift cylinder. See Figure 19. 7. Remove caps from hydraulic line and cylinder port. Connect hydraulic line to cylinder port. NOTE: Chain sheave cover plate to be installed with chamfer outboard. Use mounting slot as needed for fit. 8. Install chain sheave cover plate, washer, and top capscrew onto chain stubshaft. DO NOT tighten top capscrew. See Figure 18. 9. Install washer and bottom capscrew on chain sheave cover plate and cylinder mount bracket. See Figure 18. 10. Tighten bottom capscrew to 38 N•m (28 lbf ft). 11. Tighten top capscrew to 72 N•m (53 lbf ft).

CAUTION Disposal of lubricants and fluids must meed local environmental regulations. 12. Remove drain pan from beneath hydraulic fitting area and dispose of contents.

Lift Cylinder Repair for Lift Truck ERP15VT (G807) Main Lift Cylinder - Two-Stage LFL Mast

WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast.

2100 YRM 1382 9. Install washer and bottom capscrew onto chain sheave cover plate and cylinder mount bracket. See Figure 20. 10. Tighten bottom capscrew to 38 N•m (28 lbf ft). 11. Tighten top capscrew to 72 N•m (53 lbf ft).

NOTE: The following procedures are for the installation of lift cylinders with the mast installed on lift truck. 1. Install shims, as noted during removal, onto top of lift cylinder. See Figure 21. The mast must be chained before proceeding to the next step in this procedure. 2. Using a lifting device, install lift cylinder onto mast. Extend rod out of lift cylinder. NOTE: Mast must be raised for bottom of cylinder to clear outer mast crossmember.

CAUTION Disposal of lubricants and fluids must meed local environmental regulations. 12. Remove drain pan from beneath hydraulic fitting area and dispose of contents. 13. Repeat Step 1 through Step 12 for opposite lift cylinder. System Air Bleed Procedures NOTE: The procedures for bleeding air out of the lift cylinders apply only to lift trucks equipped with a twostage FFL mast. Trucks equipped with a three or fourstage FFL mast or two-stage LFL mast do not need to have air bled out of the lift cylinders. 1. Remove the air from main lift cylinders as described below. See Figure 25, Two-Stage FFL shown.

3. Install washer and snap ring onto top of lift cylinder. See Figure 21.

a. Loosen capscrew two turns to permit oil to flow around threads of capscrew.

NOTE: Nut to be toward back of lift truck.

b. With forks unloaded, raise carriage using hydraulic control. Raise carriage 300 mm (12 in.) and then stop for 10 seconds to reduce the pressure in the cylinder. Repeat this procedure until the oil flowing from around the threads is free of air bubbles.

4. Install clamp, capscrew, and nut onto cylinder and plate. See Figure 21. Tighten nut to 19 N•m (14 lbf ft). 5. Connect main lift chain at chain anchor bracket. See Figure 21. Use new cotter pin and bend both legs of cotter pin a minimum of 90 degrees against chain anchor pin to secure lift chain to chain anchor. 6. Install cylinder restraint bracket and two capscrews. See Figure 21. Tighten capscrews to 52 N•m (38 lbf ft). 7. Remove caps from hydraulic line and cylinder port. Connect hydraulic line to cylinder port. See Figure 21. Extend rod out of lift cylinder. NOTE: Chain sheave cover plate to be oriented with chamfer outboard. Use mounting slot as needed for fit. 8. Install chain sheave cover plate, washer, and top capscrew onto chain stubshaft. See Figure 20. DO NOT tighten top capscrew.

c. Stop carriage at the top of the cylinder stroke. Tighten capscrew to 5.5 to 6.5 N•m (49 to 58 lbf in). All Main Lift Cylinders 1. Use a lifting device to lower the inner mast weldment (two-stage) or intermediate mast weldment (three-stage) onto the lift cylinder. NOTE: Mast must be raised for bottom of cylinder to clear outer mast crossmember. 2. Install carriage as described in carriage installation procedures located in the section Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 or Mast Repair, 2, 3, And 4-Stage Heavy Duty Masts 4000 YRM 1405.

2100 YRM 1382 3. Adjust lift cylinders as specified in section Mast Repair, 2- and 3-Stage High Visibility Masts 4000

Lift Cylinder Repair YRM 1386 or Mast Repair, 2, 3, And 4-Stage Heavy Duty Masts 4000 YRM 1405.

Lift Cylinder Repair for Lift Trucks ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-40AC (B883) MAIN LIFT CYLINDER

Two-Stage FFL

Remove

NOTE: Perform the following step for Right-Hand lift cylinder only.

WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast. NOTE: The following procedures are for the removal of lift cylinders with the mast installed on lift truck. NOTE: Except as noted, the following procedures are for removal of both lift cylinders. 1. Remove the carriage as described in the carriage removal procedures located in the section Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 for European lift truck models • ERP16-20VT (G807) • ERP16-20VF (A955) Mast Repair, 2, 3, And 4-Stage Heavy Duty Masts 4000 YRM 1405 for European and Americas lift truck models • ERP16-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) • ESC030-40AC (B883) NOTE: Perform Step 2 for lift trucks equipped with Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL masts. Perform Step 3 for lift truck equipped with Four-Stage FFL mast. 2. Raise and chain the mast as instructed in Safety Procedures When Working Near Mast section. The mast must be chained before proceeding to the next step in this procedure.

1. Remove fitting at top of cylinder. See Figure 25.

3. Remove mast from lift truck as described in the section Mast Repair, 2, 3, And 4-Stage Heavy Duty Masts 4000 YRM 1405 for lift truck models (ERP030-040VT) (G807)

Lift Cylinder Repair

2100 YRM 1382 Two-Stage LFL

Three-Stage FFL

WARNING

1. Remove snap ring, washer, and shims, if installed, from top of cylinder. See Figure 25.

1. Remove snap ring and shims from top of cylinder. See Figure 25.

WARNING

Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool.

2. Put a drain pan under the area of the hydraulic fittings. Disconnect hydraulic lines at cylinder and drain oil from cylinder. Cap hydraulic lines and cylinder ports.

2. Put a drain pan under the area of the hydraulic fittings. Disconnect hydraulic line at cylinder and drain oil from cylinder. Cap hydraulic lines and cylinder ports.

3. Remove nut, spacer, capscrew, and washer at mounting plate. See Figure 25.

3. Remove nut, two washers, spacer, and capscrew at mounting plate. See Figure 25.

4. Disconnect main lift chain at mount.

5. Using a lifting device, remove lift cylinder from mast.

NOTE: Raise the mast high enough for the bottom of the cylinder to clear the crossmember on the outer mast weldment and push the rod back into the cylinder being removed.

6. Repeat Step 1 through Step 5 for opposite cylinder.

6. Repeat Step 1 through Step 5 for opposite lift cylinder.

Legend for Figure 25 NOTE: CROSSMEMBER REMOVED FOR CLARITY. NOTE: TWO-STAGE FFL MAIN LIFT CYLINDER SHOWN. 1. 2. 3. 4. 5. 6. 7. 8.

LEFT-HAND MAIN LIFT CYLINDER RIGHT HAND MAIN LIFT CYLINDER FITTING WITH O-RING SNAP RING WASHER SHIMS CAPSCREW SPACER

9. 10. 11. 12. 13. 14. 15.

NUT FILL SCREW SEAL LOWERING CONTROL VALVE LOWERING CONTROL HOUSING FITTING HOSE ASSEMBLY

2100 YRM 1382

Lift Cylinder Repair

Figure 25. Main Lift Cylinder - Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL Masts

Lift Cylinder Repair Four-Stage FFL 1. Insert 5 x 10 cm (2 x 4 in.) wood block between lower crossmembers of outer and outer intermediate masts to prevent movement out the bottom of mast assembly. See Figure 26. 2. Lay mast assembly facedown on wood blocks as shown in Figure 26. Ensure mast assembly is level, and inner masts move freely.

WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool. 3. Place drain pan under the area of the hydraulic fittings. Disconnect cylinder supply hoses from special long fittings. See Figure 26. 4. Remove special long fitting from cylinder inlet ports and install plugs. See Figure 26.

2100 YRM 1382 or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. 5. Remove snap ring from top of left-hand cylinder rod. See Figure 26. 6. Remove fitting and tube from top of right-hand cylinder rod. See Figure 26. 7. Pull inner, inner intermediate, and outer intermediate masts from outer mast 30 to 60 cm (1 to 2 ft) and disengage cylinder rods from outer intermediate mast. 8. Lift cylinders from mounting boss of outer mast and angle inward. Remove cylinders through sides of the masts. NOTE: Note number of shims at top of each rod to aid in installation. 9. Remove shims, If present, from tops of cylinders.

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal

2100 YRM 1382

Lift Cylinder Repair

A. MAST PULL DIRECTION

B. CYLINDER REMOVAL DIRECTION

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13. 14.

WOOD BLOCK CROSSMEMBER HOSE CYLINDER INPUT PORT SPECIAL LONG FITTING SNAP RING LEFT-HAND CYLINDER ROD

TUBE FITTING RIGHT-HAND CYLINDER ROD MOUNTING BOSS SHIM LEFT-HAND CYLINDER RIGHT-HAND CYLINDER

Figure 26. Main Lift Cylinders, Four-Stage FFL Mast

Lift Cylinder Repair

2100 YRM 1382

Disassemble

3. Remove rod and piston assembly from shell. See Figure 27. Drain any remaining hydraulic oil into drain pan.

Two-Stage FFL 1. Loosen gland with spanner wrench. 2. Remove gland from rod and shell. See Figure 27.

A. RIGHT-HAND CYLINDER

B. LEFT-HAND CYLINDER

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11. 12.

SHELL ROD GLAND SPACER ROD WIPER BACKUP RING

O-RING WEAR RING ROD SEAL CAPSCREW SEAL PISTON RING

Figure 27. Main Lift Cylinder, Two-Stage FFL Mast

2100 YRM 1382 NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 4. Remove and discard rod wiper, rod seal, backup ring, and O-ring from gland. See Figure 27. 5. Remove spacer, if installed, from rod. See Figure 27.

Lift Cylinder Repair or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal or installation. 7. Remove snap ring, washer, and check valve from piston base. Remove and discard O-ring from check valve. See Figure 28.

NOTE: Perform the following step for Right-Hand Main Lift Cylinder. 6. Remove and discard wear ring from piston. See Figure 27. NOTE: Perform the following step for Left-Hand Main Lift Cylinder. 7. Remove piston ring and wear ring from piston. Discard wear ring. See Figure 27. NOTE: Perform the following step only if piston is damaged. 8. Remove piston from rod. See Figure 27. 9. Remove capscrew and seal from shell. Discard seal. See Figure 27. Three-Stage FFL 1. Loosen gland with spanner wrench. 2. Remove gland from rod and shell. See Figure 28. 3. Remove rod and piston assembly from shell. See Figure 28. Drain any remaining hydraulic oil into drain pan. NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 4. Remove and discard rod wiper, backup ring, rod seal, wear ring, and O-ring from gland. See Figure 28. 5. Remove spacer, if installed, from rod. See Figure 28. 6. Remove piston ring, wear ring, seal, and backup ring from piston. Discard wear ring, seal, and backup ring. See Figure 28.

1. 2. 3. 4. 5. 6. 7.

SHELL ROD GLAND SPACER CHECK VALVE WASHER SNAP RING

8. 9. 10. 11. 12. 13. 14.

ROD WIPER SEAL O-RING BACKUP RING WEAR RING ROD SEAL PISTON RING

Figure 28. Main Lift Cylinder, Three-Stage FFL Mast

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal

Lift Cylinder Repair

2100 YRM 1382

Two-Stage LFL 1. Loosen gland with spanner wrench. 2. Remove gland from rod and shell. See Figure 29. 3. Remove rod and piston assembly from shell. See Figure 29. Drain any remaining hydraulic oil into drain pan.

NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 4. Remove and discard rod wiper, backup ring, rod seal, wear ring, and O-ring from gland. See Figure 29. 5. Remove spacer, if installed, from rod. See Figure 29. 6. Remove and discard wear ring, seal, and backup ring from piston See Figure 29.

1. 2. 3. 4. 5. 6. 7.

SHELL ROD GLAND SPACER CHECK VALVE WASHER SNAP RING

8. 9. 10. 11. 12. 13.

ROD WIPER SEAL O-RING BACKUP RING WEAR RING ROD SEAL

Figure 29. Main Lift Cylinder, Two-Stage LFL Mast

2. Remove and discard backup rings, O-rings, rod seal, and wiper from gland. See Figure 30. 3. Remove rod and piston assembly from shell. See Figure 30. Drain any remaining hydraulic oil into drain pan. 4. Remove three check valves from piston. See Figure 31.

2100 YRM 1382

Lift Cylinder Repair Legend for Figure 30 1. 2. 3. 4. 5. 6. 7. 8.

ROD END GLAND BACKUP RING O-RING ROD SEAL WIPER ROD PISTON

1. CHECK VALVE

9. 10. 11. 12. 13. 14. 15. 16.

SHELL CHECK VALVE CUSHION SLEEVE WEAR RING PISTON SEAL NYLON RING SPACER WIRE RING

2. PISTON

Figure 31. Right-Hand Main Lift Cylinder, Piston Check Valve 5. Place rod and piston assembly into soft jaw vise. Using strap wrench and spanner wrench, remove piston from rod as specified below: a. Turn piston until circlip end is visible through hole. See Figure 32. b. Pull circlip end out of hole. See Figure 32. c. Turn piston to feed circlip out. Discard circlip. See Figure 32. d. Pull piston from rod

Figure 30. Right-Hand Main Lift Cylinder, Four-Stage FFL Mast

Lift Cylinder Repair

2100 YRM 1382 13. Remove O-ring and spacer from rod. O-ring. See Figure 33.

Discard

14. Place rod and piston assembly into soft-jawed vise. Using spanner wrench, remove piston from rod. See Figure 33. 15. Remove circlip and cushion sleeve from bottom of piston. Discard circlip. See Figure 33. 16. Remove and discard wear ring, piston seal, nylon ring, and wire ring from piston. See Figure 33. 1. STRAP WRENCH 2. CIRCLIP

3. SPANNER WRENCH

Figure 32. Piston Removal 6. Remove cushion sleeve from bottom of piston. See Figure 30. 7. Remove O-ring and spacer, if present, from rod. Discard O-ring. See Figure 30. 8. Using spanner wrench, remove rod end from rod. Remove and discard O-rings and backup rings from rod. See Figure 30. NOTE: Note orientation of seals prior to disassembly to aid in assembly. 9. Remove and discard ware ring, seal, nylon ring, spacer, and wire ring from piston. See Figure 30. NOTE: Perform Step 10 through Step 18 for Left-Hand Main Lift Cylinder. 10. Using spanner wrench, remove gland from rod and shell. See Figure 33. NOTE: Note orientation of seals prior to disassemble to aid in assembly. 11. Remove and discard wiper, U-cup seal, backup ring, and O-ring from gland. See Figure 33. 12. Remove rod and piston assembly from shell. Drain any remaining hydraulic oil into drain pan.

17. Remove circlip, washer, and control valve from piston. Discard circlip. See Figure 33. 18. Remove and discard O-ring from control valve. See Figure 33.

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION DO NOT allow cleaning solvent to come in contact with rubber components, as it will damage those components. Clean all metal parts in solvent and dry with compressed air.

2100 YRM 1382

Lift Cylinder Repair Legend for Figure 33 1. 2. 3. 4. 5. 6. 7. 8. 9.

GLAND WIPER U-CUP SEAL BACKUP RING O-RING SHELL ROD WIRE RING SPACER

10. 11. 12. 13. 14. 15. 16. 17.

CONTROL VALVE PISTON NYLON RING PISTON SEAL WEAR RING WASHER CIRCLIP CUSHION SLEEVE

Inspect Inspect gland for damage to threads and seal surfaces. If damaged, replace gland. Inspect piston for any damage to seal surfaces. If damaged, replace piston on two-stage FFL and four-stage FFL or rod and piston assembly on three-stage FFL and two-stage LFL main lift cylinders. Inspect rod for damage to rod surface and ensure that the rod is not bent. If damaged, replace rod. Inspect inner surface of cylinder tube for damage. If damaged, replace cylinder assembly. For four-stage FFL right-hand main lift cylinder, inspect check valves for missing O-rings or damage. Replace O-rings if missing or check valve if damaged.

Assemble Two-Stage FFL 1. Lubricate all internal parts of the lift cylinder with clean hydraulic oil. Use new O-rings, seals, and wear rings for installation. NOTE: Perform the following step only if piston was removed from rod. 2. Install piston onto rod. Tighten piston to 170 to 200 N•m (125 to 148 lbf ft). NOTE: Perform the following step for Right-Hand Main Lift Cylinder. 3. Install wear ring onto piston. See Figure 27. NOTE: Perform the following step for Left-Hand Main Lift Cylinder. Figure 33. Left-Hand Main Lift Cylinder, Four-Stage FFL Mast

4. Install wear ring and piston ring onto piston. See Figure 27. 5. Install spacer, if removed, onto rod. See Figure 27.

Lift Cylinder Repair

2100 YRM 1382 5. Install spacer, if required, onto rod. See Figure 28. 6. Install new O-ring, wear ring, rod seal, backup ring, and rod wiper on gland. See Figure 28. 7. Install rod and piston assembly into shell. See Figure 28. NOTE: To prevent possible damage to rod and piston assembly, use care while installing gland. 8. Install gland on rod in shell. Tighten gland to 340 to 410 N•m (250 to 300 lbf ft). See Figure 28.

7. Install rod and piston assembly into shell. See Figure 27.

Two-Stage LFL

NOTE: To prevent possible damage to rod and piston assembly, use care while installing gland.

1. Lubricate all internal parts of the lift cylinder with clean hydraulic oil. Use new O-rings, seals, and wear rings.

8. Install gland onto rod in shell. Tighten gland to 340 to 410 N•m (250 to 300 lbf ft). See Figure 27. 9. Install seal and capscrew into shell. Tighten capscrew to 6.0 to 8.0 N•m (53 to 71 lbf in). See Figure 27. Three-Stage FFL 1. Lubricate all internal parts of the lift cylinder with clean hydraulic oil. Use new O-rings, seals, and wear rings for installation. NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings. 2. Install new O-ring onto check valve. See Figure 28.

NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings 2. Install new O-ring on check valve. See Figure 29.

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal or installation. 3. Install check valve, washer, and snap ring into piston base. See Figure 29. 4. Install new backup ring, seal, and wear ring onto piston. See Figure 29. 5. Install spacer, if removed, onto rod. See Figure 29. 6. Install rod and piston assembly into shell. See Figure 29. 7. Install new O-ring, wear ring, rod seal, backup ring, and rod wiper on gland. See Figure 29. NOTE: To prevent possible damage to rod and piston assembly, use care while installing gland. 8. Install gland onto rod in shell. Tighten gland to 340 to 410 N•m (250 to 300 lbf ft). See Figure 29. Four-Stage FFL NOTE: Perform Step 1 through Step 10 for Right-Hand Main Lift Cylinder.

2100 YRM 1382

Lift Cylinder Repair

Perform Step 11 through Step 19 for Left-Hand Main Lift Cylinder. NOTE: Lubricate new rings and seals with clean hydraulic oil prior to assembly. 1. Install wire ring, spacer, nylon ring, piston seal, and wear ring onto piston as noted during disassembly. See Figure 30.

NOTE: Lubricate new rings and seals with hydraulic oil prior to installation. Be sure to install rod seal as noted during disassembly. 9. Install new wiper, rod seal, O-rings, and backup rings onto gland. See Figure 30. NOTE: Apply Loctite™ 242 or equivalent to gland threads prior to assembly.

2. Install new backup rings and O-rings onto rod. See Figure 30.

10. Install gland onto rod end and shell. See Figure 30. Tighten gland to 68 N•m (50 lbf ft).

3. Install spacer, if present, and new O-ring onto rod. See Figure 30.

NOTE: Perform Step 11 through Step 19 for Left-Hand Main Lift Cylinder.

NOTE: Apply Loctite™ 242 or equivalent to rod end threads prior to assembly.

NOTE: Lubricate new rings and seals with hydraulic oil prior to installation.

4. Install rod end onto rod. See Figure 30. Tighten rod end to 68 N•m (50 lbf ft).

11. Install new O-ring onto control valve. ure 33.

5. Install cushion sleeve into bottom of piston. See Figure 30.

12. Install control valve, washer, and new circlip into piston. See Figure 33.

NOTE: Apply Loctite™ 242 or equivalent to piston threads prior to assembly.

13. Install new wire ring, nylon ring, piston seal, and war ring onto piston. See Figure 33.

6. Install piston onto rod as specified below:

14. Install cushion sleeve and new circlip into bottom of piston. See Figure 33.

a. Install new circlip onto piston. See Figure 34. b. Install piston onto rod. See Figure 34. c. Tighten piston to 68 N•m (50 lbf ft). 7. Install three check valves into piston. ure 31.

See Fig-

8. Install rod and piston assembly into shell. See Figure 30.

See Fig-

NOTE: Apply Loctite™ 242 or equivalent to gland threads prior to assembly. 15. Install piston onto rod. See Figure 33. Tighten piston to 68 N•m (50 lbf ft). NOTE: Lubricate new rings and seals with hydraulic oil prior to installation. 16. Install spacer and new O-ring onto rod. See Figure 33. 17. Install rod and piston assembly into shell. 18. Install new O-ring, backup ring, U-cup seal, and wiper onto gland. See Figure 33. NOTE: Apply Loctite™ 242 or equivalent to gland threads prior to assembly.

1. STRAP WRENCH 2. CIRCLIP

3. SPANNER WRENCH

Figure 34. Piston Installation

19. Install gland onto rod and shell. See Figure 33. Tighten gland to 68 N•m (50 lbf ft).

Install NOTE: Except as noted, the following procedures are for installation of both lift cylinders.

Lift Cylinder Repair Two-Stage FFL

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 3. Uncap hydraulic lines and cylinder ports. Connect hydraulic lines at cylinder.

2100 YRM 1382 System Air Bleed Procedures NOTE: The procedures for bleeding air out of the lift cylinders apply only to lift trucks equipped with a twostage FFL mast. Trucks equipped with a three or fourstage FFL mast or two-stage LFL mast do not need to have air bled out of the lift cylinders. 1. Remove the air from main lift cylinders as described below. See Figure 25. a. Loosen capscrew two turns to permit oil to flow around threads of capscrew. b. With forks unloaded, raise carriage using hydraulic control. Raise carriage 300 mm (12 in.) and then stop for 10 seconds to reduce the pressure in the cylinder. Repeat this procedure until the oil flowing from around the threads is free of air bubbles. c. Stop carriage at the top of the cylinder stroke. Tighten capscrew to 6.0 to 8.0 N•m (53 to 71 lbf in). Three-Stage FFL Mast

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 7. Remove drain pan from beneath hydraulic fitting area and dispose of contents.

WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast. NOTE: The following procedures are for the installation of lift cylinders with the mast installed on lift truck. 1. Using a lifting device install lift cylinder onto mast. The mast must be chained before proceeding to the next step in this procedure. 2. Connect main lift chain at mount. Use new cotter pin and bend both legs of cotter pin a minimum of 90 degrees against chain anchor pin to secure lift chain to chain anchor. 3. Install spacer, washer, capscrew, and nut at mounting plate. See Figure 25. Tighten nut to 40 N•m (30 lbf ft). 4. Uncap hydraulic lines and cylinder ports. Connect hydraulic line at cylinder.

2100 YRM 1382

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 6. Remove drain pan from beneath hydraulic fitting area and dispose of contents. Two-Stage LFL

WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast. NOTE: The following procedures are for the installation of lift cylinders with the mast installed on lift truck. 1. Using a lifting device, install lift cylinder onto mast. The mast must be chained before proceeding to the next step in this procedure. 2. Connect main lift chain at mount. Use new cotter pin and bend both legs of cotter pin a minimum of 90 degrees against chain anchor pin to secure lift chain to chain anchor. 3. Install spacer, two washers, capscrew, and nut at mounting plate. Tighten nut to 40 N•m (30 lbf ft). See Figure 25. 4. Uncap hydraulic lines and cylinder ports. Connect hydraulic lines at cylinder.

Lift Cylinder Repair NOTE: One washer and snap ring required at top of each main lift cylinder. 5. Install shims, if removed, washer, and snap ring at top of cylinder. See Figure 25.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 6. Remove drain pan from beneath hydraulic fitting area and dispose of contents. Four-Stage FFL NOTE: Main lift cylinders install with mast removed from lift truck. 1. Install shims onto tops of cylinders as noted during removal. See Figure 26. 2. Install cylinder through sides of masts and onto mounting boss. 3. Engage cylinder rods with outer intermediate mast. Push outer intermediate, inner intermediate, and inner masts into working position.

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. 4. Install snap ring onto top of left hand cylinder rod. See Figure 26. 5. Install tube and fitting onto top of right-hand cylinder rod. See Figure 26. 6. Remove plugs and install special long fittings into cylinder inlet ports. See Figure 26. 7. Connect cylinder supply hoses to special long fittings. See Figure 26. 8. Ensure inner masts move freely. 9. Remove wood block from low crossmembers of outer intermediate and outer masts. See Figure 26.

Free-Lift Cylinder Repair

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 10. Remove drain pan and dispose of contents. Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 1. Use a lifting device to lower the inner mast weldment (two-stage) or intermediate mast weldment (three-stage) onto the lift cylinder. 2. Install carriage as described in carriage removal procedures located in the section Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 for European lift truck models • ERP16-20VT (G807) • ERP16-20VF (A955) Mast Repair, 2, 3, And 4-Stage Heavy Duty Masts 4000 YRM 1405 for European and Americas lift truck models • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) • ESC030-40AC (B883)

2100 YRM 1382 3. Adjust lift cylinders as specified in section Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 for European lift truck models • ERP16-20VT (G807) • ERP16-20VF (A955) Mast Repair, 2, 3, And 4-Stage Heavy Duty Masts 4000 YRM 1405 for European and Americas lift truck models • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) • ESC030-40AC (B883) Mast and Carriage Installation for Four-Stage FFL 1. Use a lifting device to position mast onto lift truck. Install mast. See section Mast Repair, 2, 3, And 4-Stage Heavy Duty Masts 4000 YRM 1405. 2. Install carriage as described in section Mast Repair, 2, 3, And 4-Stage Heavy Duty Masts 4000 YRM 1405. 3. Adjust lift cylinders as specified in section Mast Repair, 2, 3, And 4-Stage Heavy Duty Masts 4000 YRM 1405.

Free-Lift Cylinder Repair for Lift Trucks ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) FREE-LIFT CYLINDER Remove Two and Three-Stage FFL Mast

WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool.

Before working on or near the mast, see Safety Procedures When Working Near Mast.

2. Put drain pan under the area of the hydraulic fittings. Disconnect hydraulic lines at free-lift cylinder and drain oil from cylinder. Cap hydraulic lines and cylinder ports.

1. Remove the carriage as described in the carriage removal procedures in the section Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338.

3. Remove capscrew, two washers, pin, and chain guard from crosshead. See Figure 35. Repeat for opposite side.

WARNING

Lower the mast completely.

2100 YRM 1382

Free-Lift Cylinder Repair 7. Remove snap ring and chain sheaves from crosshead. See Figure 35. 8. Remove two pins from each side of crosshead. 9. Remove snap ring and crosshead from the cylinder rod. See Figure 35. Disassemble crosshead as necessary. Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968)

WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast. 1. Remove the carriage as described in the carriage removal procedures in the section Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338. Lower the mast completely. 1. 2. 3. 4. 5.

LIFT CHAIN CHAIN SHEAVE CHAIN GUARD SNAP RING CROSSHEAD

6. PIN 7. FREE-LIFT CYLINDER 8. WASHER 9. CAPSCREW

Figure 35. Crosshead Assembly, Two and Three-Stage FFL Mast 4. Remove lift chains from chain sheaves. See Figure 35. NOTE: Note placement of components during removal to aid in installation. 5. Remove brackets, capscrews, spacers, washers, and nuts holding free-lift cylinder to mast. 6. Using a lifting device, as necessary, remove free-lift cylinder from mast.

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause and injury. Always use the correct snap ring pliers, and wear eye and face protection during removal and installation.

WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool. 2. Put drain pan under the area of the hydraulic fittings. Disconnect the hydraulic lines at the cylinder and drain oil from cylinder. Cap hydraulic lines and cylinder ports. 3. Remove two capscrews, two washers, two pins, and chain guard from crosshead. See Figure 36. 4. Remove chains from chain sheaves. ure 36.

See Fig-

5. Remove two nuts, two washers, and strap from mount. See Figure 36. 6. Remove four nuts, four washers, bracket, four spacers, and four capscrews from mast. See Figure 36. 7. Using lifting device, remove free-lift cylinder from mast.

Free-Lift Cylinder Repair

2100 YRM 1382

Figure 36. Free-Lift Cylinder and Crosshead - Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968)

2100 YRM 1382

Free-Lift Cylinder Repair Legend for Figure 36

1. 2. 3. 4. 5. 6. 7.

HOSE HOSE SHEAVE STUB SHAFT WELDMENT WASHER CAPSCREW CHAIN GUARD HOSE GUIDE

8. 9. 10. 11. 12. 13. 14.

CHAIN SHEAVE SNAP RING PIN CROSSHEAD ALIGNMENT PIN FREE-LIFT CYLINDER STRAP

15. SPACER 16. BRACKET 17. LOWERING CONTROL VALVE FITTING 18. NYLON WASHER 19. NUT 20. CLAMP

Disassemble Two and Three-Stage FFL Mast NOTE: Perform only those steps below required to repair the lift cylinder. 1. Loosen gland with spanner wrench. 2. Remove gland from rod and shell. See Figure 37. 3. Remove rod and piston assembly from shell. Drain any remaining hydraulic oil into drain pan. NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 4. Remove and discard rod wiper, rod seal, backup ring, and O-ring from gland. See Figure 37. 5. Remove and discard wear ring, rod seal, and backup ring from piston. See Figure 37.

1. 2. 3. 4. 5. 6. 7.

SHELL ROD GLAND CAPSCREW CHECK VALVE SEAL SNAP RING

8. 9. 10. 11. 12. 13.

ROD WIPER ROD SEAL BACKUP RING O-RING WEAR RING WASHER

Figure 37. Free-Lift Cylinder - Two and Three-Stage FFL Mast

Free-Lift Cylinder Repair

2100 YRM 1382 Compressed air can move particles so they can cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION DO NOT allow cleaning solvent to come in contact with rubber components, as it will damage those components. Clean all metal parts in solvent and dry with compressed air.

Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) NOTE: Perform only those steps below required to repair the lift cylinder. 1. Loosen gland with spanner wrench. 2. Remove gland from rod and shell. See Figure 38. 3. Remove rod and piston assembly from shell. Drain any remaining hydraulic oil into drain pan. 4. Remove and discard rod wiper, rod seal, backup ring, and O-ring from gland. See Figure 38. 5. Remove and discard backup ring, seal, and wear ring from piston. See Figure 38.

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

1. 2. 3. 4. 5. 6. 7.

SHELL ROD GLAND ROD WIPER ROD SEAL BACKUP RING O-RING

8. 9. 10. 11. 12. 13. 14.

SEAL WEAR RING CHECK VALVE WASHER SNAP RING CAPSCREW WASHER-SEAL

Figure 38. Free Lift Cylinder - Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968)

2100 YRM 1382

Inspect Inspect gland for damage to threads and seal surfaces. If damaged, replace gland. Inspect piston for any damage to seal surfaces. If damaged, replace rod and piston assembly.

Free-Lift Cylinder Repair NOTE: To prevent possible damage to rod and piston assembly, use care while installing gland. 7. Install gland onto rod in shell. Tighten gland to 475 to 540 N•m (350 to 400 lbf ft).

Inspect rod for damage to rod surface and ensure that rod is not bent. If damaged, replace rod and piston assembly.

8. Pour 150 cc (5 oz) of hydraulic oil into the cylinder through the capscrew hole. This oil provides a hydraulic cushion when cylinder reaches the top of its stroke. Install seal and capscrew. Tighten capscrew to 5.5 to 6.5 N•m (49 to 58 lbf in)

Inspect inner surface of cylinder shell for damage. If damaged, replace free-lift cylinder assembly.

Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968)

Assemble

1. Lubricate all internal parts of the lift cylinder with clean hydraulic oil. Use new O-rings, seals, backup rings, and wear rings.

Two and Three-Stage FFL Mast 1. Lubricate all internal parts of the lift cylinder with clean hydraulic oil. Use new O-rings, seals, backup rings, and wear rings.

2. Install O-ring onto check valve. See Figure 38.

NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings.

2. Install O-ring onto check valve. See Figure 37.

WARNING

3. Install snap ring, washer, and check valve into piston base. Make sure arrow on check valve is toward piston base. See Figure 38.

CAUTION A difficult and important step in assembling lift cylinders is the correct installation of seals. Most lift cylinder maintenance is cause by seal leaks. DO NOT damage any parts during assembly. NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings. 4. Install backup ring, seal, and wear ring onto piston. See Figure 38. 5. Install backup ring, O-ring, rod seal, and wiper ring onto gland. See Figure 38. 6. Install rod and piston assembly into shell. NOTE: To prevent possible damage to rod and piston assembly, use care while installing gland. 7. Install gland onto rod in shell. Tighten gland to 475 to 540 N•m (350 to 400 lbf ft).

Free-Lift Cylinder Repair

Install Two and Three-Stage FFL Mast

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. 1. Assemble crosshead, if disassembled. Install crosshead and snap ring onto cylinder rod. See Figure 35. 2. Install chain sheaves and snap rings onto crosshead. See Figure 35. 3. Using a lifting device install free-lift cylinder into mast. 4. Install spacers, brackets, washers, capscrews, and nuts onto crossmembers to hold free-lift cylinder on mast as noted during removal. Tighten nuts to 53 N•m (39 lbf ft). 5. Install two pins into each side of crosshead. 6. Install lift chains to chain sheaves. See Figure 35. 7. Install chain guard, pin, two washers, and capscrew into crosshead. Pin to be installed on right-hand side of crosshead. See Figure 35.

2100 YRM 1382 Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1. Install alignment pin into free-lift cylinder. See Figure 36. 2. Install crosshead, two washers, and capscrew onto free-lift cylinder. See Figure 36.

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. 3. Install two chain sheaves, four hose guides, and four snap rings into crosshead. See Figure 36. 4. Using a lifting device install free-lift cylinder onto mast. 5. Install four spacers, bracket, four washers, four capscrews, and four nuts around cylinder onto mast. Tighten nuts to 53 N•m (39 lbf ft). See Figure 36. 6. Install strap, two washers, and two nuts onto mount. See Figure 36. 7. Install chains into chain sheaves. See Figure 36. 8. Install chain guard, two pins, two washers, and two capscrews onto crosshead. Tighten capscrews to 38 N•m (28 lbf ft). See Figure 36.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 8. Uncap hydraulic line and cylinder port. Connect hydraulic line to free-lift cylinder. Dispose of drain pan contents. 9. Install carriage as described in the carriage installation procedures in the section Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338. 10. Adjust cylinders as specified in Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 9. Uncap hydraulic line and cylinder pors. Connect hydraulic line to free-lift cylinder. Dispose of drain pan contents. 10. Install carriage as described in the carriage installation procedures in the section Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338. 11. Adjust cylinders as specified in Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338.

2100 YRM 1382

Free Lift Cylinder Repair for Lift Truck ERP15VT (G807)

Free Lift Cylinder Repair for Lift Truck ERP15VT (G807) FREE-LIFT CYLINDER

Three-Stage FFL Mast

Remove

WARNING

1. Remove the carriage as described in the carriage removal procedures in the section Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386.

Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool. 1. Put a drain pan under the area of the hydraulic fittings. Disconnect free-lift hose at fitting and cap free-lift hose. Drain oil from cylinder. See Figure 39.

Figure 39. Free-Lift Cylinder - Three-Stage FFL Mast

Free Lift Cylinder Repair for Lift Truck ERP15VT (G807)

2100 YRM 1382

Legend for Figure 39 NOTE: OUTER MAST AND CROSSMEMBERS REMOVED FOR CLARITY 1. 2. 3. 4. 5. 6. 7.

FREE-LIFT CYLINDER FITTING FREE-LIFT HOSE CYLINDER MOUNTING BRACKET NUT WASHER INNER MAST CROSSMEMBER

8. 9. 10. 11. 12. 13.

CAPSCREW CHAIN GUARD BRACKET CROSSHEAD CHAIN SUPPORT PLATE PIN FLOW VALVE

1. 2. 3. 4. 5.

CHAIN SHEAVE CROSSHEAD CROSSHEAD PIN BUSHING CAPSCREW

2. Remove fitting from flow valve. See Figure 39. 3. Remove flow valve from free-lift cylinder. Drain hydraulic oil from cylinder. See Figure 39. Cap cylinder. 4. Remove four capscrews and chain guard bracket from crosshead. See Figure 39. 5. Remove two nuts, two washers, cylinder mounting bracket, and two capscrews from inner mast crossmember. See Figure 39. 6. Remove pin to disconnect lift chain from chain support plate. See Figure 39. 7. Remove chain from chain sheave. 8. Using a lifting device, remove free-lift cylinder from mast. 9. Remove crosshead pin, two bushings, and chain sheave from crosshead. See Figure 40. 10. Remove capscrew, washer, crosshead, and pin from free-lift cylinder. See Figure 40.

Disassemble 1. Loosen gland with spanner wrench. 2. Remove gland from rod and shell. See Figure 41. 3. Remove rod and piston assembly from shell. Drain any remaining hydraulic oil into drain pan. NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 4. Remove and discard rod wiper, seal, O-ring, and backup ring from gland. See Figure 41.

6. WASHER 7. PIN 8. FREE-LIFT CYLINDER

Figure 40. Crosshead - Three-Stage FFL Mast

2100 YRM 1382

Free Lift Cylinder Repair for Lift Truck ERP15VT (G807)

CAUTION DO NOT allow cleaning solvent to come in contact with rubber components, as it will damage those components. Clean all metal parts in solvent and dry with compressed air.

Inspect Inspect gland for damage to threads and seal surfaces. If damaged, replace gland. 1. 2. 3. 4. 5. 6.

SHELL ROD GLAND SCREW CHECK VALVE WASHER

7. 8. 9. 10. 11. 12.

SNAP RING ROD WIPER SEAL BACKUP RING O-RING WEAR RING

Figure 41. Free-Lift Cylinder - Three-Stage FFL Mast

WARNING

Inspect piston for damage to seal surfaces. If damaged, replace rod and piston assembly. Inspect rod for damage to rod surface and ensure that rod is not bent. If damaged, replace rod. Inspect inner surface of cylinder tube for damage. If damaged, replace cylinder assembly.

Assemble

1. Lubricate all internal parts of the free-lift cylinder with clean hydraulic oil. Use new O-rings, seals, and wear rings.

5. Remove snap ring, washer, and check valve from piston base. Remove and discard O-ring from check valve. See Figure 41.

2. Install new O-ring onto check valve. See Figure 41.

6. Remove and discard wear ring, seal, and backup ring from piston. See Figure 41.

7. Remove screw and seal from shell. Discard seal. See Figure 41.

NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings.

WARNING

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

3. Install check valve, washer and snap ring into piston base. Make sure arrow on check valve is toward piston base. See Figure 41. 4. Install new backup ring, seal, and wear ring onto piston. See Figure 41. 5. Install new seal, rod wiper, backup ring, and O-ring onto gland. See Figure 41. 6. Install rod and piston assembly into shell. See Figure 41.

Free Lift Cylinder Repair NOTE: To prevent possible damage to the rod and piston assembly, use care when installing gland. 7. Install gland onto rod in shell. Tighten gland to 475 to 540 N•m (350 to 400 lbf ft). See Figure 41. 8. Add 100 cc (3 oz) of hydraulic oil into cylinder through screw hole. This oil provides a hydraulic cushion when cylinder reaches the top of its stroke. Install seal and screw. See Figure 41.

2100 YRM 1382 inner mast crossmember. Nuts are to be toward front of lift truck. See Figure 39. Tighten capscrews to 82 N•m (60 lbf ft). 7. Install chain guard bracket and four capscrews on crosshead. See Figure 39. Tighten capscrews to 52 N•m (38 lbf ft). 8. Uncap cylinder and install flow valve onto free-lift cylinder. See Figure 39 9. Install fitting onto flow valve. See Figure 39.

Install 1. Install pin, crosshead, washer, and capscrew onto free-lift cylinder. See Figure 40. 2. Install pin, chain sheave, two bushings, and crosshead pin into crosshead. See Figure 40. 3. Using lifting device, install free-lift cylinder onto mast. 4. Install chain onto chain sheave. 5. Connect lift chain to chain support plate by installing pin. See Figure 39.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 10. Uncap free-lift hose and connect free-lift hose to fitting. Discard drain pan contents. 11. Install carriage as described in section Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386.

6. Install cylinder mount bracket, two capscrews, two washers, and two nuts onto free-lift cylinder and

Free Lift Cylinder Repair for Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-40AC (B883) FREE-LIFT CYLINDER Remove

Two and Three-Stage FFL Mast

WARNING

1. Remove the carriage as described in the carriage removal procedures in section:

Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool.

Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 for European lift truck models • ERP16-20VT (G807) • ERP16-20VF (A955)

1. Put a drain pan under the area of the hydraulic fittings. Disconnect hydraulic line at free-lift cylinder and drain oil from cylinder. Cap hydraulic line and cylinder port.

Mast Repair, 2, 3, And 4-Stage Heavy Duty Masts 4000 YRM 1405 for European and Americas lift truck models • ERP16-20VT (ERP030-040VT) (G807 • ERP16-20VF (ERP30-40VF) (A955) • ESC030-40AC (B883)

2. Remove four capscrews and chain guard from top of free-lift cylinder. See Figure 42.

2100 YRM 1382

Free Lift Cylinder Repair Legend for Figure 42 NOTE: MASTS REMOVED FOR CLARITY - TWOSTAGE FFL SHOWN. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

INNER MAST MIDDLE CROSSMEMBER INNER MAST BOTTOM CROSSMEMBER CAPSCREW CYLINDER GUARD BRACKET BRACKET WASHER NUT CHAIN GUARD FREE-LIFT CYLINDER PIN CHAIN CHAIN ANCHOR

3. Remove two nuts, two washers, cylinder guard bracket, and two capscrews from inner mast middle crossmember. See Figure 42. 4. Remove two capscrews, two washers, bracket and two nuts from inner mast bottom crossmember. See Figure 42. 5. Disconnect pin and chain from chain anchor. See Figure 42. 6. Remove chain from chain sheave. See Figure 43. 7. Using a lift device remove free-lift cylinder from mast. 8. Remove crosshead pin, two spacers, and chain sheave with bearings from crosshead. See Figure 43. Figure 42. Free-Lift Cylinder - Two and Three-Stage FFL Mast

9. Remove capscrew, washer, pin, and crosshead from free-lift cylinder. See Figure 43.

Free Lift Cylinder Repair

2100 YRM 1382 Four-Stage FFL Mast

WARNING Mast parts are heavy and can shift. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage. Be sure that all lifting devices are suitable and of adequate capacity to lift the mast and components.

WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic lines of the system until the oil for the system is cool and the pressure is relieved. NOTE: Perform Step 1 through Step 9 if mast is on lift truck. Perform Step 10 through Step 18 if mast has been removed from lift truck. 1. Completely lower carriage. Remove forks or other attachment, if equipped. Make sure free-lift cylinder is completely retracted.

WARNING The carriage must be supported by a block while removing the cylinder to avoid possible injury. 2. Using lifting device, raise carriage to center of freelift cylinder. Place wood block between lower carriage bar and floor. See Figure 44.

WARNING 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

CHAIN CHAIN SHEAVE CROSSHEAD PIN BEARING SPACER FREE-LIFT CYLINDER CAPSCREW WASHER PIN CROSSHEAD

Figure 43. Crosshead - Two and Three-Stage FFL Mast

Be careful when installing/removing snap rings. Use snap ring pliers. Always wear protective clothing and eye protection. 3. Remove snap ring securing crosshead to cylinder rod. See Figure 44. 4. Pull crosshead off cylinder rod. Secure crosshead to top bar of carriage. NOTE: Position a suitable drip pan under hydraulic connection before disconnecting. 5. Disconnect hydraulic supply tube from fitting at bottom of free-lift cylinder. See Figure 44.

2100 YRM 1382

Free Lift Cylinder Repair 6. Attach lifting device to free-lift cylinder. 7. Remove Allen screws and cylinder mounting strap from free-lift cylinder. See Figure 44. 8. Remove roll pin from bottom of cylinder and mast. 9. Remove free-lift cylinder from mast. See Figure 44. NOTE: Perform Step 10 through Step 18 if mast has been removed from lift truck. 10. Lay mast face up, with blocks under lower mounts to level mast. See Figure 45. 11. Roll carriage upward to slacken free-lift chains and hoses.

WARNING Be careful when installing/removing snap rings. Use snap ring pliers. Always wear protective clothing and eye protection. 12. Remove snap ring securing crosshead to cylinder rod. See Figure 45. 13. Pull crosshead, with chains and hoses, from cylinder rod. 14. Roll carriage above free-lift cylinder. See Figure 45. 15. Disconnect tube from cylinder fitting. ure 45. Cap cylinder fitting and tube.

See Fig-

16. Remove Allen screws and cylinder mounting strap from free-lift cylinder. See Figure 45. 17. Remove roll pin from bottom of cylinder and mast. 18. Remove cylinder from mast. See Figure 45. A. LIFTING DEVICE DIRECTION B. CYLINDER REMOVAL DIRECTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

LIFTING DEVICE CARRIAGE BLOCK SNAP RING CROSSHEAD TUBE FITTING CYLINDER MOUNT STRAP FREE-LIFT CYLINDER ALLEN SCREW

Figure 44. Free-Lift Cylinder Removal (Mast on Truck)

Free Lift Cylinder Repair

2100 YRM 1382

A. CARRIAGE ROLL DIRECTION

B. CYLINDER REMOVE DIRECTION

1. 2. 3. 4. 5.

6. 7. 8. 9.

BLOCK SNAP RING CROSSHEAD TUBE CYLINDER FITTING

CYLINDER MOUNTING STRAP FREE-LIFT CYLINDER CARRIAGE ALLEN SCREW

Figure 45. Free-Lift Cylinder Removal (Mast on Floor)

2100 YRM 1382

Free Lift Cylinder Repair

Disassemble

6. Remove and discard wear ring, seal, and backup ring from piston end of rod. See Figure 46.

Two-Stage and Three-Stage FFL Masts 1. Loosen gland with spanner wrench.

7. Remove screw and seal from shell. Discard seal. See Figure 46.

2. Remove gland from rod and shell. See Figure 46.

Four Stage FFL Mast 1. Using strap wrench to hold cylinder shell, remove gland from rod using claw-type spanner wrench. See Figure 47.

1. 2. 3. 4. 5. 6.

SHELL ROD GLAND SCREW CHECK VALVE WASHER

7. 8. 9. 10. 11. 12.

SNAP RING ROD WIPER SEAL BACKUP RING O-RING WEAR RING

Figure 46. Free-Lift Cylinder - Two-Stage and Three-Stage FFL Mast

1. 2. 3. 4.

STRAP WRENCH CLAW-TYPE SPANNER WRENCH CYLINDER SHELL GLAND Figure 47. Gland Remove/Install

3. Remove rod and piston assembly from shell. Drain any remaining hydraulic oil into drain pan.

NOTE: Note orientation of seals prior to disassembly to aid in assembly.

NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings.

2. Remove and discard wiper, rod seal, O-ring, and backup ring from gland. See Figure 48.

4. Remove and discard rod wiper, seal, O-ring, and backup ring from gland. See Figure 46.

3. Remove rod and piston assembly from shell. See Figure 48. Drain any remaining hydraulic oil into drain pan.

4. Remove piston from rod. See Figure 48. 5. Remove and discard nylon ring, piston seal, wire ring, and wear ring from piston. See Figure 48. 6. Remove circlip, washer, and check valve from bottom of piston. See Figure 48. 7. Remove and discard O-ring from check valve. See Figure 48.

Free Lift Cylinder Repair

2100 YRM 1382 Legend for Figure 48 1. 2. 3. 4. 5. 6. 7. 8.

GLAND WIPER ROD SEAL BACKUP RING O-RING ROD PISTON NYLON RING

9. 10. 11. 12. 13. 14. 15. 16.

PISTON SEAL WIRE RING WEAR RING CIRCLIP WASHER CHECK VALVE FITTING SHELL

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

CAUTION DO NOT allow cleaning solvent to come in contact with rubber components, as it will damage those components. Clean all metal parts in solvent and dry with compressed air.

Inspect Inspect gland for damage to threads and seal surfaces. If damaged, replace gland. Inspect piston for damage to seal surfaces. If damaged, replace rod and piston assembly. Inspect rod for damage to rod surface and ensure that rod is not bent. If damaged, replace rod. Inspect inner surface of cylinder tube for damage. If damaged, replace cylinder assembly.

Figure 48. Free-Lift Cylinder Assembly

2100 YRM 1382

Assemble Two-Stage and Three-Stage FFL Masts 1. Lubricate all internal parts of the free-lift cylinder with clean hydraulic oil. Use new O-rings, seals, and wear rings. NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings. 2. Install new O-ring onto check valve. See Figure 46.

Free Lift Cylinder Repair 3. Install check valve, washer, and circlip into bottom of piston. See Figure 48. 4. Install new wear ring, wire ring, piston seal, and nylon ring onto piston as noted during disassembly. See Figure 48. 5. Install piston onto rod. See Figure 48. 6. Install rod and piston assembly into shell. See Figure 48. 7. Pour 120 ml (4 oz) hydraulic oil into cylinder shell.

8. Install new backup ring, O-ring, rod seal, and wiper onto gland. See Figure 48. 9. Using strap wrench and claw-type spanner wrench, install gland onto rod and shell. See Figure 47. Tighten gland to 129 to 169 N•m (95 to 125 lbf ft).

Install Two-Stage and Three-Stage FFL Masts

4. Install new backup ring, seal, and wear ring onto piston. See Figure 46.

1. Install crosshead, pin, washer, and capscrew on top of free-lift cylinder. See Figure 43. Tighten capscrew to 270 N•m (199 lbf ft).

5. Install new seal, rod wiper, backup ring, and O-ring onto gland. See Figure 46.

2. Install chain sheave with bearings, two spacers, and crosshead pin into crosshead. See Figure 43.

6. Install rod and piston assembly into shell. See Figure 46.

3. Using a lifting device install free-lift cylinder onto mast.

NOTE: To prevent possible damage to the rod and piston assembly, use care when installing gland.

4. Install chain into chain sheave. See Figure 43.

7. Install gland onto rod in shell. Tighten gland to 475 to 540 N•m (350 to 400 lbf ft). See Figure 46. 8. Add 150 cc (5 oz) of hydraulic oil into cylinder through screw hole. This oil provides a hydraulic cushion when cylinder reaches the top of its stroke. Install seal and screw. See Figure 46. Four-Stage FFL Mast 1. Lubricate all internal parts of the free-lift cylinder with clean hydraulic oil. Use new O-rings, seals, and wear rings. NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings. 2. Install new O-ring onto check valve. See Figure 48.

5. Connect chain and pin to chain anchor. See Figure 42. 6. Install chain guard and four capscrews onto top of free-lift cylinder. See Figure 42. NOTE: Nuts for two-stage FFL to be toward back of lift truck, nuts for three-stage FFL to be toward front of lift truck. 7. Install bracket, two washers, two capscrews, and two nuts onto inner mast bottom crossmember. Tighten nuts to 53 N•m (39 lbf ft). See Figure 42. NOTE: Nuts to be toward front of lift truck. 8. Install cylinder guard bracket, two capscrews, two washers, and two nuts onto inner mast middle crossmember. Tighten nuts to 53 N•m (39 lbf ft). See Figure 42.

Free Lift Cylinder Repair

2100 YRM 1382

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 9. Uncap hydraulic line and cylinder ports. Connect hydraulic line at free-lift cylinder. Dispose of drain pan contents. Four-Stage FFL Mast NOTE: Perform Step 1 through Step 8 if mast is on lift truck. Perform Step 9 through Step 17 if mast has been removed from lift truck. 1. Using lifting device, install free-lift cylinder onto mast. See Figure 49. 2. Install roll pin into mast and bottom of cylinder. 3. Install cylinder mounting strap and Allen screws onto free-lift cylinder. See Figure 49.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 4. Connect hydraulic supply tube to fitting at bottom of free-lift cylinder. See Figure 49. Dispose of drain pan contents. 5. Install crosshead onto top of free-lift cylinder.

WARNING Be careful when installing/removing snap rings. Use snap ring pliers. Always wear protective clothing and eye protection. 6. Install snap ring securing crosshead to free-lift cylinder rod. See Figure 49. 7. Using lifting device, raise carriage and remove wood block between lower carriage bar and floor. See Figure 49. 8. Lower carriage. Install forks or other attachments, if equipped. NOTE: Perform Step 9 through Step 17 if mast has been removed from lift truck. 9. Using lifting device, install free-lift cylinder onto mast. See Figure 50.

A. CYLINDER INSTALL DIRECTION B. LIFT DIRECTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

FREE-LIFT CYLINDER CYLINDER MOUNTING STRAP FITTING SNAP RING LIFTING DEVICE TUBE BLOCK CARRIAGE CROSSHEAD ALLEN SCREW

Figure 49. Free-Lift Cylinder - Install (Mast on Truck)

2100 YRM 1382

Free Lift Cylinder Repair

A. CARRIAGE ROLL DIRECTION

B. CYLINDER INSTALL DIRECTION

1. 2. 3. 4. 5.

6. 7. 8. 9.

BLOCK CYLINDER MOUNTING STRAP CYLINDER FITTING TUBE CARRIAGE

FREE-LIFT CYLINDER CROSSHEAD SNAP RING ALLEN SCREW

Figure 50. Free-Lift Cylinder - Install (Mast on Floor) 10. Install roll pin into mast and bottom of free-lift cylinder.

14. Install crosshead, with chains and hoses, onto cylinder rod.

11. Install cylinder mounting strap and Allen screws onto free-lift cylinder. See Figure 50.

15. Install snap ring securing crosshead to cylinder rod. See Figure 50.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

16. Roll carriage downward to tighten free-lift chains and hoses. 17. Using lifting device raise mast upright and install onto lift truck.

12. Uncap and connect tube to cylinder fitting. See Figure 50. Dispose of drain pan contents. 13. Roll carriage into position above free-lift cylinder as shown in Figure 50.

Torque Specifications All Masts 1. Install carriage as described in section Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 for European lift truck models • ERP16-20VT (G807) • ERP16-20VF (A955)

2100 YRM 1382 Mast Repair, 2, 3, And 4-Stage Heavy Duty Masts 4000 YRM 1405 for European and Americas lift truck models • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) • ESC030-40AC (B883)

Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) TILT CYLINDERS

MAIN AND FREE-LIFT CYLINDER

Piston Rod Nut

Main Lift Cylinder Piston 170 to 200 N•m (125 to 148 lbf ft)

ERC22-25VG (ERC045-055VG) (A968), and ERP22-25VL (ERP045-050VL) (A976) 170 to 220 N•m (125 to 163 lbf ft)

Gland, Main Lift Cylinders 340 to 410 N•m (250 to 300 lbf ft)

ERC30-35VG (ERC060-070VG) (A968), and ERP30-35VL (ERP060-070VL) (A976) 320 to 400 N•m (240 to 295 lbf ft)

Gland ERC22-25VG (ERC045-055VG) (A968), and ERP22-25VL (ERP045-050VL) (A976) 170 to 237 N•m (125 to 175 lbf ft) ERC30-35VG (ERC060-070VG) (A968), and ERP30-35VL (ERP060-070VL) (A976) 400 to 500 N•m (295 to 370 lbf ft)

Tilt Cylinder Mounting Capscrew For lift truck models ERC22-35VG (ERC045-070VG) (A968), and ERP22-25VL (ERP045-070VL) (A976) 38 N•m (28 lbf ft)

Tilt Cylinder Rod End Capscrew For lift truck models ERC22.35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 90 N•m (66 lbf ft)

Main Lift Cylinder Capscrew 6.0 to 8.0 N•m (53 to 71 lbf in) Main Lift Cylinder Mount Nut 40 N•m (30 lbf ft) Main Lift Cylinder Keeper Nut - Four-Stage Mast 33 N•m (24 lbf ft) Gland, Free-Lift Cylinder - Two and Three-Stage Mast 475 to 540 N•m (350 to 400 lbf ft) Free-Lift Cylinder Bracket Capscrews 53 N•m (39 lbf ft) Gland, Free-Lift Cylinder - Four-Stage Mast 340 to 410 N•m (250 to 300 lbf ft) Gland, Two-Stage Limited Free-Lift Cylinder 340 to 410 N•m (250 to 300 lbf ft) Full Free-Lift Cylinder Capscrew 5.5 to 6.5 N•m (49 to 58 lbf in) Free-Lift Crosshead Capscrew - Four-Stage Mast 38 N•m (28 lbf ft)

2100 YRM 1382

Torque Specifications for Lift Truck Model ERP15VT (G807)

Torque Specifications for Lift Truck Model ERP15VT (G807) TILT CYLINDERS Piston Rod Lock-Nut 163-190 N•m (120-140 lbf ft) Gland 163-190 N•m (120-140 lbf ft) Tilt Cylinder Mounting Capscrew 90 N•m (66 lbf ft) Tilt Cylinder Rod End Capscrew 38 N•m (28 lbf ft)

MAIN AND FREE-LIFT CYLINDERS Gland, Main Lift Cylinder 340 to 410 N•m (250 to 300 lbf ft) Piston, Main Lift Cylinder Two-Stage FFL 170 to 200 N•m (125 to 148 lbf ft) Main Lift Cylinder Capscrew - Two-Stage FFL 6.0 to 8.0 N•m (53 to 71 lbf in) Main Lift Cylinder Mount Nut 40 N•m (30 lbf ft) Gland, Free-Lift Cylinder 475 to 540 N•m (350 to 400 lbf ft) Crosshead Mount Capscrew 270 N•m (199 lbf ft) Bracket Mount Capscrew 53 N•m (39 lbf ft) Cylinder Guard Bracket Nuts 53 N•m (39 lbf ft) Cylinder Clamp - Two-Stage FFL Mast 19 N•m (14 lbf ft)

Chain Sheave Cover Plate Top Capscrew 72 N•m (53 lbf ft) Cylinder Clamp Nut, Left-Hand Main Lift Cylinder - Three-Stage FFL 25 N•m (18 lbf ft) Cylinder Restraint Bracket Nut, Left-Hand Main Lift Cylinder - Three-Stage FFL 52 N•m (38 lbf ft) Free-Lift Sheave Mounting Bracket Nut, Left-Hand Main Lift Cylinder - Three-Stage FFL 25 N•m (18 lbf ft) Hose Sheave Cover Plate Bottom Capscrew, Left-Hand Main Lift Cylinder - Three-Stage FFL 38 N•m (28 lbf ft) Hose Sheave Cover Plate Top Capscrew, Left-Hand Main Lift Cylinder - Three-Stage FFL 38 N•m (28 lbf ft) Tube Mounting Plate Nut, Left-Hand Main Lift Cylinder - Three-Stage FFL 25 N•m (18 lbf ft) Cylinder Port Clamp Nut, Right-Hand Main Lift Cylinder - Three-Stage FFL 25 N•m (18 lbf ft) Cylinder Restraint Capscrew, Right-Hand Main Lift Cylinder - Three-Stage FFL 52 N•m (38 lbf ft) Chain Sheave Cover Plate Bottom Capscrew, Right-Hand Main Lift Cylinder - Three-Stage FFL 38 N•m (28 lbf ft) Chain Sheave Cover Plate Top Capscrew, Right-Hand Main Lift Cylinder - Three-Stage FFL 72 N•m (53 lbf ft)

Cylinder Restraint Capscrew 52 N•m (38 lbf ft) Chain Sheave Cover Plate Bottom Capscrew 38 N•m (28 lbf ft)

Torque Specifications

2100 YRM 1382

Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-40AC (B883) TILT CYLINDERS Piston Rod Lock-Nut 163-190 N•m (120-140 lbf ft) Gland 163-190 N•m (120-140 lbf ft) Tilt Cylinder Mounting Capscrew 90 N•m (66 lbf ft) Tilt Cylinder Rod End Capscrew 38 N•m (28 lbf ft)

MAIN AND FREE-LIFT CYLINDERS Gland, Main Lift Cylinder - Two-Stage and Three-Stage FFL 340 to 410 N•m (250 to 300 lbf ft) Gland, Main Lift Cylinder - Four-Stage FFL 68 N•m (50 lbf ft) Piston, Main Lift Cylinder - Two-Stage FFL 170 to 200 N•m (125 to 148 lbf ft) Piston, Main Lift Cylinder - Four-Stage FFL 68 N•m (50 lbf ft) Main Lift Cylinder Capscrew - Two-Stage FFL 6.0 to 8.0 N•m (53 to 71 lbf in)

Main Lift Cylinder Mount Nut - Two-Stage and Three-Stage FFL 40 N•m (30 lbf ft) Right-Hand Main Lift Cylinder Rod End - Four-Stage FFL 68 N•m (50 lbf ft) Gland, Free-Lift Cylinder - Two-Stage and Three-Stage FFL 475 to 540 N•m (350 to 400 lbf ft) Gland, Free-Lift Cylinder - Four-Stage FFL 129 to 169 N•m (95 to 125 lbf ft) Crosshead Mount Capscrew - Two-Stage and Three-Stage FFL 270 N•m (199 lbf ft) Bracket Mount Capscrew - Two-Stage and Three-Stage FFL 53 N•m (39 lbf ft) Cylinder Guard Bracket Nuts - Two-Stage and Three-Stage FFL 53 N•m (39 lbf ft)

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

2100 YRM 1382

5/10 (2/10)(9/09)(8/08)(7/08) Printed in U.S.A.

Maintenance

DIAGNOSTIC TROUBLESHOOTING MANUAL ERC22-35VG (ERC045-070VG) [A968]; ERC16-20VA (ERC030-040VA) [A969]; ERP22-35VL (ERP045-070VL) [A976]; ERP16-20VF (ERP030-040VF) [A955]; ERP15-20VT (ERP030-040VT) [G807]

This manual contains information that is confidential and/or proprietary to Yale Materials Handling Corporation, its subsidiaries and/or vendors. Copying or distribution of any sections of this manual marked "Confidential/Proprietary" is prohibited.

PART NO. 524319504

9000 YRM 1377

SAFETY PRECAUTIONS TROUBLESHOOTING PROCEDURES • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. • Keep the unit clean and the working area clean and orderly. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage! On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Diagnostic Troubleshooting Manual

Table of Contents

TABLE OF CONTENTS SECTION 9010–OPERATIONAL DIAGNOSTIC PROCEDURES Group 05 - Operational Checkout.......................................................................................................... SECTION 9025–TRACTION MOTOR Group 10 - Principles of Operation........................................................................................................ SECTION 9030–ELECTRICAL SYSTEM Group 03 - General Maintenance and Diagnostic Data ........................................................................ Diagnostic Trouble Code (DTC) Chart........................................................................................... Group 10 - Principles of Operation........................................................................................................ Group 20 - Diagnostic Trouble Codes ................................................................................................... Group 30 - Observed Symptoms........................................................................................................... Group 55 - Icons and Graphics ............................................................................................................. SECTION 9035–DRIVE AXLE/UNIT Group 10 - Principles of Operation........................................................................................................ Group 30 - Observed Symptoms........................................................................................................... SECTION 9050–HYDRAULIC SYSTEMS Group 10 - Principles of Operation........................................................................................................ Group 33 - Observed Symptoms-Gear Pump ....................................................................................... Group 43 - Tests and Adjustments-Gear Pump .................................................................................... SECTION 9060–OPERATORS STATION Group 10 - Principles of Operation........................................................................................................ Display Menu Flowchart ................................................................................................................. SECTION 9070–FRONT END (MAST) AND CHASSIS Group 10 - Principles of Operation........................................................................................................ Group 30 - Observed Symptoms........................................................................................................... SECTION 9080–SUPPLEMENTARY DATA Group 50 - Abbreviations and Acronyms............................................................................................... Group 70 - Fault Mode Indicator Reference ..........................................................................................

9010-05-1 9025-10-1 9030-03-1 9030-03-6 9030-10-1 9030-20-1 9030-30-1 9030-55-1 9035-10-1 9035-30-1 9050-10-1 9050-33-1 9050-43-1 9060-10-1 9060-10-8 9070-10-1 9070-30-1 9080-50-1 9080-70-1

This manual covers the following models: ERC22-35VG (ERC045-070VG) [A968]; ERC16-20VA (ERC030-040VA) [A969]; ERP22-35VL (ERP045-070VL) [A976]; ERP16-20VF (ERP030-040VF) [A955]; ERP15-20VT (ERP030-040VT) [G807]

How to Use This Manual

Diagnostic Troubleshooting Manual

How To Use This Troubleshooting Manual GENERAL INSTRUCTIONS AND SAFETY INFORMATION WARNING DO NOT add to or modify the lift truck. Any modification that affects the safe operation of the truck cannot be undertaken without written authorization of the Yale company. Any change to the lift truck, the tires, or its equipment can change the lifting capacity. The lift truck must be rated as equipped and the nameplate must show the new rating capacity.

WARNING The technician must be aware of, and follow, all general safety precautions that are published in the Operating Manual and that are posted as Safety Decals on and in the lift truck. Before starting, the technician should be familiar with certain policies, requirements, and instructions used in the troubleshooting procedures. Using the troubleshooting procedures correctly helps the technician to perform the procedure safely and prevents damage to the machine and support equipment.

HOW TO USE DIAGNOSTIC TROUBLESHOOTING MANUAL Manual Layout: Sections: The manual is divided into eight sections, each representing a major system, functional area, or specific operation on the lift truck. • 9010 – Operational Diagnostic Procedures • 9025 – Traction Motor

• • • • • •

9030 – Electrical System 9035 – Drive Axle/Unit 9050 – Hydraulic Systems 9060 – Operator’s Station 9070 – Front End (Mast) and Chassis 9080 – Supplementary Data

Groups: The sections of the manual are further subdivided into groups, where applicable, that identify specific functions, operating criteria, or maintenance tasks. • • • • • • • • • • •

01 – Introduction to the Troubleshooting Manual 03 – General Maintenance/Diagnostic Data 05 – Operational Checkout 10 – Principles of Operation 20 – Diagnostic Trouble Codes 30 – Observed Symptoms 33 – Observed Symptoms – Gear Pump 43 – Test and Adjustments – Gear Pump 50 – Abbreviation and Acronyms 55 – Icons and Graphics 70 – Fault Mode Indicator Reference

For Diagnostic Trouble Code listings, see General Maintenance and Diagnostic Data, Diagnostic Trouble Codes, Page 9030-03-6. NOTE: Not all groups will appear in all sections. Supplementary Data: The supplementary data section of the manual includes information and data that apply to many sections or groups and is stored here for access by all users of the manual. This data includes, but is not limited to: • • • •

Abbreviations and Acronyms Special Tools List Fault Mode Indication Reference Table Supplier Specification Data

Confidential/Proprietary - Do Not Copy or Duplicate

Diagnostic Troubleshooting Manual

GENERAL INSTRUCTIONS 1. Become familiar with the content, layout, and access provisions of data in this manual. This will improve your efficiency and decrease the time required to resolve the problems. 2. Use all sections of the manual for relevant information on the subject system. 3. Once you begin a troubleshooting procedure, do not skip steps. 4. If you reach the end of a procedure without resolving the problem and you are not directed to another procedure contact Resident Service Engineering through the Contact Management System. 5. Do not limit yourself, remember to apply your own experience and knowledge to assist in resolving the problems, but do not compromise safety in doing so. 6. Most of the cross-reference data in the manual will be electronically linked for rapid and easy access. Use the links wherever the cursor highlights an item as a linkable option.

Confidential/Proprietary - Do Not Copy or Duplicate

How to Use This Manual As an example of this linking option: Assume that during a procedure or test, it is necessary to refer to a different section of manual, in this case, the Light Circuit Check in the Operational Checkout part of this manual. The instruction would read, "refer to, or see" followed by text identifying what the reference is (for hard-copy, paper manual use). When the cursor is placed over the text, it will then indicate that it is active, and left-clicking will direct the system to take you directly to that reference. Try it using the process below: See Operational Checkout, Light Circuit Check, Page 9010-05-3. When you have reviewed the reference document or manual, and need to return to the troubleshooting procedure, the "BACK" button will permit you to do this.

iii

SECTION 9010

OPERATIONAL DIAGNOSTIC PROCEDURES TABLE OF CONTENTS Group 05 - Operational Checkout Operational Checkout Procedures ........................................................................................................ Display Panel (DP) Check ................................................................................................................... Operator Presence System Check...................................................................................................... Display Backlight and Icon Power Check ............................................................................................ Light Circuit Check .............................................................................................................................. Horn Circuit Check .............................................................................................................................. Backup Alarm Check (If equipped) ..................................................................................................... Heater Check (If equipped) ................................................................................................................. Brake Pedal Check.............................................................................................................................. Park Brake Sensor Check ................................................................................................................... Park Brake Check ............................................................................................................................... Brake and Axle Drag Check ................................................................................................................ Priority Flow Divider Valve Check ....................................................................................................... Mast Cushion Check - Free Lift Cylinder............................................................................................. Lift Drift Check..................................................................................................................................... Lift/Tilt Mast Adjustment Check........................................................................................................... Tilt Function Drift Check...................................................................................................................... Tilt Racking Check .............................................................................................................................. Tilt Function, Tilt Lock Piston .............................................................................................................. Mast Cushion Check - Main Lift Cylinder ............................................................................................ Mast Channel Check ......................................................................................................................... Mast Mounting Check ....................................................................................................................... Chain and Header Hose Adjustment Check ..................................................................................... Chain Sheave Check......................................................................................................................... Carriage Adjustment Check .............................................................................................................. Carriage Adjustment Check (Standard and Integral Side Shift) ........................................................ Steering Relief Valve Low Pressure Check....................................................................................... Steering Relief Valve High Pressure Check ......................................................................................

Confidential/Proprietary - Do Not Copy or Duplicate

9010-05-1 9010-05-2 9010-05-2 9010-05-3 9010-05-3 9010-05-4 9010-05-4 9010-05-4 9010-05-4 9010-05-5 9010-05-5 9010-05-6 9010-05-6 9010-05-7 9010-05-7 9010-05-8 9010-05-8 9010-05-8 9010-05-9 9010-05-9 9010-05-10 9010-05-10 9010-05-10 9010-05-11 9010-05-12 9010-05-12 9010-05-12 9010-05-12

9010-1

9010-2

Operational Diagnostic Procedures

Operational Checkout

Group 05

Operational Checkout Operational Checkout Procedures These procedures are designed so technicians can make a quick check of the operation of the machine while sitting in operator’s seat.

Adequate space is required to do the driving checks. Some checks require the lift truck and other major components to be at operating temperature.

WARNING Be sure to read the warnings prior to performing the checkout procedures.

WARNING Before operating the lift truck, FASTEN YOUR SEAT BELT. There are a number of operations, if not performed carefully, that can cause the lift truck to tip. If you have not read the WARNING page in front of the Operating Manual, do so NOW. As you study the following information about how to properly operate a lift truck, remember the Warnings.

WARNING

Before performing the operational checkout, complete the INSPECTION BEFORE OPERATION in the Operating Manual.

Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage. • Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed. Also make sure the power is OFF and the key is removed. Fasten a DO NOT OPERATE tag in the operator’s compartment. • Be careful of the forks. When the mast is raised, the forks can be at a height that may cause an injury. • DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast. • DO NOT use blocks to support the mast weldments nor to restrain their movement. • Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the mast.

Confidential/Proprietary - Do Not Copy or Duplicate

Before starting operational checkout, talk to the operator and check Diagnostic Trouble Codes (DTC) using the Display Panel (DP). See General Maintenance and Diagnostic Data, Troubleshooting Guidelines and Procedures, Page 9030-03-1. All DTCs must be corrected or cleared before starting this checkout.

9010-05-1

Operational Checkout

Operational Diagnostic Procedures

No special tools or gauges are needed. Always start sequence from left to right. Before doing check, read each check completely.

• If the answer indicates that the check is not OK, you will be given a required YRM repair or be linked to the test to perform.

At the end of each check, a question is asked:

When a problem is found, stop operational checkout and correct it before going to the next check. Repeat check after repair to confirm repair was successful before proceeding with the remaining checks.

• If the answer indicates the check is OK, you will be instructed to go to next check.

CHECK Display Panel (DP) Check

Operator Presence System Check

PROCEDURE

ACTION

1. Turn key or keyless switch to ON position. 2. Check display for any DTCs. See General Maintenance and Diagnostic Data, Diagnostic Trouble Codes, Page 9030-03-6.

YES: Refer to General Maintenance and Diagnostic Data, Diagnostic Trouble Codes, Page 9030-03-6.

Are any DTCs displayed?

NO: DTCs are OK. Go to next check.

NOTE: This procedure requires Service Password.

YES: Continue with this procedure.

NOTE: Operator presence sensor requires a minimum of 45.4 kg (100 lb) to actuate. 1. While operator is in seat, power truck ON. 2. See Display Panel Flowchart. At the Display Panel, Enter Main Display, enter password, scroll to Diagnostics, Enter. 3. Scroll to Seat Symbol Enter. Read display.

NO: Go to DTC 12816, or DTC 12819 Seat Sensor Out of Range High (OORH) and troubleshoot per procedure.

Does display show 1.4 volts or greater? Continue: While operator is out of seat, power truck ON. Does display show less than 0.8 volts? NOTE: BEFORE PROCEEDING TO NEXT CHECK, RETURN TO SEAT AND FASTEN SEAT BELT.

9010-05-2

YES: Operator presence sensor is OK. Go to next check. NO: Operator presence sensor has failed. Replace seat sensor. See Electrical System 2200 YRM 1337.

Confidential/Proprietary - Do Not Copy or Duplicate

Operational Diagnostic Procedures

CHECK

Operational Checkout

PROCEDURE

Display Backlight and Icon Power Check

ACTION YES: Display power is OK. Go to next step. NO: See No Display/No Truck Operation.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

INDICATOR LIGHT, PERFORMANCE MODE WARNING LIGHT, LOW BRAKE FLUID WARNING LIGHT, FASTEN SEAT BELT INDICATOR LIGHT, BATTERY DISPLAY INDICATOR (BDI) INDICATOR LIGHT, DIRECTION INDICATORS INDICATOR LIGHT, LOAD WEIGHT INDICATOR LIGHT, SYSTEM TIME WARNING LIGHT, SERVICE DUE LIGHT WARNING LIGHT, MOTOR TEMPERATURE HIGH WARNING INDICATOR LIGHT, HAZARD FLASHERS INDICATOR LIGHT, TIRE ANGLE INDICATOR LIGHT, FRONT WORK LIGHTS INDICATOR LIGHT, REAR WORK LIGHTS

Turn Keyless Start Switch or Key Switch to ON position with park brake applied.

Do the Display Backlight and icons appear on the LCD screen? NOTE: Fasten seat belt, icon will turn off after 10 seconds. Continue: Light Circuit Check

1. Turn front and rear work light switches ON. Do lights turn on?

YES: Lights are OK. Go to next check. NO: See Observed Symptoms, Light Operation

Confidential/Proprietary - Do Not Copy or Duplicate

9010-05-3

Operational Checkout

Operational Diagnostic Procedures

CHECK

Horn Circuit Check

PROCEDURE

ACTION

NOTE: There can be up to three horn buttons on the lift truck: 1. Steering Wheel 2. Right Rear Grab Handle 3. MLM Armrest

YES: Horn is OK. Go to next check.

Press horn button.

NO: Refer to Observed Symptoms, Observed Symptoms, Horn Failure, Page 9030-30-34.

Does horn sound? Backup Alarm Check (If equipped)

1. With lift truck running, apply service brake. 2. Release park brake. 3. Select reverse direction.

Does backup alarm sound? Heater Check (If equipped)

1. Turn key switch to ON position or press power ON/OFF button. 2. Check display for any error codes.

Are any error codes displayed?

YES: Back up alarm is OK. Go to next check. NO: Check wiring connections. YES: Correct error codes. See Electrical System 2200 YRM 1337 or Electrical System 2200 YRM 1369. NO: Heater is okay. Go to next check.

Brake Pedal Check

YES: Brake adjustment is OK. Go to next check. NO: Adjust brakes. see Brake System 1800 YRM 1332.

TOP OF FLOOR MAT 1. With lift truck running, release park brake. 2. Depress and hold brake pedal with approximately 45.4 kg (100 lb) force. 3. Measure pedal distance from floor mat as shown in the illustration.

Does brake pedal remain at least 15 mm (0.6 in.) off floor mat?

9010-05-4

Confidential/Proprietary - Do Not Copy or Duplicate

Operational Diagnostic Procedures

CHECK

Park Brake Sensor Check

Operational Checkout

PROCEDURE

ACTION

1. With lift truck running, release park brake. 2. Slowly apply park brake and note when park brake display comes ON.

YES: Park brake sensor is OK. Go to next check.

Does display come on before park brake reaches first click of engagement? Park Brake Check

NO: Adjust park brake, see Brake System 1800 YRM 1332. YES: Park brake is OK. Go to next check. NO: Adjust park brake, see Brake System 1800 YRM 1332.

WARNING Ensure load is secured so it will not move when mast is tilted fully forward. 1. Stop lift truck in an uphill direction with rated load on 15% grade or less, and apply park brake. 2. Shut lift truck OFF and note if machine remains static. 3. Start lift truck and remove rated load. 4. Position lift truck with No Load in a downhill direction, on 15% grade or less, and apply park brake. 5. Shut lift truck OFF and note if machine remains static.

Does machine remain static on grade in both directions?

Confidential/Proprietary - Do Not Copy or Duplicate

9010-05-5

Operational Checkout

CHECK

Brake and Axle Drag Check

Operational Diagnostic Procedures

PROCEDURE

ACTION

NOTE: This check applies to ERC22-35VG (ERC045-070VG) (A968) with manually applied brake, and ERP22-35VL (ERP040-070VL) (A976).

YES: Repair brakes. See Brake System 1800 YRM 1332.

NOTE: Move truck to level surface before performing the following steps.

NO: Brakes are OK. Continue with this procedure.

1. Raise lift truck until drive tires are off ground. Support lift truck using suitable shop standard. (See "How to Raise Drive Tire" procedure in Operating Manual.) 2. Shut lift truck OFF and release park brake. Handle provided under floor plate to manually release the park brake. 3. Check brakes for dragging.

Are the brakes dragging?

Priority Flow Divider Valve Check

Continue: Manually turn one tire by hand. Does the tire turn with moderate force and does the other tire turn in the opposite direction?

YES: Axle is OK. Adjust park brake back to correct setting. Go to next check.

NOTE: Observe the movement of lift carriage frame (1) during the following two operations:

YES: Continue with this procedure.

NO: If opposite wheel does not turn, differential is damaged. If equipped, remove differential cover and inspect. See Transaxle 1300 YRM 1330

NO: If no steering, flow divider spool is stuck. Remove, clean, and inspect spool. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439.

1. With lift truck running at low idle, turn steering wheel to right axle stop and then back to left axle stop in one continuous cycle while raising lift carriage.

Does carriage lift speed decrease while steering?

9010-05-6

Confidential/Proprietary - Do Not Copy or Duplicate

Operational Diagnostic Procedures

CHECK

Mast Cushion Check Free Lift Cylinder

Operational Checkout

PROCEDURE

ACTION

Continued: 2. Release steering wheel. Does carriage lift speed increase when not steering?

YES: Flow divider is OK. Go to next check.

NOTE: This check applies to free lift cylinders.

YES: Free lift is OK. Go to next check.

1. Raise forks at maximum lift speed with no load. 2. When free cylinder reaches top of stroke, observe transition to main lift cylinder phase and speed of free lift rod during transition.

Does free lift rod speed slow and does hissing sound come from top of cylinder, with no audible impact at top of stroke? Lift Drift Check

Ensure the following before starting procedure: • Truck operating on flat surface. • Hydraulic oil at operating temperature.

WARNING Ensure load is secured so it will not move when mast is tilted fully forward.

NO: Inspect and clean relief valves. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439.

NO: Remove oil fill port screw at top of free lift cylinder; add 100 cc (3.40 oz) of hydraulic oil. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. YES: Go to Tests and Adjustments-Gear Pump, Lift Cylinder Leakage Test, Page 905043-23 to isolate if problem is in cylinder or control valve. NO: Main cylinder drift is OK. Continue with this procedure.

• Secured capacity load on forks. 1. Install angle meter on mast and position mast at approximately 90° angle to ground. 2. Raise mast until approximately 75 mm (3 in.) of main lift cylinder rods are exposed on mast. Record this measurement. 3. Shut lift truck OFF. 4. After 5 minutes, measure mast main lift cylinder drop.

Does main lift cylinder rod retract more than 50 mm (2 in.)? Continue: 5. Raise free lift cylinder approximately 75 mm (3 in.) and mark cylinder rod to record movement. 6. After 5 minutes, measure free lift cylinder drop. Does free lift drop more than 50 mm (2 in.)?

Confidential/Proprietary - Do Not Copy or Duplicate

YES: Go to Tests and Adjustments-Gear Pump, Lift Cylinder Leakage Test, Page 905043-23 to isolate if problem is in cylinder or control valve. NO: Free lift drift is OK. Go to next check.

9010-05-7

Operational Checkout

CHECK

Lift/Tilt Mast Adjustment Check

Operational Diagnostic Procedures

PROCEDURE

Ensure the following before starting procedure: • Truck operating on flat surface. • Adequate overhead clearance to raise forks to maximum height. • No load on forks. 1. Raise forks to maximum height Does the top sections of mast kick to one side at maximum height?

Tilt Function Drift Check

ACTION

YES: Shim lift cylinders. See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386. NO: Mast cylinder is adjusted OK. Continue with this procedure.

Continue: 2. Slowly tilt the mast full forward and then full backward at maximum height and observe movement of mast. Does the top sections of mast make noise during tilting and show excessive movement of mast sections?

YES: Shim and adjust mast. See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386.

Ensure the following before starting procedure:

YES: Go to Tests and Adjustments-Gear Pump, Tilt Cylinder Leakage Test, Page 905043-25 to confirm if cylinder or control valve is leaking.

• Truck operating on flat surface. • Hydraulic oil at operating temperature.

WARNING Ensure load is secured so it will not move when mast is tilted fully forward.

NO: Mast shimming is OK. Go to next check.

NO: Tilt drift is OK. Go to next check.

• Secured capacity load on forks. 1. Raise mast approximately 300 mm (12 in.) off floor. 2. Install angle meter on mast and position mast at approximately 90° angle to ground. 3. Ensure lift truck is OFF. 4. After 5 minutes, measure mast angle and compare to original reading. Does mast tilt drift more than 2 degrees in 5 minutes? Tilt Racking Check

9010-05-8

Actuate mast back tilt function until hydraulic valve goes over relief.

YES: Tilt stops are adjusted OK. Go to next check.

Do both sides of mast stop evenly?

NO: Adjust tilt stops. See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386.

Confidential/Proprietary - Do Not Copy or Duplicate

Operational Diagnostic Procedures

CHECK Tilt Function, Tilt Lock Piston

Operational Checkout

PROCEDURE

WARNING Ensure load is secured so it will not move when mast is tilted fully forward. 1. Put secured capacity load on forks and raise forks approximately 1 m (3 ft). 2. Tilt load back to tilt stop. 3. Move tilt lever to tilt forks forward full stroke and observe speed.

Can tilt speed be controlled? Mast Cushion Check Main Lift Cylinder

Ensure the following before starting procedure: • Truck operating on flat surface. • Adequate overhead clearance to raise forks to maximum height.

WARNING Ensure load is secured so it will not move when mast is tilted fully forward.

ACTION YES: Tilt lock is OK. Go to next check. NO: Repair tilt lock piston valve in tilt spool. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439. YES: Piston ring is OK. Go to next check. NO: Inspect and clean piston ring. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382.

• Secured capacity load on forks. 1. Raise forks to maximum height of main lift cylinders. 2. Lower forks as fast as possible and observe cylinder rod as main lift cylinders reach bottom of stroke.

Does fork speed slow and does a hissing sound come from cylinder at bottom of stroke?

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9010-05-9

Operational Checkout

CHECK

Mast Channel Check

Operational Diagnostic Procedures

PROCEDURE

ACTION

NOTE: This is a visual check of the mast to determine if parts are worn or out of adjustment.

YES: Repair mast channels. See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386.

1. Raise mast to full height without load and shut lift truck OFF. 2. Inspect outer and inner channels for wear pattern and gouging. 3. Move forks to lowered position. 4. Inspect the inner channel wear pattern for wear or gouging.

NO: Mast wear is OK. Continue with this procedure.

Do channels show signs of excess wear?

Mast Mounting Check

Continue: 5. Inspect spacing between channels. Is the channel spacing even on each side?

YES: Channel spacing is OK. Go to next check.

1. Move mast to lowered position and shut lift ruck OFF. 2. Inspect the mounting hardware at axle. 3. Push the top of mast by hand while off the lift truck and note any movement of lift truck.

YES: Inspect and repair mast mounting. See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386.

NOTE: If the mast mounting is loose, mast will move without moving truck frame.

NO: Adjust or repair mast. See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386.

NO: Mast mounting is OK. Go to next check.

Is the mast mounting loose? Chain and Header Hose Adjustment Check

Ensure the following before starting procedure: • Truck operating on flat surface. • Hydraulic oil at operating temperature. • No load on forks. 1. Install angle meter on mast and position mast at approximately 90° angle to ground. 2. Raise and lower forks through two complete lift cycles. 3. Lower forks to lowest position.

YES: Adjust lift chains. See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386. NO: Chains are adjusted OK. Continue with this procedure.

NOTE: The carriage safety stop does not make contact at full extension, but that a minimum gap of 6 mm (0.25 in.) remains. NOTE: The correct fork height adjustment is approximately 6 mm (0.25 in.) off floor.

Does the heel of forks touch the floor?

9010-05-10

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Operational Diagnostic Procedures

CHECK

Chain Sheave Check

Operational Checkout

PROCEDURE

ACTION

Continue: 4. Look at condition of hoses as they go over sheaves. Are the hoses compressed?

YES: Adjust header hoses. See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386.

Continue: 5. Inspect contact of hoses with any crossmember or load backrest near sheave area. Are the hoses contacting any crossmember or the load backrest?

YES: Adjust header hoses.

1. Lower forks. Shut lift truck OFF. 2. Inspect wear pattern on chain sheaves.

YES: Chain sheaves are OK. Go to next check.

Does sheave show a wear pattern without side wear?

NO: Replace chain sheaves. See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386.

Confidential/Proprietary - Do Not Copy or Duplicate

NO: Hose tension is OK. Continue with this procedure. NO: Hose adjustment is OK. Go to next check.

9010-05-11

Operational Checkout

CHECK

Carriage Adjustment Check

Operational Diagnostic Procedures

PROCEDURE

ACTION

1. Lower forks to approximately 50 mm (2 in.) off ground. Shut lift truck OFF. 2. Rock the carriage frame side to side.

YES: Adjust or repair carriage bearings. See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386.

Does carriage move more than 0.5 mm (0.020 in.) at tightest point?

Carriage Adjustment Check (Standard and Integral Side Shift)

1. Lower forks. Shut lift truck OFF. 2. Inspect wear on carriage stop.

Does carriage stop show a wear pattern on it?

NO: Carriage adjustment is OK. Go to next check. YES: Chains are out of adjustment. See Mast Repair, 2and 3-Stage High Visibility Masts 4000 YRM 1386. NO: Checks complete.

Steering Relief Valve Low Pressure Check

1. Turn key switch to ON position. 2. Position steer axle wheels straight to start check. 3. Turn steering wheel stop-to-stop in both directions.

Does steer axle wheels turn stop-to-stop without stopping?

Steering Relief Valve High Pressure Check

1. With lift truck running, turn steering wheel to stop. Then, jerk wheel against the stop and continue to turn with moderate force. 2. Observe reaction of steering wheel as tilt function is held over relief. Repeat several times.

YES: Relief pressure is OK. Go to next check. NO: If steer axle wheels do not turn stop-to-stop, pressure is too low. Adjust steering relief pressure. Go to Tests and Adjustments-Gear Pump, Steering Relief Pressure Test and Adjustment, Page 9050-43-18. YES: Steering relief valve high pressure setting is OK. Continue with this procedure.

It is normal for steering wheel to jerk when tilt function is held over relief because the secondary relief valve is set higher than the steering relief.

NO: If steering wheel does not jerk and moves faster when tilt is held over relief, relief pressure is set too high. Adjust steering relief pressure. Go to Tests and Adjustments-Gear Pump, Steering Relief Pressure Test and Adjustment, Page 9050-43-18.

Does the rpm’s drop when tilt function goes over relief?

YES: Secondary relief is working. Go to next check.

Does steering wheel jerk each time tilt function is held over relief? NOTE: Continue:

NO: Do Tests and Adjustments-Gear Pump, Steering Relief Pressure Test and Adjustment, Page 9050-43-18.

9010-05-12

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SECTION 9025

TRACTION MOTOR TABLE OF CONTENTS Group 10 - Principles of Operation Traction Motor........................................................................................................................................ Principles of Operation .......................................................................................................................

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9025-10-1 9025-10-1

9025-1

9025-2

Traction Motor

Principles of Operation

Group 10

Principles of Operation Traction Motor PRINCIPLES OF OPERATION All electric forklift trucks covered by this manual use three-phase AC induction traction motors. AC motors are all very similar but motors used across the product line do vary in some ways. This Principles of Operation will identify the significant differences. The AC electric motor is an electrical device which uses an AC current provided to a wire wound stator supplied by a DC to AC inverter to induce north and south magnetic poles to an internal rotating device in a controlled environment. The reaction between the internal rotor and stator creates a push-pull effect on the rotor causing the rotor to turn, creating a force to do mechanical work. In lift trucks the DC current is provided by the lead acid battery. The DC (direct current) voltage is changed to AC (alternating current) by the traction motor controller. By changing the frequency of the AC power to the motor, the motor speed can be controlled. This job is done by the traction motor controller. The controller also manages the direction of the motor and thus the lift truck. It works in conjunction with the VSM. A speed sensor is used to detect and communicate the speed and direction of the rotor to the controller. This is done by sending electric pulses on two separate channels to the controller. The controller knows the direction of the motor by which channel’s signal it receives first. It knows the speed by the frequency of the pulses. The controller’s software continually monitors this information. Using this feedback, the AC motor control system can provide regenerative braking, controlled acceleration and declaration. By changing the frequency of the AC power to the motor, which is also managed by the motor controller, the motor speed can be controlled. These AC motors have a temperature sensor built into the stator to monitor motor temperature and provide

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continual temperature feedback to the thermal management system. That system is designed to protect components from failure due to overheating. If the motor winding temperature reaches its specified limit, the VSM signals the traction controller to reduce the motor performance or may even disable traction to protect the motor. When the traction system components are in thermal management, there is no affect on the hydraulic system performance. The connector for this temperature sensor is serviceable, but the sensor itself is not. The rotor shaft extends out each side of the traction motor. The drive end head interfaces to the drive unit or drive axle, depending upon configuration. A short, round section of the shaft protrudes from the non-drive end head of the motor. This end supports the parking brake hub using a woodruff key and a snap ring. There is a bearing between the motor and the parking brake. The parking brake is replaceable. UL safety rated EE traction motors are available as an option on these forklifts. These motors have covered vent holes and are only a part of the necessary equipment required for the EE safety rating. Traction motors are long life components and very low maintenance. They have no brushes. The motor bearings, rotor, stator and speed sensor are serviceable. The traction motors vary depending upon the configuration of your forklift. The model designation A955, G807 and the model designation A976 use two traction motors and two motor controllers. The splined motor shaft on the drive unit side has no bearing and is centered by the internal spline and pilot on the motor end head. A motor is mounted to a drive unit on each side of the vehicle and powers the drive tires. The speed sensor for these motors is physically located on the drive unit housing, not on the motor. See Figure 9025-10-1, Page 9025-10-2.

9025-10-1

Principles of Operation

1. 2. 3. 4. 5. 6.

TRANSMISSION PARKING BRAKE WIRE HARNESS SOCKET HEAD CAPSCREW LOCKWASHER WASHER PARKING BRAKE

Traction Motor

7. 8. 9. 10. 11.

TRACTION MOTOR SPLINED HUB SNAP RING WOODRUFF KEY TRACTION MOTOR MOUNTING CAPSCREW

Figure 9025-10-1. Transaxle Assembly ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (A955)

9025-10-2

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Traction Motor

Principles of Operation

1. RH TRANSMISSION OUTPUT ASSEMBLY 2. RH TRACTION MOTOR 3. SERVICE BRAKE ACTUATOR

4. LH TRACTION MOTOR 5. LH TRANSMISSION OUTPUT ASSEMBLY 6. PARK BRAKE ACTUATOR

Figure 9025-10-2. Transaxle Assembly ERP22-35VL (ERP45-70VL) (A976)

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9025-10-3

Principles of Operation

Traction Motor

The model designation A968 uses only one traction motor and one controller. It is mounted perpendicular to the drive axle. The speed sensor for this motor is located on the motor itself. See Figure 9025-10-3, Page 9025-10-4.

1. TRANSMISSION

2. TRACTION MOTOR

Figure 9025-10-3. Transmission Mounting

9025-10-4

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SECTION 9030

ELECTRICAL SYSTEM TABLE OF CONTENTS Group 03 - General Maintenance and Diagnostic Data Troubleshooting Guidelines and Procedures......................................................................................... Troubleshooting Guidelines ................................................................................................................. Troubleshooting Procedures ............................................................................................................... Troubleshooting Procedures, Identification ....................................................................................... Troubleshooting Procedures, Location.............................................................................................. Troubleshooting Procedures, Structure............................................................................................. Troubleshooting Procedures, Performance ....................................................................................... Troubleshooting Procedures, Final.................................................................................................... Diagnostic Trouble Codes ..................................................................................................................... Diagnostic Trouble Code (DTC) Chart............................................................................................. Wiring Reference Data ........................................................................................................................ Harness Assembly Data...................................................................................................................... Group 10 - Principles of Operation Electrical System................................................................................................................................... General Description ............................................................................................................................ Battery............................................................................................................................................... Power Distribution Module (PDM) ..................................................................................................... Contactor ........................................................................................................................................ Fuses .............................................................................................................................................. Relays ............................................................................................................................................. Wire Harnesses .............................................................................................................................. Operator Interface ............................................................................................................................. Display ............................................................................................................................................ Controllers......................................................................................................................................... Vehicle System Manager (VSM) ..................................................................................................... Motor Controllers ............................................................................................................................ E-Hydraulics Mini Levers Module (MLM) ........................................................................................ System Controlled Outputs ............................................................................................................. Valve Coils .................................................................................................................................... Lights and Backup Alarm .............................................................................................................. Cab options................................................................................................................................... PRINCIPLES OF OPERATION, COMPONENTS ............................................................................. Power Distribution ........................................................................................................................... Contactor ...................................................................................................................................... Positive Temperature Coefficient (PTC)........................................................................................ Fuses ............................................................................................................................................ Relays ........................................................................................................................................... Operator Interface ........................................................................................................................... Display .......................................................................................................................................... Controllers....................................................................................................................................... Vehicle System Manager (VSM): .................................................................................................. Motor Controller ............................................................................................................................ E-Hydraulics Mini Levers Module (MLM) ...................................................................................... PRINCIPLES OF OPERATION, SYSTEM ........................................................................................ Battery (Plug-In)..............................................................................................................................

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9030-03-1 9030-03-1 9030-03-4 9030-03-4 9030-03-4 9030-03-4 9030-03-5 9030-03-5 9030-03-6 9030-03-6 9030-03-10 9030-03-13 9030-10-1 9030-10-1 9030-10-6 9030-10-6 9030-10-6 9030-10-6 9030-10-6 9030-10-7 9030-10-7 9030-10-7 9030-10-7 9030-10-7 9030-10-8 9030-10-9 9030-10-10 9030-10-10 9030-10-11 9030-10-11 9030-10-12 9030-10-12 9030-10-12 9030-10-12 9030-10-12 9030-10-13 9030-10-14 9030-10-14 9030-10-15 9030-10-15 9030-10-17 9030-10-18 9030-10-19 9030-10-19

9030-1

Section 9030

Electrical System

TABLE OF CONTENTS (Continued) Key ON and Operation .................................................................................................................... Sensors........................................................................................................................................... Switches.......................................................................................................................................... Outputs ........................................................................................................................................... Relays ........................................................................................................................................... Hydraulic Valve ............................................................................................................................. Cab Devices.................................................................................................................................. Lights and Backup Alarm .............................................................................................................. Group 20 - Diagnostic Trouble Codes Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL): DTC 12844 - Load Weigh Pressure DTC 12836 - Service Brake Pressure................................................................................................. Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH): DTC 12845 - Load Weigh Pressure DTC 12837 - Service Brake Pressure................................................................................................. Accelerator Pedal Position A/B Out of Range Low (OORL): DTC 12808 - Accelerator Pedal Position A DTC 12810 - Accelerator Pedal Position B ....................................................................................... Accelerator Pedal Position A/B Out of Range High (OORH): DTC 12809 - Accelerator Pedal Position A DTC 12811 - Accelerator Pedal Position B .......................................................................................................................................... Accelerator Pedal Position A/B Data Incorrect: DTC 12812 - Accelerator Pedal Position A to B ................................................................................ Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL): DTC 12820 - Steering Wheel Position DTC 12824 - Steering Axle Position.................................................................................................. Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH): DTC 12821 - Steering Wheel Position DTC 12825 - Steering Axle Position.................................................................................................. Steer Axle Calibration Required: DTC 4098 - Steer Axle Calibration .................................................................................................... Hydraulic Temperature Sensor Out of Range High (OORL) : DTC 12852 - Hydraulic Temperature................................................................................................. Hydraulic Temperature Sensor Out of Range High (OORH) : DTC 12853 - Hydraulic Temperature................................................................................................. Hydraulic Fluid Level Sensor Out Of Range Low (OORL): DTC 12872 - Hydraulic Fluid Level ................................................................................................... Hydraulic Fluid Level Sensor Out Of Range High (OORH): DTC 12873 - Hydraulic Fluid Level ................................................................................................... Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL): DTC 12832 - Park Brake Position DTC 12840 - Mast Tilt Position ......................................................................................................... Park Brake/Mast Tilt Position Sensor Out of Range High (OORH): DTC 12831 - Park Brake Position DTC 12841 - Mast Tilt Position ......................................................................................................... Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL): DTC 12800 - Directional Select A DTC 12804 - Directional Select B .....................................................................................................

9030-2

9030-10-19 9030-10-19 9030-10-23 9030-10-23 9030-10-23 9030-10-23 9030-10-24 9030-10-24

9030-20-1

9030-20-6

9030-20-11

9030-20-15 9030-20-20

9030-20-26

9030-20-30 9030-20-35 9030-20-39 9030-20-43 9030-20-48 9030-20-54

9030-20-58

9030-20-62

9030-20-67

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Section 9030

Electrical System

TABLE OF CONTENTS (Continued) Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH): DTC 12801 - Directional Select A DTC 12805 - Directional Select B ..................................................................................................... Seat Sensor Out of Range Low (OORL): DTC 12816 - Seat Sensor................................................................................................................. Seat Sensor Out of Range High (OORH): DTC 12819 - Seat Sensor................................................................................................................. Battery OORH/OORL: DTC 12545 - Battery OORH DTC 12546 - Battery OORL .............................................................................................................. VSM 5 Volt Supply (OORL) (OORH): DTC 13056 - 5V OORL DTC 13057 - 5V OORH .................................................................................................................... Manual Hydraulic Position Sensors Out Of Range Low (OORL): DTC 12856 - Manual Hyd 1 DTC 12860 - Manual Hyd 2 DTC 12864 - Manual Hyd 3 DTC 12868 - Manual Hyd 4 .............................................................................................................. Manual Hydraulic Position Sensor Out Of Range High (OORH): DTC 12857 - Manual Hyd 1 DTC 12861 - Manual Hyd 2 DTC 12865 - Manual Hyd 3 DTC 12869 - Manual Hyd 4 ............................................................................................................ E-Hydraulic Enable System Data Incorrect: DTC 12332 - Data Incorrect ............................................................................................................ E-Hydraulic Coils Short To Battery Positive (STBP): DTC 8960 - Lift DTC 8964 - Lower DTC 8968 - Tilt Forward DTC 8972 - Tilt Back DTC 8978 - Aux 1A DTC 8980 - Aux 1B DTC 8984 - Aux 2A DTC 8988 - Aux 2B ......................................................................................................................... E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC): DTC 13312 - Lift DTC 13316 - Lower DTC 13320 - Tilt Forward DTC 13324 - Tilt Back DTC 13328 - Aux 1A DTC 13332 - Aux 1B DTC 13336 - Aux 2A DTC 13340 - Aux 2B .......................................................................................................................

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9030-20-71 9030-20-76 9030-20-80

9030-20-84

9030-20-91

9030-20-98

9030-20-102 9030-20-107

9030-20-112

9030-20-117

9030-3

Section 9030

Electrical System

TABLE OF CONTENTS (Continued) A955 – G807 CAN Communication Failure: DTC 33025 - VSM to Display DTC 33026 - VSM to Traction 1 (Right) DTC 33027 - VSM to Traction 2 (Left) DTC 33029 - VSM to Pump DTC 33034 - VSM to MLM (DCS) DTC 33035 - VSM to Impact DTC 33036 - VSM to CAN Reserved 1 DTC 33037 - VSM to CAN Reserved 2 DTC 33038 - VSM to CAN Reserved 3 DTC 33057 - Display to VSM .......................................................................................................... CBB 4 Wheel CAN Communication: DTC 33025 - VSM to Display DTC 33026 - VSM to Traction 1 (Right) DTC 33027 - VSM to Traction 2 (Left) DTC 33029 - VSM to Pump DTC 33034 - VSM to MLM (DCS) DTC 33035 - VSM to Impact DTC 33036 - VSM to CAN Reserved 1 DTC 33037 - VSM to CAN Reserved 2 DTC 33038 - VSM to CAN Reserved 3 DTC 33057 - Display to VSM .......................................................................................................... DBB 4 Wheel CAN Communication: DTC 33025 - VSM to Display DTC 33026 - VSM to Traction 1 (Right) DTC 33027 - VSM to Traction 2 (Left) DTC 33029 - VSM to Pump DTC 33034 - VSM to MLM (DCS) DTC 33035 - VSM to Impact DTC 33036 - VSM to CAN Reserved 1 DTC 33037 - VSM to CAN Reserved 2 DTC 33038 - VSM to CAN Reserved 3 DTC 33057 - Display to VSM .......................................................................................................... MLM Failure: DTC 21830 - MLM EEPROM Write Error DTC 21834 - MLM Sensor 1 Out of Range DTC 21835 - MLM Sensor 2 Out of Range DTC 21836 - MLM Sensor 3 Out of Range DTC 21837 - MLM Sensor 4 Out of Range DTC 25344 - MLM Checksum Error................................................................................................ MLM Incorrect Lever Installed: DTC 4112 - Incorrect Lever 1 Installed DTC 4113 - Incorrect Lever 2 Installed DTC 4114 - Incorrect Lever 3 Installed DTC 4115 - Incorrect Lever 4 Installed DTC 4116 - Incorrect Lever 5 Installed ........................................................................................... VSM 12 Volts Supply OORL/OORH: DTC 13060 - VSM 12V OORL DTC 13061 - VSM 12V OORH........................................................................................................

9030-4

9030-20-122

9030-20-136

9030-20-152

9030-20-164

9030-20-170

9030-20-173

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Section 9030

Electrical System

TABLE OF CONTENTS (Continued) Display Internal Failure: DTC 22032 - Display EEPROM Checksum Error DTC 22033 - Display Cell Write Error DTC 33056 - Display Internal CAN Failure DTC 33057 - Display Communications Error with VSM DTC 8704 - Display Internal LCD Backlight DTC 12934 - Display Internal LCD Backlight DTC 12935 - Display Internal LCD Backlight DTC 8705 - Display Internal LCD Heater DTC 12936 - Display Internal LCD Heater DTC 12937 - Display Internal LCD Heater DTC 22528 - Display Button * DTC 22529 - Display Button # DTC 22530 - Display \ Arrow DTC 22531 - Display ] Arrow DTC 22532 - Display Button 1 DTC 22533 - Display Button 2 DTC 22534 - Display Button 3 DTC 22535 - Display Button 4 DTC 22536 - Display Button 5 DTC 22537 - Display Button 6 DTC 22538 - Display Button 7 DTC 22539 - Display Button 8 DTC 22540 - Display Button 9 DTC 22541 - Display Button 0......................................................................................................... Display Failure – Keyswitch Relay Output: DTC 9041 - Display Keyswitch Output DTC 12940 - Display Keyswitch Output DTC 12941 - Display Keyswitch Output .......................................................................................... VSM Controller Check: DTC 21760 - VSM BOOT_BLOCK Checksum failure DTC 21761 - CDF_Checksum_failure DTC 21762 - VSM APPLICATION_SOFTWARE Checksum failure/Error DTC 21764 - VSM EEPROM Checksum failure/Error DTC 21766 - VSM EEPROM Cell failure Write Error DTC 21792 - VSM Serial Number Error.......................................................................................... Display Failure – Temperature/Buzzer: DTC 12928 - Display Temperature Sensor (Freezer Option Only) DTC 12929 - Display Temperature Sensor (Freezer Option Only) DTC 9040 - Display Buzzer Output DTC 12938 - Display Buzzer Output DTC 12939 - Display Buzzer Output ...............................................................................................

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9030-20-182

9030-20-187

9030-20-198

9030-20-203

9030-5

Section 9030

Electrical System

TABLE OF CONTENTS (Continued) Contactor/Relay/Valve Coil Short to Battery Positive (STBP): DTC 9000 - Diverter Valve DTC 9004 - E Hyd Enable DTC 9008 - Clamp Solenoid (Optional) DTC 9012 - Acc 2 Relay DTC 9016 - Forward Relay DTC 9020 - Reverse Relay DTC 9026 - Spare 1 Relay DTC 9028 - Spare 2 Relay DTC 9032 - Main Contactor DTC 9036 - 2nd Contactor .............................................................................................................. Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC): DTC 13352 - Diverter Valve DTC 13356 - E Hyd Enable DTC 13360 - Acc 1 Relay DTC 13364 - Acc 2 Relay DTC 13368 - Motion Relay DTC 13372 - Reverse Relay DTC 13376 - Spare 1 Relay DTC 13380 - Spare 2 Relay DTC 13384 - Main Contactor DTC 13388 - 2nd Contactor ............................................................................................................ A955 – G807 Motor Controller Contactor Failure: DTC 21569 - Contactor Open DTC 21570 - Contactor Closed....................................................................................................... A955 – G807 Motor Controller Capacitor Failure: DTC 12592 - Capacitor Charge ...................................................................................................... A955 – G807 Motor Speed Sensor Failure: DTC 29456 - Sensor Fault .............................................................................................................. CBB/DBB Motor Speed Sensor Failure: DTC 25104 - Sensor Fault DTC 29456 - Sensor Fault .............................................................................................................. A955 – G807 Motor Auto Brake Failure: DTC 8786 - Brake Coil Shorted DTC 12834 - Aux Driver Short to Bat (-) Brake Coil Open Circuit DTC 12835 - Aux Driver Open Circuit Excess Current ................................................................... A955 – G807 Motor Controller Power Mosfet Failure : DTC 65513 - Power MOS Shorted.................................................................................................. A955 – G807 Motor/Motor Controller Failure: DTC 12576 - Motor Voltage Not OK................................................................................................ A955 – G807 Motor Controller Failure: DTC 65280 - Controller Failure ....................................................................................................... CBB/DBB Motor/Motor Controller Failure: DTC 8976 - AC Current – Over Current DTC 9024 - AC Current – Short Circuit........................................................................................... A955 – G807 Motor Controller CAN Communication Failure: DTC 65527 - No CAN Communication ........................................................................................... CBB/DBB Motor Controller CAN Communication Failure: DTC 33024 - CAN Communication Failure .....................................................................................

9030-6

9030-20-209

9030-20-214

9030-20-220 9030-20-231 9030-20-238

9030-20-249

9030-20-261 9030-20-271 9030-20-279 9030-20-289

9030-20-296 9030-20-307 9030-20-315

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Section 9030

Electrical System

TABLE OF CONTENTS (Continued) Travel Direction Select Incorrect: DTC 12802 - Direction Select Data Incorrect – Direction Signals Incorrect .............................................................................................................. 9030-20-325 Travel Direction Select Data Incorrect – 2 Sources: DTC 12806 - Direction Select – Data Incorrect 2 + Direction Devices Installed........................................................................................................ 9030-20-332 Direction Select Data Incorrect - No DCS Source: DTC 12807 - Direction Select Data Incorrect - No DCS Source ..................................................... 9030-20-336 CBB/DBB Motor/Motor Controller Temperature Sensor Failure: DTC 16912 - Motor Temperature High DTC 17168 - Controller/Heatsink Temperature High DTC 25105 - Temperature Sensor Failure ...................................................................................... 9030-20-344 CBB/DBB Motor Controller Current Sensor Failure : DTC 21008 - Current Sensor Offset Calibration Error .................................................................... 9030-20-357 Hydraulic Calibration Required: DTC 4096 - Hydraulic Calibration Required .................................................................................... 9030-20-363 CBB/DBB Motor Controller 15 – 5 Volt Internal Failure: DTC 20753 - 15 Volt Supply Low Voltage DTC 20755 - 5 Volt Supply Low/High Voltage................................................................................. 9030-20-367 CBB/DBB Motor Controller DC Bus Low/High: DTC 12576 - DC Bus Charging Timeout DTC 12817 - DC Bus Hi – Software Detected DTC 12818 - DC Bus Hi – Hardware Detected DTC 12833 - DC Bus Low – Hardware/Software ............................................................................ 9030-20-373 CBB/DBB Motor Aux Driver Failure: DTC 21520 - Aux Driver Current High............................................................................................. 9030-20-390 Group 30 - Observed Symptoms No Display/No Truck Operation: DTC None - No Display/No Truck Operation....................................................................................... 9030-30-1 A955 – G807 Motor Controller Fan Failure: DTC None - A955 – G807 Motor Controller Fan Failure ................................................................... 9030-30-10 A955 – G807 Motor/Motor Controller Temperature Sensor Failure: DTC None - A955 – G807 Motor/Motor Controller Temperature Sensor Failure .............................. 9030-30-23 Horn Failure......................................................................................................................................... 9030-30-34 Group 55 - Icons and Graphics Icon Glossary ........................................................................................................................................ 9030-55-1 Introduction to Icons............................................................................................................................ 9030-55-1

Confidential/Proprietary - Do Not Copy or Duplicate

9030-7

9030-8

Electrical System

General Maintenance and Diagnostic Data

Group 03

General Maintenance and Diagnostic Data Troubleshooting Guidelines and Procedures TROUBLESHOOTING GUIDELINES The troubleshooting procedures that will be encountered in this manual require that the individual be familiar with certain policies, requirements, and instructions before starting any of the procedures. These are included to assure the safety of the technician performing the tasks, simplify the procedures, and prevent damage to the machine and supporting equipment.

WARNING All safety precautions for working on and around powered vehicles must be observed and maintained. (Refer to Operating or Repair Manual.) 1. Initial conditions will be with the vehicle power OFF and park brake set, unless directed otherwise. 2. The Diagnostic Trouble Code (DTC) Chart includes: • Diagnostic Trouble Code • A brief description of the fault/symptom • Page number of applicable Troubleshooting Procedures This number is the number displayed in the Liquid Crystal Display (LCD) section of the Display Panel (DP). In addition to active faults that will be displayed on the LCD, the system is capable of displaying fault history data that is stored in the VSM and other controller units, if equipped. • • • • • • •

VSM Fault Log Traction Controller 1 and 2 Fault Log HYDR PUMP Controller Fault Log LIGHT Controller Fault Log MLM Fault Log IMPACT Fault Log DISPLAY Fault Log

These fault history logs are accessible to service level technicians. See Troubleshooting Procedures for directions on how to access fault history logs.

defined in Abbreviations and Acronyms that accompanies this document. 4. Most procedures will require the use of a Digital MultiMeter (DMM) and associated probes. The service technician should be familiar with the operation, range scales, polarity selection, and measurement techniques. a. Unless otherwise directed, the RED probe of the DMM will always be connected to the point indicated as (+) and the BLACK probe will always be connected to the point indicated as ( ). b. When performing a continuity check, all signal circuits should be equal or less than 0.5 ohms. At the start of troubleshooting procedures, verify that the DMM will display 0 ohms when the resistance scale is selected and the probes are shorted together. If the DMM display indicates a value less than 1 ohm and that value is consistently repeated, it may be considered as the zero value. Resistance readings during testing will require correction by this small value. If the DMM display is not correct or is greater than 1 ohm, have the meter calibrated/serviced. c. In some improved DMMs, when the test probes are shorted together, a momentary push-button switch will re-zero the meter scale and maintain that zero position as a reference until the meter is turned off. If this feature is available, be sure to re-zero each time meter power is cycled. d. Probing the back of connectors for obtaining in-line voltage measurements requires a special probe extension for the meter probes. Failure to use this tool can result in damage to the integrity of the connector seal and may cause a failure in the harness/connector assembly. See Wire Harness Repair 2200 YRM 1128.

3. Abbreviations and Acronyms will be defined when first used in a procedure. They are also listed and

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9030-03-1

General Maintenance and Diagnostic Data

Electrical System Prior to making any corrections or changes to the wiring, verify that the wire number and color coincide with the information on the referenced schematics, wiring diagrams, or special instructions, if any.

5. Most electrical problems will be harness related: • • • •

Connectors not fully engaged and locked Connector pins not fully inserted Circuit repairs incorrectly wired at connectors Damaged connector pins

6. Major component service tips: a. Vehicle System Manager (VSM): • Connectors are keyed and color coded • Non-serviceable part • Last replaceable item in troubleshooting procedures • Do not transfer VSMs or Display Panel from other trucks • Always confirm VSM/Display Panel and lift truck serial numbers match before doing any servicing 7. When troubleshooting electrical/electronic faults and symptoms: a. Verify that the connector is properly engaged and that connector security clips, tabs, and other locking devices are properly attached. b. Visually examine the connectors and harness termination points for “pushed” or “recessed” pins or sockets. c. The Electric Truck Battery Negative and Positive are isolated from the Vehicle Frame. Unless directed in a Procedure, no measurements will be made using the vehicle frame as an electrical path. d. Before opening any connector or removing any wires from their termination point, disconnect the circuits from the battery as directed in the procedure. Trucks are equipped with a Emergency Disconnect Switch. Pushing the emergency disconnect switch in until it clicks, disconnects the power supply to the lift truck. NOTE: The Electrical System Schematic referenced in this manual will be supplied in Diagrams. Verify that this data is current and the revisions are up to date before making any changes or alterations to the truck wiring.

9030-03-2

NOTE: There may be customer options and equipment installed on the lift trucks by third-party services that do not comply with the standard wiring specifications and standards. Suppliers are encouraged to follow these standards for circuits when possible. 8. The chassis wiring used in these vehicles conforms to the electrical circuit identification standard ES-1359 and in addition to surface marked ID circuit numbers, generally utilizes the colors that are indicated below. a. Red = Battery level power circuits b. Black = Heavy current grounds c. Green = Signal Grounds d. White = Other circuits e. Twisted Pair (preferred CAN option) • Yellow = CANbus Hi • Green = CANbus Lo f.

Twisted Pair (non-preferred CAN option) • White = CAN-Hi • White = CAN-Lo

g. Orange = 5 volt h. Pink = 12 volt 9. Connectors used on schematics and reference drawings are identified as follows: See Figure 9030-03-1, Page 9030-03-3 in this section. a. CPSXXX -- Connector Plug Socket (CPS), with XXX being the identity number. b. CRPXXX -- Connector Receptacle Pin (CRP), with XXX being the identity number.

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Electrical System

General Maintenance and Diagnostic Data

1. PLUG TYPE CONNECTOR BODY 2. RECEPTACLE TYPE CONNECTOR BODY 3. CAVITY PLUG

4. PIN-TYPE TERMINAL 5. SECONDARY LOCK 6. SOCKET TYPE TERMINAL

Figure 9030-03-1. Typical DT Series Connector 10. At the completion of a Troubleshooting Procedure, verify the following: a. All components removed for replacement, test or access purposes have been correctly reinstalled.

e. Support equipment and tools are removed and properly stored. f.

If operation is complete and the lift truck is to be stored or shut down, verify: (1)

Mast/Carriage/Forks are properly positioned.

c. If operational test or checkout is to be performed, make sure operating area is free of personnel, obstructions, and ground hazards.

(2)

By pushing the emergency disconnect switch down until it clicks, disconnects the power supply to the lift truck.

d. Vehicle is in proper location and configuration for safe operation.

(3)

Cab (if equipped) is closed and secured.

b. All electrical connections are restored.

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9030-03-3

General Maintenance and Diagnostic Data

TROUBLESHOOTING PROCEDURES This section describes the general process of identification, location, structure, and performance of the troubleshooting procedures that are included in this manual.

Troubleshooting Procedures, Identification The various procedures are identified by the fault characteristic.

Troubleshooting Procedures, Location Once a DTC number has been displayed, indicating a fault has been detected, the operator/service technician can review the DTC chart in this section to determine where the appropriate troubleshooting procedure is located. The reported DTCs are listed in numerical order, along with the DTC title description of the detected fault. DTCs are also stored in the Fault Logs, where a history of repeat failures is maintained, until cleared by an authorized service technician. When working from an Integrated Electronic Technical Manual (IETM) format, clicking on the DTC index number, or the page in the Table of Contents, will link you to the applicable procedure in section 9030-20. If working from a hardcopy (paper) manual, this capability is not available. NOTE: Access to the following Fault Log menus requires Service password. NOTE: The only Fault Logs available for display are those for the controllers installed in your lift truck, as defined in the VSM’s Configuration Data File (CDF) Access to Fault History Codes — Fault Logs store a history of DTCs within a specific controller file. These fault logs are accessible through the Display Panel main menu. At the Display Panel menu enter the supervisor password, scroll to Diagnostics, ENTER, and scroll to appropriate fault log. See Display Menu Flowchart.

Troubleshooting Procedures, Structure The structure or makeup of the troubleshooting procedures is generally the same for all entries. The procedures are graphical in nature with some text explanation

9030-03-4

Electrical System below the relevant graphic. In the text explanation symbols are used wherever possible. See Icons and Graphics, Icon Glossary, Page 9030-55-1 for definitions. Minor differences in the beginning of a procedure are determined by whether the procedure has: • A single fault code with a single schematic diagram • A single fault code with multiple schematic diagrams In this instance, the technician will have to select the appropriate schematic based on the DTC and the lift truck type/configuration. • Multiple fault codes with a single or multiple schematic diagram(s) • A single fault code with no schematic diagrams, used when only the operational check and replacement procedures are employed in the procedure. Troubleshooting procedures include several elements. • DTC number(s) which this procedure applies to. • DTC Identification e.g. Seat Sensor. • CHECK List - Determines if the Fault is still active and helps identify the Possible Cause. • POSSIBLE CAUSES • MAIN SCHEMATIC • OPERATIONAL CHECKS • Verify the DTC is still a valid fault. If the DTC is cleared during the power cycling, it may not have been a hard failure and if it does not reoccur on the display, there is no method of identifying or troubleshooting the problem. If this situation occurs randomly or reoccurs frequently with the same DTC, access and review the fault history log for that group to determine the frequency of failure and the last reported time it occurred. This information can be helpful in isolating intermittent problems when known conditions under which it occurred can be repeated. • The operational check will also direct the technician to the proper cause in the procedure, based on truck/ system configuration, other symptoms, and advise the user if any special conditions are required (i.e. Operate the truck until it has reached normal temperature, recharge the battery before proceeding etc.). • The operational check is also performed to verify that the problem has been corrected and that the components and devices have been restored to an operating condition.

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Electrical System The next item that appears in the procedure is the CAUSE A. This introduces the troubleshooter to the first sequence of tests or measurements to follow. Continuing through the procedure in the step-by-step directions will lead the user to: • • • •

Additional possible causes Replacement/repair instructions Correction of the fault Operational check of the repaired/replaced device

It must be noted that Service Manual factory directions discourage probing of the connectors using any type of wire or pin and that resistance or continuity measurements of these connections should only be done with the appropriate service tool and breakout connectors. Following through the procedure, the next items are the DIAGRAMS that support the troubleshooting and provide relevant data for wiring, connectors, power, signal and other reference data. These will enable the troubleshooter to measure, verify, and make critical decisions leading to the root cause. The diagrams may include: • • • •

A mini-schematic of the suspect circuit Wire identification and circuit function Connector pin-out locators Special reference data for device or component

Troubleshooting Procedures, Performance It is important to remember the basics of troubleshooting when checking the electronically reported faults. Prior to starting any of the listed procedures, it is recommended that the items listed below be reviewed. These may help to isolate the problem, eliminate some steps or enforce the procedure that has been identified. These items are: • LOOK — Are there any observable symptoms, visual evidence or obvious conditions that could result in, or contribute to, the reported fault. Are the displayed Icons due to Interlocks? See User Interface, Supervisor 2200 YRM 1335 or User Interface, Service Technician 2200 YRM 1336.

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General Maintenance and Diagnostic Data • LISTEN — If the lift truck can be operated with the reported problem, are there any unusual noises or vibrations that could result in, or contribute to, the reported fault. • TOUCH OR SMELL — High operating temperatures and excessive wear can sometimes produce an odor or visual evidence that can be linked to other faults or conditions. • In general, let your senses and your experience assist you in resolving the problem in the most efficient manner. Ask yourself: • What is required for this device or operation to function correctly? • Where are the devices/parts located? • Has this problem been reported before? If so, how frequently? Use the fault history logs to help identify repeated problems. This can be very helpful in analyzing faults of an intermittent nature which may be difficult to duplicate. • Has repair work, disassembly or other maintenance work been performed on suspect device or system recently? • Once these questions have been considered, proceed with the DTC resolution as per the procedure, using any additional information to assist in resolving the discrepancy.

Troubleshooting Procedures, Final DTCs are stored in the FAULT CODE LOGS, where a history of repeat failures is maintained, until cleared by an authorized service technician. All DTCs are to be cleared prior to operating the lift truck. Fault code logs should only be cleared once the data is recorded by a authorized service technician. See Display Menu Flowchart. NOTE: Motor/Motor Controller Fault Logs cannot be cleared. Once the Motor Controller Log is full, DTCs are removed on a First In, First Out (FIFO) basis.

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General Maintenance and Diagnostic Data

DIAGNOSTIC TROUBLE CODES The Diagnostic Trouble Codes that appear in the table that follows are those codes that have been stored in the memory of the VSM or in certain cases the Display Panel or other Controllers. They will be displayed

Electrical System via the Display Panel upon detection and will remain in the applicable fault history logs until service intervention clears the logs. The DTC list is comprised of the DTC number and a brief description of the fault item.

Diagnostic Trouble Code (DTC) Chart DTC

DESCRIPTION

12332 12545 12546 12576 12576 12592 12800 12801 12802

Data Incorrect .................................................................................................................. 9030-20-107 Battery OORH.................................................................................................................... 9030-20-84 Battery OORL .................................................................................................................... 9030-20-84 DC Bus Charging Timeout ............................................................................................... 9030-20-373 Motor Voltage Not OK ...................................................................................................... 9030-20-279 Capacitor Charge............................................................................................................. 9030-20-231 Directional Select A............................................................................................................ 9030-20-67 Directional Select A............................................................................................................ 9030-20-71 Direction Select Data Incorrect – Direction Signals Incorrect ............................................................................................... 9030-20-325 Directional Select B............................................................................................................ 9030-20-67 Directional Select B............................................................................................................ 9030-20-71 Direction Select – Data Incorrect 2 + Direction Devices Installed......................................................................................... 9030-20-332 Direction Select Data Incorrect - No DCS Source ........................................................... 9030-20-336 Accelerator Pedal Position A.............................................................................................. 9030-20-11 Accelerator Pedal Position A ........................................................................................................................... 9030-20-15 Accelerator Pedal Position B.............................................................................................. 9030-20-11 Accelerator Pedal Position B ........................................................................................................................... 9030-20-15 Accelerator Pedal Position A to B ...................................................................................... 9030-20-20 Seat Sensor ....................................................................................................................... 9030-20-76 DC Bus Hi – Software Detected....................................................................................... 9030-20-373 DC Bus Hi – Hardware Detected ..................................................................................... 9030-20-373 Seat Sensor ....................................................................................................................... 9030-20-80 Steering Wheel Position..................................................................................................... 9030-20-26 Steering Wheel Position..................................................................................................... 9030-20-30 Steering Axle Position........................................................................................................ 9030-20-26 Steering Axle Position........................................................................................................ 9030-20-30 Park Brake Position............................................................................................................ 9030-20-62 Park Brake Position............................................................................................................ 9030-20-58 DC Bus Low – Hardware/Software .................................................................................. 9030-20-373 Aux Driver Short to Bat (-) Brake Coil Open Circuit ......................................................... 9030-20-261 Aux Driver Open Circuit Excess Current.......................................................................... 9030-20-261 Service Brake Pressure ....................................................................................................... 9030-20-1 Service Brake Pressure ....................................................................................................... 9030-20-6 Mast Tilt Position................................................................................................................ 9030-20-58 Mast Tilt Position................................................................................................................ 9030-20-62 Load Weigh Pressure .......................................................................................................... 9030-20-1 Load Weigh Pressure .......................................................................................................... 9030-20-6 Hydraulic Temperature....................................................................................................... 9030-20-39 Hydraulic Temperature....................................................................................................... 9030-20-43

12804 12805 12806 12807 12808 12809 12810 12811 12812 12816 12817 12818 12819 12820 12821 12824 12825 12831 12832 12833 12834 12835 12836 12837 12840 12841 12844 12845 12852 12853

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Electrical System

General Maintenance and Diagnostic Data

Diagnostic Trouble Code (DTC) Chart (Cont) DTC 12856 12857 12860 12861 12864 12865 12868 12869 12872 12873 12928 12929 12934 12935 12936 12937 12938 12939 12940 12941 13056 13057 13060 13061 13312 13316 13320 13324 13328 13332 13336 13340 13352 13356 13360 13364 13368 13372 13376 13380 13384 13388 16912 17168 20753 20755 21008 21520 21569 21570 21760

DESCRIPTION PAGE NO. Manual Hyd 1..................................................................................................................... 9030-20-98 Manual Hyd 1................................................................................................................... 9030-20-102 Manual Hyd 2..................................................................................................................... 9030-20-98 Manual Hyd 2................................................................................................................... 9030-20-102 Manual Hyd 3..................................................................................................................... 9030-20-98 Manual Hyd 3................................................................................................................... 9030-20-102 Manual Hyd 4..................................................................................................................... 9030-20-98 Manual Hyd 4................................................................................................................... 9030-20-102 Hydraulic Fluid Level.......................................................................................................... 9030-20-48 Hydraulic Fluid Level.......................................................................................................... 9030-20-54 Display Temperature Sensor (Freezer Option Only) ........................................................ 9030-20-203 Display Temperature Sensor (Freezer Option Only) ........................................................ 9030-20-203 Display Internal LCD Backlight ........................................................................................ 9030-20-182 Display Internal LCD Backlight ........................................................................................ 9030-20-182 Display Internal LCD Heater ............................................................................................ 9030-20-182 Display Internal LCD Heater ............................................................................................ 9030-20-182 Display Buzzer Output ..................................................................................................... 9030-20-203 Display Buzzer Output ..................................................................................................... 9030-20-203 Display Keyswitch Output................................................................................................. 9030-20-187 Display Keyswitch Output................................................................................................. 9030-20-187 5V OORL ........................................................................................................................... 9030-20-91 5V OORH........................................................................................................................... 9030-20-91 VSM 12V OORL............................................................................................................... 9030-20-173 VSM 12V OORH .............................................................................................................. 9030-20-173 Lift .................................................................................................................................... 9030-20-117 Lower ............................................................................................................................... 9030-20-117 Tilt Forward ...................................................................................................................... 9030-20-117 Tilt Back ........................................................................................................................... 9030-20-117 Aux 1A ............................................................................................................................. 9030-20-117 Aux 1B ............................................................................................................................. 9030-20-117 Aux 2A ............................................................................................................................. 9030-20-117 Aux 2B ............................................................................................................................. 9030-20-117 Diverter Valve................................................................................................................... 9030-20-214 E Hyd Enable ................................................................................................................... 9030-20-214 Acc 1 Relay ...................................................................................................................... 9030-20-214 Acc 2 Relay ...................................................................................................................... 9030-20-214 Motion Relay .................................................................................................................... 9030-20-214 Reverse Relay.................................................................................................................. 9030-20-214 Spare 1 Relay .................................................................................................................. 9030-20-214 Spare 2 Relay .................................................................................................................. 9030-20-214 Main Contactor................................................................................................................. 9030-20-214 2nd Contactor .................................................................................................................. 9030-20-214 Motor Temperature High .................................................................................................. 9030-20-344 Controller/Heatsink Temperature High............................................................................. 9030-20-344 15 Volt Supply Low Voltage.............................................................................................. 9030-20-367 5 Volt Supply Low/High Voltage ....................................................................................... 9030-20-367 Current Sensor Offset Calibration Error........................................................................... 9030-20-357 Aux Driver Current High ................................................................................................... 9030-20-390 Contactor Open................................................................................................................ 9030-20-220 Contactor Closed ............................................................................................................. 9030-20-220 VSM BOOT_BLOCK

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General Maintenance and Diagnostic Data

Electrical System

Diagnostic Trouble Code (DTC) Chart (Cont) DTC 21761 21762 21764 21766 21792 21830 21834 21835 21836 21837 22032 22033 22528 22529 22530 22531 22532 22533 22534 22535 22536 22537 22538 22539 22540 22541 25104 25105 25344 29456 33024 33025 33026 33027 33029 33034 33035 33036 33037 33038 33056 33057 33057 4096 4098 4112 4113 4114

9030-03-8

DESCRIPTION PAGE NO. Checksum failure ............................................................................................................. 9030-20-198 CDF_Checksum_failure ................................................................................................... 9030-20-198 VSM APPLICATION_SOFTWARE Checksum failure/Error ............................................. 9030-20-198 VSM EEPROM Checksum failure/Error ...................................................................................................................... 9030-20-198 VSM EEPROM Cell failure Write Error ....................................................................................................................... 9030-20-198 VSM Serial Number Error ................................................................................................ 9030-20-198 MLM EEPROM Write Error .............................................................................................. 9030-20-164 MLM Sensor 1 Out of Range ........................................................................................... 9030-20-164 MLM Sensor 2 Out of Range ........................................................................................... 9030-20-164 MLM Sensor 3 Out of Range ........................................................................................... 9030-20-164 MLM Sensor 4 Out of Range ........................................................................................... 9030-20-164 Display EEPROM Checksum Error.................................................................................. 9030-20-182 Display Cell Write Error.................................................................................................... 9030-20-182 Display Button * ............................................................................................................... 9030-20-182 Display Button #............................................................................................................... 9030-20-182 Display \ Arrow ................................................................................................................. 9030-20-182 Display ] Arrow ................................................................................................................. 9030-20-182 Display Button 1............................................................................................................... 9030-20-182 Display Button 2............................................................................................................... 9030-20-182 Display Button 3............................................................................................................... 9030-20-182 Display Button 4............................................................................................................... 9030-20-182 Display Button 5............................................................................................................... 9030-20-182 Display Button 6............................................................................................................... 9030-20-182 Display Button 7............................................................................................................... 9030-20-182 Display Button 8............................................................................................................... 9030-20-182 Display Button 9............................................................................................................... 9030-20-182 Display Button 0............................................................................................................... 9030-20-182 Sensor Fault..................................................................................................................... 9030-20-249 Temperature Sensor Failure............................................................................................. 9030-20-344 MLM Checksum Error ...................................................................................................... 9030-20-164 Sensor Fault..................................................................................................................... 9030-20-238 CAN Communication Failure............................................................................................ 9030-20-315 VSM to Display ................................................................................................................ 9030-20-122 VSM to Traction 1 (Right)................................................................................................. 9030-20-122 VSM to Traction 2 (Left) ................................................................................................... 9030-20-122 VSM to Pump................................................................................................................... 9030-20-122 VSM to MLM (DCS) ......................................................................................................... 9030-20-152 VSM to Impact ................................................................................................................. 9030-20-152 VSM to CAN Reserved 1 ................................................................................................. 9030-20-122 VSM to CAN Reserved 2 ................................................................................................. 9030-20-136 VSM to CAN Reserved 3 ................................................................................................. 9030-20-152 Display Internal CAN Failure............................................................................................ 9030-20-182 Display Communications Error with VSM ........................................................................ 9030-20-182 Display to VSM ................................................................................................................ 9030-20-136 Hydraulic Calibration Required ........................................................................................ 9030-20-363 Steer Axle Calibration ........................................................................................................ 9030-20-35 Incorrect Lever 1 Installed................................................................................................ 9030-20-170 Incorrect Lever 2 Installed................................................................................................ 9030-20-170 Incorrect Lever 3 Installed................................................................................................ 9030-20-170

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General Maintenance and Diagnostic Data

Diagnostic Trouble Code (DTC) Chart (Cont) DTC 4115 4116 65280 65513 65527 8704 8705 8786 8960 8964 8968 8972 8976 8978 8980 8984 8988 9000 9004 9008 9012 9016 9020 9024 9026 9028 9032 9036 9040 9041 None None None

DESCRIPTION PAGE NO. Incorrect Lever 4 Installed................................................................................................ 9030-20-170 Incorrect Lever 5 Installed................................................................................................ 9030-20-170 Controller Failure.............................................................................................................. 9030-20-289 Power MOS Shorted ........................................................................................................ 9030-20-271 No CAN Communication.................................................................................................. 9030-20-307 Display Internal LCD Backlight ........................................................................................ 9030-20-182 Display Internal LCD Heater ............................................................................................ 9030-20-182 Brake Coil Shorted........................................................................................................... 9030-20-261 Lift .................................................................................................................................... 9030-20-112 Lower ............................................................................................................................... 9030-20-112 Tilt Forward ...................................................................................................................... 9030-20-112 Tilt Back ........................................................................................................................... 9030-20-112 AC Current – Over Current .............................................................................................. 9030-20-296 Aux 1A ............................................................................................................................. 9030-20-112 Aux 1B ............................................................................................................................. 9030-20-112 Aux 2A ............................................................................................................................. 9030-20-112 Aux 2B ............................................................................................................................. 9030-20-112 Diverter Valve................................................................................................................... 9030-20-209 E Hyd Enable ................................................................................................................... 9030-20-209 Clamp Solenoid (Optional)............................................................................................... 9030-20-209 Acc 2 Relay ...................................................................................................................... 9030-20-209 Forward Relay.................................................................................................................. 9030-20-209 Reverse Relay.................................................................................................................. 9030-20-209 AC Current – Short Circuit ............................................................................................... 9030-20-296 Spare 1 Relay .................................................................................................................. 9030-20-209 Spare 2 Relay .................................................................................................................. 9030-20-209 Main Contactor................................................................................................................. 9030-20-209 2nd Contactor .................................................................................................................. 9030-20-209 Display Buzzer Output ..................................................................................................... 9030-20-203 Display Keyswitch Output................................................................................................. 9030-20-187 A955 – G807 Motor Controller Fan Failure ........................................................................ 9030-30-10 A955 – G807 Motor/Motor Controller Temperature Sensor Failure ................................... 9030-30-23 No Display/No Truck Operation............................................................................................ 9030-30-1

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General Maintenance and Diagnostic Data

Electrical System

Wiring Reference Data NOTE: When troubleshooting the electrical wiring harness for your lift truck, the wire connectors may be different but the pin numbers for the connectors are the same between the different connectors. Function/Circuit Identification — A standard numbering and color-coding system is used in the lift truck wiring. This system will simplify repairs. The Electrical Circuit Identification Specification is ES-1359. The ID data is described in Table 9030-03-1, Page 9030-03-10. Each circuit Function ID has a number from 1 through 999, as indicated in the Table 9030-03-1, Page 903003-10.

• A circuit labeled with a single numerical Function ID shall be electrically equivalent throughout the harness (physically connected through splices or connectors). • Wires which are connected only through an internal connection in a controller shall have separate Function ID numbers. • Wire Function ID numbers will be stamped at 50mm intervals along the wire length. • The Function IDs are assigned into groups as shown in the table. Unless noted otherwise, specific functions are to be preassigned to unique Function IDs. If a circuit function does not meet one of the preassigned numbers, and its function is unique within the truck series and option, then a number from the “NonStandard Functions” range may be used.

Table 9030-03-1. Circuit Group Identification Number Range

Function/Group Grounds (IDs not preassigned within this range)

101-149

Current sense ground

150-199

Switched B+ (IDs not preassigned within this range)

200-239

Fused B+ (IDs not preassigned within this range)

240-249

Regulated Power 5V (IDs not preassigned within this range)

250-279

Regulated Power 12V

280-299

Analog Inputs – hydraulics / mast

300-319

Analog Inputs – chassis

320-339

Analog Inputs – powertrain

340-399

Analog Inputs – CAB / OHG

400-419

Reserved for additional analog inputs

420-499

Digital inputs – hydraulics / mast

500-509

Digital inputs – chassis

510-539

Digital inputs – powertrain

540-559

Digital inputs – CAB / OHG

560-569

Encoder inputs

570-599

Reserved for additional digital inputs

600-699

Digital outputs – hydraulics / mast

700-719

Digital outputs – chassis

720-749

Digital outputs – powertrain

750-779

Digital outputs – CAB /OHG

780-799

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General Maintenance and Diagnostic Data

Table 9030-03-1. Circuit Group Identification (Continued) Function/Group

Number Range

PWM outputs – hydraulics / mast

800-829

PWM outputs – chassis

830-839

PWM outputs – powertrain

840-889

PWM outputs – CAB / OHG

890-899

Communications (eg., CANbus)

900-909

Non-Standard functions

910-999

Wiring Color Codes — The colors used to identify the lift truck wiring, in addition to the surface marked circuit ID data, are identified in Table 9030-03-2, Page 903003-11. Many Diagrams and Schematics in this book can be viewed and printed in color. If not printed or viewed in color refer to the electrical circuit identification located on schematic circuits. When viewing a color version of the diagrams and schematics, the white chassis wires are seen as yellow. Other wires are shown in colors similar to actual colors, i.e., tan shows as yellow. Use circuit identification for true wire color. Foot Directional Control, wiring to sensors and other applications vary with respect to wire colors.

Table 9030-03-2. Yale Wiring Color Codes Color

Use/Function

Red

Battery-level power circuits

Black

Heavy current grounds

Green

Signal grounds

White

Other circuits

Twisted Pair (Yellow/Green) Yellow Green

Preferred CAN Option CAN-Hi CAN-Lo

Twisted Pair (Yellow/Green) White White

Non-Preferred CAN Option CAN-Hi CAN-Lo

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Symbol Definitions Type "S", Identifies information for UL Safety rated trucks. Arrow Symbols, Go to specified page of schematic. Page number is located in the “hexagon symbol” on schematic. ---x, Go to specified sheet of diagram. Sheet number is located in lower right corner of figure. Circuit Segment Suffix Letter — A circuit ID has a segment suffix letter as required (splices or passing through a connector). Each circuit ID is unique and each circuit ID has a suffix. The circuit connects to all other wires in the vehicle with the same circuit ID number. For example, 42-A will be connected to 42-B, 42-J, etc. Function ID numbers appear with suffix letters, the base number is not used by itself. For example, when labeling a circuit #42, start with “42-A” rather than “42”. Suffix letters should be assigned from “A” to “Z” (but “Q” and “V” are not used). Additional branches beyond “Z” to be assigned as “AA”, AB”, etc. If a Suffix is used, the parts of the circuit identification number will be separated by dashes. For example:

9030-03-11

General Maintenance and Diagnostic Data

WIRE # 751 (RED), SEGMENTED, SUFFIX LETTERS A, O, P WIRE # 870 (WHITE), NON-SEGMENTED, SUFFIX LETTER A

Electrical System

WIRE #S 383, 384 (WHITE), NON-SEGMENTED, TWISTED PAIR, SUFFIX LETTER A (SHOWN WITH SHIELD THAT TERMINATES AT PIN B2)

Figure 9030-03-2. Single Wiring Sample Circuit

WIRE # 751 (RED), SEGMENTED, SUFFIX LETTERS A, O, P WIRE # 870, 871 (WHITE), NON-SEGMENTED, SUFFIX LETTER A

WIRE #S 383, 384, 387, AND 388 (WHITE), NON-SEGMENTED, TWISTED PAIR, SUFFIX LETTER A (SHOWN WITH SHIELD THAT TERMINATES AT PIN B2)

Figure 9030-03-3. Dual Wiring Sample Circuit

9030-03-12

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

General Maintenance and Diagnostic Data

Harness Assembly Data This section depicts the lift truck harness assemblies with their respective connector identifications. The harnesses are arranged as follows: • Wire Harness – Auxillary Key Switch Figure 903003-4, Page 9030-03-14 • Wire Harness Steering Figure 9030-03-5, Page 903003-15 • Display Wire Harness Standard Figure 9030-03-6, Page 9030-03-16 • Display Wire Harness Freezer Figure 9030-03-7, Page 9030-03-17 • Wire Harness Main Electro – Hydraulic Figure 903003-8, Page 9030-03-18 • Wire Harness Main Manual – Hydraulic Figure 903003-9, Page 9030-03-20 • Wire Harness Front Switch Figure 9030-03-10, Page 9030-03-22 • Wire Harness Back Up Alarm Strobe w/o Conv.Figure 9030-03-11, Page 9030-03-23 • Wire Harness Lights LH - OHG Figure 9030-03-12, Page 9030-03-24 • Wire Harness Manual Hydraulics Figure 9030-03-13, Page 9030-03-25 • Wire Harness Display Freezer Figure 9030-03-14, Page 9030-03-26

Confidential/Proprietary - Do Not Copy or Duplicate

• Wire Harness Turn Signal Figure 9030-03-15, Page 9030-03-27 • Wire Harness Synchro Steer Figure 9030-03-16, Page 9030-03-28 • Wire Harness Park Brake Figure 9030-03-17, Page 9030-03-29 • Wire Harness LH OHG w/Turn Signals Figure 903003-18, Page 9030-03-30 • Wire Harness Steering Column Figure 9030-03-19, Page 9030-03-31 • Wire Harness Lights w/OHG - RH Figure 9030-03-20, Page 9030-03-32 • Wire Harness Lights Chassis Main Figure 9030-0321, Page 9030-03-33 • Wire Harness Seat E-Hydraulic Figure 9030-03-22, Page 9030-03-34 • Wire Harness Seat Manual-Hydraulic Figure 903003-23, Page 9030-03-35 • Wire Harness Main w/Manual – Hydraulic Figure 9030-03-24, Page 9030-03-36 • Wire Harness Main w/E – Hydraulic Figure 9030-0325, Page 9030-03-38

9030-03-13

General Maintenance and Diagnostic Data

1. T115 FUSE BLOCK 2. T116 FUSE BLOCK

Electrical System

3. T114 KEY SWITCH 4. T113 KEY SWITCH

Figure 9030-03-4. ; ERP15-20VT (ERP030-040VT) (G807); Wire Harness – Auxillary Key Switch

9030-03-14

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

1. 2. 3. 4.

TF15 HORN SWITCH NO TF14 HORN SWITCH C CPS78 STEERING WHEEL POSITION SENSOR CPS28 DIAGNOSTIC CONNECTION

General Maintenance and Diagnostic Data

5. CPS128 STEER MAKE-UP VALVE 6. CRP132 MAIN HARNESS 7. CRP133 MAIN HARNESS

Figure 9030-03-5. ; ERP15-20VT (ERP030-040VT) (G807); Wire Harness Steering

Confidential/Proprietary - Do Not Copy or Duplicate

9030-03-15

General Maintenance and Diagnostic Data

1. CRP135 MAIN HARNESS 2. CRP180 MAIN HARNESS 3. CPS20 DISPLAY

Electrical System

4. CPS103 RIGHT FRONT WORK LIGHT 5. CPS166 RIGHT FRONT MARKER LIGHT 6. BUZZER

Figure 9030-03-6. ; ERP15-20VT (ERP030-040VT) (G807); Display Wire Harness Standard

9030-03-16

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

1. 2. 3. 4.

CRP135 MAIN HARNESS CRP180 MAIN HARNESS CPS20 DISPLAY CPS103 RIGHT FRONT WORK LIGHT

General Maintenance and Diagnostic Data

5. CPS166 RIGHT FRONT MARKER LIGHT 6. CPS165 TEMPERATURE SENSOR 7. BUZZER

Figure 9030-03-7. ; ERP15-20VT (ERP030-040VT) (G807); Display Wire Harness Freezer

Confidential/Proprietary - Do Not Copy or Duplicate

9030-03-17

General Maintenance and Diagnostic Data

Electrical System

Figure 9030-03-8. ; ERP15-20VT (ERP030-040VT) (G807); Wire Harness Main Electro – Hydraulic

9030-03-18

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

General Maintenance and Diagnostic Data

Legend for Figure 9030-03-8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

CPS31A STEER AXLE HARNESS CPS5 PUMP CONTROLLER CPS95B HYDRAULIC COOLING FAN CPS95A HYDRAULIC CONTROLLER COOLING FAN CPS146 MOTOR SPEED SENSOR CPS61 MOTOR TEMPERATURE SENSOR CRP52-55 MLM SEAT HARNESS TF67 ESD HYDRAULIC TANK CPS114 OHG HORN SWITCH CPS135 DISPLAY HARNESS CPS180 DISPLAY LIGHT HARNESS TF72 FLASHER TF71 FLASHER + TF70 FLASHER L CRP206 RR WORK LIGHT SWITCH CRP205 NO MARK LIGHT SWITCH CPS133 STEER MAKE UP VALVE CPS132 STEER HARNESS CPS134 TURN SIGNAL SWITCH CPS138 LIGHT OPTION HARNESS CPS90 DC-DC CONVERTER CPS157 LEFT CONTROL COOLING FAN CPS4 LEFT TRACTION MOTOR CONTROLLER CPS11 SERV. BREAK SENSOR TBF3 BREAK FLUID LEVEL SENSOR TBF4 BREAK FLUID LEVEL SENSOR CPS151 HORN ASM

Confidential/Proprietary - Do Not Copy or Duplicate

28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52.

CPS156 RIGHT CONTROL COOLING FAN TR65 B-CONT. CPS3 RIGHT TRACTION MOTOR CONTROLLER CPS74 E HYDRAULIC VALVE UPPER COILS CPS75 E HYDRAULIC VALVE LOWER COILS CPS10 LIFT PRESSURE SENSOR CPS102 BATTERY GATE MAGNETIC SWITCH CPS153 RIGHT TRACTION MOTOR SPEED SENSOR CRP8 TILT POSITION SENSOR CPS24 RIGHT ELECTRIC BREAK CPS155 RIGHT TRACTION MOTOR TEMPERATURE SENSOR CPS1 VSM CPS2 VSM CPS272 ACCELERATOR JUMPER TR3 MN CONTACT BATTERY + CPS152 LEFT TRACTION SPEED SENSOR TF11 MN CONTROLLER COIL TF10 MN CONTROLLER COIL CPS26 LEFT ELECTRIC BREAK CPS154 LEFT TRACTION MOTOR SENSOR CRS110 BREAK LIGHT RELAY CRS209 E HYDRAULIC EN-RELAY CRS210 BACK UP LIGHT RELAY CRS208 KEY SWITCH RELAY FUSES

9030-03-19

General Maintenance and Diagnostic Data

Electrical System

Figure 9030-03-9. ; ERP15-20VT (ERP030-040VT) (G807); Wire Harness Main Manual – Hydraulic

9030-03-20

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

General Maintenance and Diagnostic Data

Legend for Figure 9030-03-9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

CPS31A STEER AXLE HARNESS CPS5 PUMP CONTROLLER CPS95B HYDRAULIC COOLING FAN CPS95A HYDRAULIC CONTROLLER COOLING FAN CPS146 MOTOR SPEED SENSOR CPS61 MOTOR TEMPERATURE SENSOR CRP52-55 MLM SEAT HARNESS TF67 ESD HYDRAULIC TANK CPS114 OHG HORN SWITCH CPS135 DISPLAY HARNESS CPS180 DISPLAY LIGHT HARNESS TF72 FLASHER (-) TF71 FLASHER (+) TF70 FLASHER (L) CRP206 RR WORK LIGHT SWITCH CRP205 NO MARK LIGHT SWITCH CPS133 STEER MAKE UP VALVE CPS132 STEER HARNESS CPS134 TURN SIGNAL SWITCH CPS138 LIGHT OPTION HARNESS CPS90 DC-DC CONVERTER CPS157 LEFT CONTROL COOLING FAN CPS4 LEFT TRACTION MOTOR CONTROLLER CPS11 SERV. BREAK SENSOR TBF3 BREAK FLUID LEVEL SENSOR TBF4 BREAK FLUID LEVEL SENSOR CPS151 HORN ASM CPS156 RIGHT CONTROL COOLING FAN

Confidential/Proprietary - Do Not Copy or Duplicate

29. TR65 B-CONT. 30. CPS3 RIGHT TRACTION MOTOR CONTROLLER 31. CPS162 MANUAL HYDRAULIC SPOOL POSITION SENSOR 32. CPS10 LIFT PRESSURE SENSOR 33. CPS192 TO MAN. HYDRAULIC 34. CPS190B CLAMP INTERLOCK COIL 35. CPS102 BATTERY GATE MAGNETIC SWITCH 36. CPS160B SPOOL INTERLOCK SOLENOID 2 37. CPS160A SPOOL INTERLOCK SOLENOID 1 38. CPS153 RIGHT TRACTION MOTOR SPEED SENSOR 39. CPS155 RIGHT TRACTION MOTOR TEMPERATURE SENSOR 40. CPS24 RIGHT ELECTRIC BREAK 41. CPS1 VSM 42. CPS2 VSM 43. CPS272 ACCELERATOR JUMPER 44. TR3 MN CONTACT BATTERY + 45. CPS154 LEFT TRACTION MOTOR SENSOR 46. CPS26 LEFT ELECTRIC BREAK 47. TF11 MN CONTROLLER COIL 48. TF10 MN CONTROLLER COIL 49. CPS152 LEFT TRACTION SPEED SENSOR 50. CRS110 BREAK LIGHT RELAY 51. CRS210 BACK UP LIGHT RELAY 52. CRS208 KEY SWITCH RELAY 53. FUSES

9030-03-21

General Maintenance and Diagnostic Data

Electrical System

1. CRP206 REAR WORK LIGHT 2. CRP205 FRONT WORK LIGHT/TAIL LIGHT 3. CRP211 HARNESS-LIGHT CHASSIS MAIN

Figure 9030-03-10. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness – Front Switch

9030-03-22

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

1. CRP112 BACK UP ALARM 2. CRP137 MAIN HARNESS

General Maintenance and Diagnostic Data

3. CRP210 REVERSE RELAY 4. CRP138 LIGHT OPTION HARNESS

Figure 9030-03-11. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness – Back Up Alarm Strobe w/o Conv.

Confidential/Proprietary - Do Not Copy or Duplicate

9030-03-23

General Maintenance and Diagnostic Data

1. 2. 3. 4.

CPS106 TAIL LIGHT RH CPS87 STROBE LIGHT CPS116 REAR WORK LIGHT CPS105 TAIL LIGHT LH

Electrical System

5. CPS107 DOME LIGHT W/SWITCH 6. CPS104 WORK LIGHT FRONT LH 7. CRP138 MAIN LIGHT HARNESS

Figure 9030-03-12. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976)Wire Harness Lights LH - OHG

9030-03-24

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

General Maintenance and Diagnostic Data

1. CRP64 FWD/REV SWITCH 2. CRS196 CLAMP COIL SWITCH 3. CRP129 TO MAIN HARNESS

Figure 9030-03-13. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness Manual Hydraulics

Confidential/Proprietary - Do Not Copy or Duplicate

9030-03-25

General Maintenance and Diagnostic Data

1. CPS20 DISPLAY W/KEY SWITCH 2. CPS21 WIRE HARNESS TEMPERATURE SENSOR 3. CPS103 RH FRONT WORK LIGHT

Electrical System

4. CPS166 FRONT MARKER RH 5. CRP180 MAIN LIGHTS HARNESS 6. CRP135 MAIN HARNESS

Figure 9030-03-14. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness Display Freezer

9030-03-26

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

1. CPS35 TO TURN SIGNAL SWITCH HARNESS 2. CRP131 WIRE HARNESS LH -OHG W/TURN SIGNALS

General Maintenance and Diagnostic Data

3. CRS220 FLASHER 4. CPS180A TO DISPLAY FREEZER HARNESS 5. CRP180A TO LIGHT MAIN HARNESS

Figure 9030-03-15. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Turn Wire Harness Signal

Confidential/Proprietary - Do Not Copy or Duplicate

9030-03-27

General Maintenance and Diagnostic Data

1. CPS128 STEER MAKEUP VALVE

Electrical System

2. CRP133 MAIN HARNESS

Figure 9030-03-16. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness Synchro Steer

9030-03-28

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

General Maintenance and Diagnostic Data

1. CPS16 PARK BRAKE MODULE 2. CRS17 PARK BRAKE SOLENOID 3. CRP15 MAIN HARNESS

Figure 9030-03-17. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness Park Brake

Confidential/Proprietary - Do Not Copy or Duplicate

9030-03-29

General Maintenance and Diagnostic Data

1. 2. 3. 4. 5.

CPS106 TAIL LIGHT RH CPS87 STROBE LIGHT CPS116 REAR WORK LIGHT CPS105 TAIL LIGHT LH CPS107 DOME LIGHT

Electrical System

6. 7. 8. 9.

CPS104 WORK LIGHT FRONT LH CRP34 LH FRONT MARKER CRP138 MAIN LIGHT HARNESS CPS131 TO TURN SIGNAL HARNESS

Figure 9030-03-18. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness - LH OHG w/Turn Signals

9030-03-30

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

1. 2. 3. 4. 5.

General Maintenance and Diagnostic Data

TF15 HORN SWITCH NO TF14 HORN SWITCH C CPS78 STEER WHEEL POSITION SENSOR CPS28 DIAGNOSTIC CONNECTOR CRP132 MAIN HARNESS

Figure 9030-03-19. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness Steering Column

Confidential/Proprietary - Do Not Copy or Duplicate

9030-03-31

General Maintenance and Diagnostic Data

1. CPS103 WORK LIGHT FRONT RH 2. CPS20 DISPLAY W/KEY SWITCH

Electrical System

3. CRP135 DISPLAY HARNESS 4. CRP180 DISPLAY LIGHT HARNESS

Figure 9030-03-20. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness Lights w/OHG - RH

9030-03-32

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

1. 2. 3. 4. 5.

TFK80 FUSE 2 CPS112 BACK UP ALARM CPS90 DC - DC CONVERTER CRS210 BRAKE LIGHT RELAY CRS110 REVERSE RELAY

General Maintenance and Diagnostic Data

6. 7. 8. 9.

CPS138 WIRE HARNESS LIGHTS LH - OHG CPS211 HARNESS LIGHT SWITCH CPS180 DISPLAY LIGHT HARNESS CRP137 MAIN HARNESS

Figure 9030-03-21. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness Lights Chassis Main

Confidential/Proprietary - Do Not Copy or Duplicate

9030-03-33

General Maintenance and Diagnostic Data

Electrical System

1. CRP54 MAIN HARNESS 2. CPS52 MLM SEAT HARNESS 3. CPS55 SEAT SENSOR

Figure 9030-03-22. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness Seat E-Hydraulic

9030-03-34

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

1. CRP54 MAIN HARNESS

General Maintenance and Diagnostic Data

2. CRP55 SEAT HARNESS

Figure 9030-03-23. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness Seat Manual-Hydraulic

Confidential/Proprietary - Do Not Copy or Duplicate

9030-03-35

General Maintenance and Diagnostic Data

Electrical System

Figure 9030-03-24. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness Main w/Manual – Hydraulic

9030-03-36

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

General Maintenance and Diagnostic Data

Legend for Figure 9030-03-24 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

CPS114 OHG HORN SWITCH CPS54 SEAT HARNESS CPS157 CONTROLLER FAN CPS95 CONTROLLER FAN TFK78 FUI TF10 MAIN CONNECTOR COIL TF11 MAIN CONNECTOR COIL TR65 NEGATIVE TERMINAL TRACTION CONTROLLER CPS5 PUMP CONTROLLER CPS3 TRACTION MOTOR CONTROLLER CPS31 STEER AXLE SENSOR CPS102 BATTERY GATE MAGNETIC SWITCH CPS135 DISPLAY HARNESS CPS191 CLAMP COIL CPS161 MANUAL HYDRAULIC COIL CPS160 MANUAL HYDRAULIC COIL CPS137 LIGHT OPTION HARNESS CPS29 ACCELERATOR PEDAL POSITION SENSOR CPS65 DIRECTION SELECT SENSOR CPS10 LIFT PRESSURE CPS162 MANUAL HYDRAULIC SPOOL POSITION SENSOR

Confidential/Proprietary - Do Not Copy or Duplicate

22. CPS15 PARK BRAKE 23. CPS154 TRACTION MOTOR TEMPERATURE SENSOR 24. CPS152 TRACTION MOTOR SPEED SENSOR 25. CPS61 PUMP MOTOR TEMPERATURE SENSOR 26. CPS146 PUMP MOTOR SPEED SENSOR 27. CRS212 SYNC. STEER VALVE RELAY 28. CRS208 KEY SWITCH RELAY 29. TF04 BRAKE FLUID LEVEL 30. TF03 BRAKE FLUID LEVEL 31. CPS11 SERVICE BRAKE PRESSURE SENSOR 32. CPS2 VSM 33. CSP1 VSM 34. CPS151 HORN ASSEMBLY 35. CPS133 SYNC. STEER VALVE HARNESS 36. CPS142 TERMINATION RESISTOR 37. CPS512 PARK BRAKE POSITION 38. CPS132 STEER HARNESS 39. CPS8 TILT POSITION SENSOR 40. CPS70 HYD. OIL LEVEL SENSOR 41. CPS66 HYD. FILTER PRESSURE SWITCH 42. CPS14 HYD. OIL TEMPERATURE SENSOR 43. CPS192 MANUAL HYD. HARNESS

9030-03-37

General Maintenance and Diagnostic Data

Electrical System

Figure 9030-03-25. ERC22-35VG (ERC045-070VG) (A968); ERP22-25VL (ERP040-070VL) (A976) Wire Harness Main w/E – Hydraulic

9030-03-38

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

General Maintenance and Diagnostic Data

Legend for Figure 9030-03-25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

CPS114 OHG HORN SWITCH CPS54 SEAT HARNESS CPS157 CONTROLLER FAN CPS95 CONTROLLER FAN TFK78 FUI TFK67 ESD TRUCK FRAME TF10 MAIN CONNECTOR COIL TF11 MAIN CONNECTOR COIL TR65 NEGATIVE TERMINAL TRACTION CONTROLLER CPS3 TRACTION MOTOR CONTROLLER CPS5 PUMP CONTROLLER CPS31 STEER AXLE SENSOR CPS102 BATTERY GATE MAGNETIC SWITCH CPS135 DISPLAY HARNESS CPS137 LIGHT OPTION HARNESS CPS75 E-HYDRAULIC LOWER COIL CPS74 E-HYDRAULIC UPPER COIL CPS10 LIFT PRESSURE CPS65 DIRECTION SELECT SENSOR CPS29 ACCELERATOR PEDAL POSITION SENSOR CRS208 KEY SWITCH RELAY

Confidential/Proprietary - Do Not Copy or Duplicate

CRS212 SYNC. STEER VALVE RELAY CRS209 E-HYDRAULIC ENABLE RELAY TF03 BRAKE FLUID LEVEL TF04 BRAKE FLUID LEVEL CPS11 SERVICE BRAKE PRESSURE SENSOR CPS2 VSM CSP1 VSM CPS151 HORN ASSEMBLY CPS133 SYNC. STEER VALVE HARNESS CPS142 TERMINATION RESISTOR CPS132 STEER HARNESS CPS512 PARK BRAKE POSITION CPS70 HYD. OIL LEVEL SENSOR CPS8 TILT POSITION SENSOR CPS66 HYD. FILTER PRESSURE SWITCH CPS14 HYD. OIL TEMPERATURE SENSOR CPS146 PUMP MOTOR SPEED SENSOR CPS61 PUMP MOTOR TEMPERATURE SENSOR CPS152 TRACTION MOTOR SPEED SENSOR CPS154 TRACTION MOTOR TEMPERATURE SENSOR 42. CPS15 PARK BRAKE

22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.

9030-03-39

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

9030-03-40

Electrical System

Principles of Operation

Group 10

Principles of Operation Electrical System GENERAL DESCRIPTION The major components in the electrical system are shown in Figure 9030-10-1, Page 9030-10-1, Figure 9030-10-2, Page 9030-10-2, Figure 9030-10-3, Page 9030-10-3, Figure 9030-10-4, Page 9030-10-4, and Figure 9030-10-5, Page 9030-10-5.

Figure 9030-10-1. ERP15-20VT (ERP030-040VT) (G807) Lift Truck

Confidential/Proprietary - Do Not Copy or Duplicate

9030-10-1

Principles of Operation

Electrical System

Legend for Figure 9030-10-1 NOTE: ERP15-20VT (ERP030-040VT) (G807) IS SHOWN AND THE ERP16-20VF (A955) IS SIMILAR. 1. 2. 3. 4.

VSM DC/DC CONVERTER RELAYS MAIN CONTACTOR AND FUSES

5. DISPLAY 6. TRACTION MOTOR CONTROLLER 7. PUMP MOTOR CONTROLLER 8. MINI-LEVER MODULE (MLM)

9. 10. 11. 12.

MAIN CHASSIS HARNESS EMERGENCY STOP PUMP MOTOR TRACTION MOTOR

1. 2. 3. 4.

VSM DC/DC CONVERTER RELAYS MAIN CONTACTOR AND FUSES

5. DISPLAY 6. TRACTION MOTOR CONTROLLER 7. PUMP MOTOR CONTROLLER 8. MINI-LEVER MODULE (MLM)

9. 10. 11. 12.

MAIN CHASSIS HARNESS EMERGENCY STOP PUMP MOTOR TRACTION MOTOR

Figure 9030-10-2. ERC22-35VG (ERC045-070VG) (A968) Lift Truck

9030-10-2

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

1. 2. 3. 4.

Principles of Operation

VSM DC/DC CONVERTER RELAYS MAIN CONTACTOR AND FUSES

5. DISPLAY 6. TRACTION MOTOR CONTROLLER 7. PUMP MOTOR CONTROLLER 8. MINI-LEVER MODULE (MLM)

9. 10. 11. 12.

MAIN CHASSIS HARNESS EMERGENCY STOP PUMP MOTOR TRACTION MOTOR

Figure 9030-10-3. ERP22-35VL (ERP040-070VL) (A976) Lift Truck

Confidential/Proprietary - Do Not Copy or Duplicate

9030-10-3

Principles of Operation

Electrical System

NOTE: ERP15-20VT (ERP030-040VT) (G807) IS SHOWN AND THE ERP16-20VF (A955) IS SIMILAR. 1. DISPLAY

2. VSM

3. FUSE PANEL

Figure 9030-10-4. ERP15-20VT (ERP030-040VT) (G807) Lift Truck

9030-10-4

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

1. DISPLAY

Principles of Operation

2. VSM

3. FUSE PANEL

Figure 9030-10-5. ERC22-35VG (ERC045-070VG) (A968) Lift Truck

Confidential/Proprietary - Do Not Copy or Duplicate

9030-10-5

Principles of Operation

Electrical System

The truck’s electrical system directly controls and monitors every electrical component in the truck. See Figure 9030-10-6, Page 9030-10-6 which shows the interconnection between various components in the system.

The lift truck contains components as listed below; Component location on truck may vary with the different platforms.

Figure 9030-10-6. System Block Diagram

Battery • Deep-cycle, multi-cell, lead acid battery. • Voltage ranges 36/48/72/80 volts with different Ah ratings based on customer applications. • The battery is located below the hood in the battery compartment area.

Power Distribution Module (PDM) Contactor The contactors used are single pole single throw normally open contactors. The contactors are available in UL-E and UL-EE options.

Fuses • The main fuses are 15 Amp fast acting ceramic tubes with nickel plated brass end cap construction. • The contactor and fuses are assembled together on a single bracket.

9030-10-6

• Other fuses are located adjacent to the devices they are protecting.

Relays The relays used are 12V and 24V having high contact rating, high temperature and quick connect design. Following are the relays provided in the truck: • Standard Relays: – Key Switch Relay (12V) – E-Hyd Enable Relay (24V) (Only on E-Hydraulic Trucks) • Optional Relays: – – – –

Reverse Relay (24V) Synchronous Steer Valve Relay (24V) Brake Light Relay (24V) Flasher (Turn Signal Option) Relay (12V)

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Principles of Operation

Wire Harnesses

Controllers

Fundamental to the operation of the truck, the wire harnesses have been designed to ensure trouble free, reliable electrical operation, and ease of service. This has been achieved through the following:

Vehicle System Manager (VSM)

• Harness retention clips and brackets used for consistent routing and clean appearance. • Constructed with ultrasonically welded splices and protective conduit. • High quality sealed connectors with locks are used instead of spade type connectors and unsealed connections wherever possible. • Standardized wire colors.

The Vehicle System Manager (VSM) is a microprocessor powered controller which controls and monitors directly or indirectly every electrical device on the truck. The VSM power inputs are protected for overvoltage, reverse polarity, electrostatic discharge and short to battery. VSM outputs are protected for short to battery, short to ground, electro static discharge and transients. There are two versions of the VSM. One is for Manual Hydraulics, and one is for the E-Hydraulics configuration. See Figure 9030-10-8, Page 9030-10-7.

Operator Interface Display The display panel is located on the upper portion of the right front overhead guard leg. It is the main operator interface providing operator input through the push buttons and outputs to the operator through messages and warning icons. It also provides onboard diagnostics and setup to a qualified technician through password protection. See Figure 9030-10-7, Page 9030-10-7. There are two display options available Standard Temperature and Freezer (Arctic) Temperature. Keyed and Keyless Power on is also an option.

Figure 9030-10-8. Vehicle System Manager (VSM)

Figure 9030-10-7. Display

Confidential/Proprietary - Do Not Copy or Duplicate

9030-10-7

Principles of Operation

Electrical System

Motor Controllers Motor controllers are used to provide Traction and Pump motors with power and control signals. Traction and Pump motors are controlled individually by separate controllers. These controllers are linked to VSM via CANbus which provides control signals to controllers. See Figure 9030-10-9, Page 9030-10-8 or Figure 9030-10-10, Page 9030-10-8.

Figure 9030-10-10. Motor Controller ERP15-20VT (ERP030-040VT) (G807) Shown

Figure 9030-10-9. Motor Controller ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

9030-10-8

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Electrical System

Principles of Operation

E-Hydraulics Mini Levers Module (MLM) The electro hydraulic systems for all electric rider forklift trucks include a mini-lever module (MLM). The MLM consists of analog (levers) and digital (switch) inputs that command various hydraulic and truck functions. The hydraulic functions which are controlled by the MLM are lift/lower, tilt and up to three auxiliary functions. Auxiliary functions are used for operating “forklift attachments” such as a sideshift, rotator, clamp,

push/pull, etc. See Principles of Operation, E-Hydraulic System Interface, Page 9060-10-32. The truck utilizes CANopen communications, CAN 2.0B hardware, to link the control system components. Multiple packets of information can be sent on this bus, an operation commonly known as Multiplexing. See Figure 9030-10-11, Page 9030-10-9 which shows components connected through CANbus.

Figure 9030-10-11. CAN Network Diagram

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9030-10-9

Principles of Operation

Electrical System

The CANbus consists of a twisted pair of wires. Each of the twisted wires is uniquely color-coded. Yellow = CAN Hi Green = CAN Lo Typical characteristics of data on the CANbus are:

• Each wire broadcasts a mirror image of the other to insure signal integrity. • Each CAN connected device receives and broadcasts messages. • The message data, if viewed with an oscilloscope, would look like the signal trace shown in Figure 903010-12, Page 9030-10-10.

Figure 9030-10-12. Typical CAN Signals

System Controlled Outputs The various controllers provide electrical outputs to various devices to control variable functions; some of them are described below.

Valve Coils There are two different valve options available E-Hydraulic and Manual. • E-Hydraulic valve spool displacement is accomplished by applying an electrical signal to a solenoid located on either end of the valve section. These solenoids receive Pulse Width Modulated (PWM) signals from the VSM which provide proportional control of the spool. See Figure 9030-10-13, Page 9030-10-10.

1. E-HYDRAULIC SOLENOIDS 2. E-HYDRAULIC VALVE

Figure 9030-10-13. E-Hydraulic Valve

9030-10-10

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Electrical System • In Manual valves the spool displacement is accomplished by manual levers. The position sensors provided on the valve monitors the position of the valve spool and produce a variable output signal relative to how far the spool has traveled from its neutral position. The output signal from the sensor is used by the VSM to vary the hydraulic pump flow. The manual valve is provided with Operator presence solenoids (OPS) which allows valve operation only if operator is present on the seat. See Figure 9030-10-14, Page 9030-10-11.

1. OPS LOCKOUT SOLENOIDS 2. SPOOL POSITION SENSORS 3. MANUAL HYDRAULIC VALVE

Figure 9030-10-14. Manual Hydraulic Valve Lights and Backup Alarm The work lights are 35/55 watt halogen lights. A premium LED 37 or 55 watt work light package is also offered. Tail lights, front-marker and strobe lights are all LED lights and are used in both the incandescent and LED work light options.

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Principles of Operation Depending on your lift truck and further information pertaining to lights and schematics, see Diagrams 8000 YRM 1341 or Diagrams 8000 YRM 1384. See Figure 9030-10-15, Page 9030-10-11, which shows general locations of different lights used. They may vary depending upon your lift truck.

1. 2. 3. 4. 5. 6. 7.

FRONT WORK LIGHTS RH FRONT MARKER LIGHTS LH FRONT MARKER LIGHTS LH TAIL LIGHT REAR WORK LIGHT STROBE LIGHT RH TAIL LIGHT

Figure 9030-10-15. Light Location Cab options Some of the lift trucks are equipped with following options: • Washer/ Front-Rear Wipers • Cab Heater • Dome Light

9030-10-11

Principles of Operation

PRINCIPLES OF OPERATION, COMPONENTS Power Distribution Contactor The Contactor is an electrically controlled switch used to supply main power to the lift truck’s motion system. It consists of a set of high current contacts to carry battery power. These contacts are closed by an electromagnetic coil which when energized by the control system sends battery power to the motor controllers and other battery operated devices.

Electrical System and prior to the contactor being operated. This prevents damage to the contactor contacts due to large capacitive inrush currents.

Fuses The fuses used are 15 Amp fuses. They are typically used to connect the Emergency Disconnect Switch circuits, Primary DC/DC converter and Auxiliary DC/DC converter to battery power. See Figure 9030-10-17, Page 9030-10-12. See Figure 9030-10-18, Page 903010-12.

One of the main terminals of the contactor is connected to battery power and the other terminal is connected to the motor controllers. In order for the coil to operate there are certain interlock conditions which need to be fulfilled. Once all conditions are met the VSM provides a signal to the coil. When the operator turns on the Key or Keyless Power to ON (both are located on display), the key switch relay is energized on and the main contactor coil is energized closing its contacts. See Figure 903010-16, Page 9030-10-12.

1. CONTACTOR 2. FUSES

Figure 9030-10-17. Fuse and Contactor Assembly ERC22-35VG (ERC045-070VG) (A968) Shown

1. CONTACTOR

Figure 9030-10-16. Contactor (EE Type Shown) Positive Temperature Coefficient (PTC)

Figure 9030-10-18. Power Circuit Diagram ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

The PTC device ensures that the motor controller drive capacitors are charged when the battery is connected

9030-10-12

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Electrical System

Relays Key Switch Relay: Upon turning on the key or keyless switch located on Display panel, key switch relay gets

Principles of Operation energized and provides power to components to which it is connected. See Figure 9030-10-19, Page 903010-13.

Figure 9030-10-19. Key Switch Relay Diagram ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown E-Hydraulic Enable Relay: This relay is available on lift trucks with E-Hydraulic option and is controlled by the VSM and gets activated whenever operators send input to VSM via E-Hydraulic input device. It provides 12V power to E-Hyd coils. See Figure 9030-10-20, Page 9030-10-13.

Figure 9030-10-21. Backup Light Relay Circuit ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

Figure 9030-10-20. E-Hyd Enable Relay Circuit ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown Backup Light Relay (Optional): This device is controlled by the VSM and gets activated after detecting the selection of reverse direction. See Figure 9030-10-21, Page 9030-10-13. Brake Light Relay (Optional): This is controlled by the VSM and gets activated after brake is applied. See Figure 9030-10-22, Page 9030-10-13.

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Figure 9030-10-22. Brake Light Relay Circuit ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

9030-10-13

Principles of Operation Synchronous Steer Valve Relay (Optional): The sensors located on steering column and steer axle sends signal to VSM when there is misalignment of steering wheel and steering tire angle. The output from VSM energizes the relay to operate synchro-steer valve in order to compensate the misalignment. Motion Relay (Optional): This relay is activated via the user interface with supervisor password and energizes whenever lift truck is operational in any direction that is selected.

Electrical System

Operator Interface Display The display is the most important operator interface in the lift truck. The display is protected for reverse voltage up to -16 volts, short to 16 volts and battery negative, transients, ESD up to 8,000 volts and electromagnetic interference (EMI) up to 100 volts/meter. The display gets 12V power from VSM; also it is linked to VSM via CANbus. The Display has two controlled outputs: the Buzzer and the Key Switch Relay. The following Figure 9030-10-23, Page 9030-10-14 shows how display is connected into the system.

Figure 9030-10-23. Display CAN Connections ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown Upon turning on the Key or Keyless switch which is located on display, the key switch relay gets energized and in turn provides power to following components: • • • • • • • • • • • •

Main Contactor Coil Supplementary Contactor Coil (Optional) Traction Controller Pump Controller Park Brake Controller Park Brake Solenoid Manual Hydraulic Clamp Coil Manual Hydraulic Interlock/E-Hydraulic Enable Relay 5th Function Hydraulic Diverter Valve Reverse/Backup Light Relay Brake Light Relay Accessory Relays

9030-10-14

After the key is switched on the display screen turns on all pixels and blackens the screen for ½ second. After performing the screen check the system will transition to one of the following screens: • The Password screen if the Operator Passwords are enabled • If Operator Passwords are not enabled then the system transitions to the Operator Checklist Screen if the Operator Checklist function is enabled and the system was not powered off through the auto-power down feature. • If the Operator Checklist function is not enabled (or the system was last powered off through the autopower off function) and the Operator Passwords function is not enabled then the system transitions to the Operating Screen. Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Principles of Operation

NOTE: Some of the following icons are available options for the Freezer display only.

detect truck malfunctions and provide feedback to the operator and service technician in the form of:

The operating Screen displays several warning and information icons, these include:

• • • • •

• • • • • • • • • •

Performance Mode Seat Belt Warning Low Brake Fluid Warning Motor Temp High Service Due (Optional) Direction/Park Brake Indicator Tire Angle (Optional) Time of Day Battery Charge Lights

Controllers

Display Messages Warning Lights Audible Warnings Other Controllers A Change in truck operations (Decelerate, Shutdown)

3. The VSM can be viewed as a box containing multiple inputs and outputs, see Figure 9030-10-24, Page 9030-10-16. 4. Inputs are connected to: • • • •

Sensors Switches Control lines from other devices Voltage supplies

Vehicle System Manager (VSM): 5. Outputs are connected to: 1. The VSM is the Master Controller of the truck. It receives input from: • The Operator (Via Display) • Sensors • Controlled Devices

• • • • •

Contactor Relays E-Hyd Valve coils Lights Solenoids

2. This allows the VSM to analyze, and determine the controls of most of the lift trucks electrically controlled functions. The VSM is also programmed to

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9030-10-15

Principles of Operation

Electrical System

Figure 9030-10-24. VSM Connection Diagram ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

9030-10-16

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Electrical System

Motor Controller The traction and Hydraulic pump motor controllers have been separated and provide power and control signals to their motors. Traction Motor Controller: Each traction motor is controlled by a separate controller which gets its power from the battery and provides power and control signals to the motor. The controller is also connected by CANbus to VSM which monitors various operating parameters of the motor. Both speed and winding temperature are monitored and adjusted to provide optimum performance. Inputs from the accelerator pedal, hydraulic tank temperature, directional switch, and brake pressure sensor provide signals to the VSM which are sent by CAN to the

Principles of Operation motor controllers to provide speed, and directional control. In addition to this motor winding temperature and speed are inputs to the controllers. The diagram below shows interconnection between a traction motor and its controller. See Figure 9030-10-25, Page 9030-10-17. Hydraulic Pump Motor Controller: This motor is controlled by a separate controller, which gets its power from the battery and provides power and control signals to the hydraulic pump motor. In addition to the controller the VSM oversees motor configuration and monitoring responsibilities to ensure the motors run within given operating parameters. Both speed and winding temperature are monitored and adjusted to provide optimum performance. The following diagram shows interconnection between pump motor and its controller.

Figure 9030-10-25. Traction Motor and Controller Connections ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

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9030-10-17

Principles of Operation Inputs from the hydraulic control valves go to the VSM which communicate what required flow is needed to meet the requested function. This is communicated over the CAN to the controller to provide the needed

Electrical System motor speed. The diagram below shows interconnection between pump motor and its controller. See Figure 9030-10-26, Page 9030-10-18.

Figure 9030-10-26. Hydraulic Pump Motor and Controller Connections ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown E-Hydraulics Mini Levers Module (MLM) The E-Hydraulic mini lever module is a controller assembly that includes operator input levers and button(s). These levers and buttons provide analog and digital inputs to the E-Hydraulic input device. The E-Hydraulic input device then formats the information into a

9030-10-18

predefined protocol and broadcasts the operator inputs to the VSM via the CANopen. Inputs from the hydraulic control valves go to the VSM which communicate what required flow is needed to meet the requested function. This is communicated over the CAN to the pump controller to provide the needed pump motor speed.

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Electrical System

PRINCIPLES OF OPERATION, SYSTEM Battery (Plug-In) The power is supplied to the system after connecting battery in the system. The following components are connected to the battery voltage • The primary and auxiliary DC/DC converter which in turn provides 12V power to components to which they are connected • The VSM which in turn provides 12V power to display and E-Hydraulics Mini Levers Module (MLM) • Various relays and contactor • The motor controllers are only connected to the battery after the key is turned on. The system is powered to an non-operational state until the operator turns on the key.

Key ON and Operation When the key or keyless switch is turned ON, the display wakes up and initiates the power up sequence, as mentioned in Operator Interface. The VSM is programmed and wired to detect certain conditions before allowing the vehicle to be started. 1. Interlocks: • • • • •

Operator presence in the seat Accelerator pedal in released position All hydraulic controls must be in neutral state Battery gate switch closed (If applicable) No other operational faults

2. Upon satisfying above mentioned parameters the following events take place: • Contactor closes and provides power to the system • Motor controllers become operational • Hydraulic system becomes operational and begin to give hydraulic steering flow

Principles of Operation is the ultrasonic hydraulic level sensor which operates on 12 volts. If a sensor signal falls below or exceeds programmed values, a failure condition or a warning will be given to the operator. The functional groups are: 1. Speed (Hall Sensor Technology): • Pump motor • Traction motor 2. Pressure (Solid State Strain Gauge and Capacitive Technology): • Brake 3.45 MPa (500 psi) • Hydraulics 24 MPa (3500 psi) (Optional) 3. Position - Rotary and Linear (Hall Sensor Technology): • • • • • • • • • •

Park brake Auto park brake Accelerator Operator presence Tilt (Optional) Mast height (Optional) Manual hydraulic spool Steer wheel Steer axle (Optional) Direction control selector

4. Temperature (NTC Thermistor): • • • •

Traction motor Pump motor Hydraulic oil (Optional) Display temperature (Optional)

5. Level / Miscellaneous: • Hydraulic filter (Optional) • Hydraulic oil level • Impact sensor

Sensors The sensors are divided into 5 functional groups. Most are supplied from a VSM 5 volt sources. The exception

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9030-10-19

Principles of Operation These functional groups have common signal output characteristics: 1. Speed (4-wire devices): • Operating voltage = 12 Volts • Variable frequency (Zero to Max speed) 2. Pressure and Position (3-wire devices): • Operating voltage = 5 Volts • Variable output voltage, 0.5 volts to 4.5 volts, Zero to Full scale 3. Temperature (2-wire device): • Operating voltage = 5 Volts • Variable resistance, NTC (Increase in temperature results in decrease of resistance) 4. Level / Miscellaneous: • Ultrasonic • Reed Switch Sensor Operation Technology 1. Hall Effect (Position): This technology uses a sensor that can detect the strength of a magnetic field or in case of rotation, the angle of the magnetic field in relation to the sensor. Moving the magnet closer or further away from the sensor varies the output voltage. For rotation the output varies based on magnetic field angle.

9030-10-20

Electrical System 2. Hall Effect (Speed): This uses the same principle as described in the position sensor but uses the presence and absence of gear teeth to change the strength of the magnetic field. This causes a variable voltage that is used to operate a transistor switch output providing a pulse train that is proportional to speed. 3. Pressure: These devices use a strain gauge or capacitive sense element that generates a microvolt signal which is proportional to the pressure applied. This signal is amplified to provide an output voltage that varies between 0.5 and 4.5 Vdc in proportion to pressure changing from zero to maximum. The output is the same irrespective of the different application pressure ranges of the sensors. 4. Temperature: These devices have the same Negative Temperature Coefficient (NTC) Thermistor element in different packages. Heating of this element changes the element resistance. Higher temperature = Lower Resistance. These sensors are connected in series with a pull up resistor connected to 5 volts. The other end of the sensor is connected to Battery negative, effectively forming a variable voltage divider that the VSM can read and then interpret as a temperature reading. 5. Ultrasonic: This device uses ultrasonic waves which go out until they hit an object and return. The time of the cycle determines the distance and/or level. See Figure 9030-10-27, Page 9030-10-21.

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Electrical System

Principles of Operation

Figure 9030-10-27. Switch Connections ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown Table 9030-10-1. Silicon Temperature Sensors Iskra Motors — Philips KTY84-130 Sauer-Danfoss Motors — Philips KTY84-130 Danaher Motion — Philips KTY84-150 Ambient Temperature (°C)

KTY84-130

(°F)

Resistance ( )

KTY84-150 Temp Error

Resistance ( )

Temp Error

Min

Type

Max

(K)

Min

Type

Max

(K)

-40

340

359

379

±6.48

332

359

386

±8.85

-30

-22

370

391

411

±6.36

362

391

419

±8.76

-20

-4

403

424

446

±6.26

394

424

455

±8.7

-10

437

460

483

±6.16

428

460

492

±8.65

474

498

522

±6.07

464

498

532

±8.61

514

538

563

±5.98

503

538

574

±8.58

555

581

607

±5.89

544

581

618

±8.55

577

603

629

±5.84

565

603

641

±8.54

599

626

652

±5.79

587

626

665

±8.53

104

645

672

700

±5.69

632

672

713

±8.5

122

694

722

750

±5.59

679

722

764

±8.46

140

744

773

801

±5.47

729

773

817

±8.42

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9030-10-21

Principles of Operation

Electrical System

Table 9030-10-1. Silicon Temperature Sensors (Continued) Iskra Motors — Philips KTY84-130 Sauer-Danfoss Motors — Philips KTY84-130 Danaher Motion — Philips KTY84-150 Ambient Temperature (°C)

KTY84-130

(°F)

Resistance ( )

KTY84-150 Temp Error

Resistance ( )

Temp Error

Min

Type

Max

(K)

Min

Type

Max

(K)

158

797

826

855

±5.34

781

826

872

±8.37

176

852

882

912

±5.21

835

882

929

±8.31

194

910

940

970

±5.06

891

940

989

±8.25

100

212

970

1000

1030

±4.9

950

1000

1050

±8.17

110

230

1029

1062

1096

±5.31

1007

1062

1117

±8.66

120

248

1089

1127

1164

±5.73

1067

1127

1187

±9.17

130

266

1152

1194

1235

±6.17

1128

1194

1259

±9.69

140

284

1216

1262

1309

±6.63

1191

1262

1334

±10.24

150

302

1282

1334

1385

±7.1

1256

1334

1412

±10.8

160

320

1350

1407

1463

±7.59

1322

1407

1492

±11.37

170

338

1420

1482

1544

±8.1

1391

1482

1574

±11.96

180

356

1492

1560

1628

±8.62

1461

1560

1659

±12.58

190

374

1566

1640

1714

±9.15

1533

1640

1747

±13.2

200

392

1641

1722

1803

±9.71

1607

1722

1837

±13.85

210

410

1719

1807

1894

±10.28

1683

1807

1931

±14.51

220

428

1798

1893

1988

±10.87

1760

1893

2026

±15.19

230

446

1879

1982

2085

±11.47

1839

1982

2125

±15.88

240

464

1962

2073

2184

±12.09

1920

2073

2226

±16.59

250

482

2046

2166

2286

±12.73

2003

2166

2329

±17.32

260

500

2132

2261

2390

±13.44

2087

2261

2436

±18.15

270

518

2219

2357

2496

±14.44

2172

2357

2543

±19.36

280

536

2304

2452

2600

±15.94

2255

2452

2650

±21.21

290

554

2384

2542

2700

±18.26

2333

2542

2751

±24.14

300

572

2456

2624

2791

±22.12

2404

2624

2844

±29.05

9030-10-22

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Electrical System

Switches The switches are used for following applications: • Hydraulic filter pressure • Battery gate • Clamp solenoid Depending on your lift truck and further information pertaining to switches and schematics, see Diagrams 8000 YRM 1341 or Diagrams 8000 YRM 1384.

Outputs Relays 1. ON/OFF Operation 2. Programmed for a specific maximum current 3. The following faults are detectable • Short to Battery • Short to Ground • Open circuit

Principles of Operation a. Pulse Width Modulated (PWM) signal controls the valve opening, and therefore flow. (Higher duty cycle results in higher fluid flow). b. Each E-Hydraulics valve is independently controlled and current monitored c. The following faults are detectable: • • • •

Short to Battery Short to Ground Open circuit Current above or below normal

2. Hydraulics operation is also disabled for the following conditions: a. Operator presence in seat is not detected b. Circuit Failures in Valve Wiring/ Connectors/ Valve coils and Valve coil drivers. See Figure 9030-10-28, Page 9030-10-24.

Hydraulic Valve 1. Valve coil is controlled in following manner

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9030-10-23

Principles of Operation

Electrical System

Figure 9030-10-28. Hydraulic Valve Coil Diagram ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown Cab Devices

Lights and Backup Alarm

All CAB devices are operated from unswitched or switched battery circuits using the device’s own ON/OFF switches

1. Tail Light/Front Work Lights

• • • •

Front/Rear Wiper Washer Cab light Cab Heater

9030-10-24

a. The Tail light/front work lights can be turned ON or OFF by using a switch which is located on Dash panel. See Figure 9030-10-29, Page 9030-10-25.

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Electrical System

Principles of Operation

Figure 9030-10-29. Work/Marker Lights Diagram ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

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9030-10-25

Principles of Operation 2. Rear Work Lights a. The rear work lights can be turned ON or OFF by using switch which is located on Dash panel

Electrical System or automatically controlled by the reverse relay. See Figure 9030-10-30, Page 9030-10-26.

Figure 9030-10-30. Rear Work Lights Diagram ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

9030-10-26

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Electrical System

Principles of Operation

3. Strobe Light a. The Strobe light becomes operational whenever key switch relay is turned on. See Figure 9030-10-31, Page 9030-10-27.

Figure 9030-10-31. Strobe Light Diagram ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

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9030-10-27

Principles of Operation 4. Backup Light and Alarm a. The Backup light and Alarm are controlled by the VSM detecting the selection of reverse direction. The circuit is designed to allow a customer to connect their desired audible warning

Electrical System device. See Figure 9030-10-32, Page 903010-28.

Figure 9030-10-32. Backup Light Diagram ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

9030-10-28

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Electrical System 5. Brake Light a. This light is controlled by the VSM detecting the pressure in the brake pressure sensor when the

Principles of Operation brake is applied. See Figure 9030-10-33, Page 9030-10-29.

Figure 9030-10-33. Brake Light Diagram ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

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9030-10-29

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

9030-10-30

Electrical System

Diagnostic Trouble Codes

Group 20

Diagnostic Trouble Codes TSP Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL)

FAULT CODES:

Power OFF

12844

12836

DTC 12844

DTC 12836

Load Weigh Pressure

Service Brake Pressure

Wait 30 seconds

Power ON

POSSIBLE CAUSES LOAD WEIGH PRESSURE

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C D E > ?

(continued on next page)

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

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9030-20-1

Diagnostic Trouble Codes

Electrical System

TSP Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL) (Cont) SERVICE BRAKE PRESSURE

CAUSES A B C D E > ?

CAUSE A

Power OFF

Disconnect sensor

CAUSE A1

Power ON

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

For Service Brake Pressure, go to Cause B. For Load Weigh Pressure, go to Cause C.

Power OFF

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Electrical System

Diagnostic Trouble Codes

TSP Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL) (Cont) CAUSE B

∞

CHECK RESISTANCE -

= Open circuit

Find

≈ 4.7K

OPEN circuit

Repair OPEN circuit. See /Electrical System 2200 YRM 1337Electrical ≈ 0 System 2200 YRM 1369.

CAUSE C

- OHMS

Go to Cause D.

CHECK RESISTANCE -

- OHMS

≈ 4.7K

For Service Brake Pressure,

Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical > 10K System 2200 YRM 1369.

For Load Weigh Pressure,

= Short circuit

Find

Short circuit

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9030-20-3

Diagnostic Trouble Codes

Electrical System

TSP Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL) (Cont) CAUSE D

Power OFF

Disconnect sensor. Do not discard

Install new sensor.

Fault DTC gone

Old sensor faulty

Fault DTC present

Old sensor OK/Reinstall old sensor

Power ON

Resume operation

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Electrical System

Diagnostic Trouble Codes

TSP Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-5

Diagnostic Trouble Codes

Electrical System

TSP Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH)

FAULT CODES:

Power OFF

12845

12837

DTC 12845 Load Weigh Pressure

DTC 12837 Service Brake Pressure

Wait 30 seconds

Power ON

POSSIBLE CAUSES LOAD WEIGH PRESSURE

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C C1 C2 D E > ?

SERVICE BRAKE PRESSURE

CAUSES A B C C1 C2 D E > ?

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Electrical System

Diagnostic Trouble Codes

TSP Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

For Service Brake Pressure, go to Cause C

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B

For Load Weigh Pressure, go to Cause B

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause C.

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

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9030-20-7

Diagnostic Trouble Codes

Electrical System

TSP Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH) (Cont) CAUSE C

Reconnect sensor

Power OFF

CAUSE C1

Power ON

CHECK VOLTAGE

≈ 5 Volts = Short circuit

Find

Short circuit.

> 5.5 volts

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical < 4.5 volts = System 2200 YRM 1369.

CAUSE C2

Go to Cause C2 OK

Go to Cause D

Go to Cause D.

CHECK VOLTAGE

< 4.5 volts = > 5.5 volts = Short circuit Find Short circuit to another voltage source. Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

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Electrical System

Diagnostic Trouble Codes

TSP Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH) (Cont) CAUSE D

Power OFF

Disconnect sensor. Do not discard

Install new sensor.

Fault DTC gone

Old sensor faulty

Resume operation

Fault DTC present

Old sensor OK/Reinstall old sensor

Go to Cause E.

Power ON

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9030-20-9

Diagnostic Trouble Codes

Electrical System

TSP Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1.

Not OK Correct/ Repair Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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Electrical System

Diagnostic Trouble Codes

TSP Accelerator Pedal Position A/B Out of Range Low (OORL)

FAULT CODES:

Power OFF

12808

12810

DTC 12808

DTC 12810

Accelerator Pedal Position A

Accelerator Pedal Position B

Wait 30 seconds

Power ON

POSSIBLE CAUSES ACCELERATOR PEDAL POSITION A/B

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C D E > ?

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9030-20-11

Diagnostic Trouble Codes

Electrical System

TSP Accelerator Pedal Position A/B Out of Range Low (OORL) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause B.

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B

∞

CHECK RESISTANCE -

= Open circuit

Find

- OHMS

≈ 4.7K

OPEN circuit

Repair OPEN circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

≈ 0

= OK

Go to Cause D

Go to Cause C

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Electrical System

Diagnostic Trouble Codes

TSP Accelerator Pedal Position A/B Out of Range Low (OORL) (Cont) CAUSE C

CHECK RESISTANCE -

= Short circuit

Find

- OHMS

Short circuit

Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE D

Power OFF

Disconnect sensor. Do not discard

Install new sensor.

Fault DTC gone

Old sensor faulty

Resume operation

Fault DTC present

Old sensor OK/Reinstall old sensor

Go to Cause E.

Power ON

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9030-20-13

Diagnostic Trouble Codes

Electrical System

TSP Accelerator Pedal Position A/B Out of Range Low (OORL) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK - Go to Cause E1.

Not OK

Correct/Repair Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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Electrical System

Diagnostic Trouble Codes

TSP Accelerator Pedal Position A/B Out of Range High (OORH)

FAULT CODES:

Power OFF

12809

12811

DTC 12809

DTC 12811

Accelerator Pedal Position A

Accelerator Pedal Position B

Wait 30 seconds

Power ON

POSSIBLE CAUSES ACCELERATOR PEDAL POSITION A/B

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C C1 C2 D E > ?

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9030-20-15

Diagnostic Trouble Codes

Electrical System

TSP Accelerator Pedal Position A/B Out of Range High (OORH) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause C.

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B Not Applicable

CAUSE C

Power OFF

Reconnect sensor

Power ON

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Electrical System

Diagnostic Trouble Codes

TSP Accelerator Pedal Position A/B Out of Range High (OORH) (Cont) CAUSE C1

CHECK VOLTAGE

≈ 5 Volts = Short circuit

Find

> 5.5 volts

Short circuit.

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE C2

< 4.5 volts =

Go to Cause C2 Go to Cause D

SWITCHED VOLTAGES

> 5.5 Volts = Short circuit

Find

Power OFF

Short circuit.

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE C3

UNSWITCHED VOLTAGES

> 5.5 Volts = Short circuit

Find

< 4.5 volts =

Short circuit.

Go to Cause D

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

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9030-20-17

Diagnostic Trouble Codes

Electrical System

TSP Accelerator Pedal Position A/B Out of Range High (OORH) (Cont) CAUSE D

Power OFF

Disconnect sensor. Do not discard

Install new sensor.

Fault DTC gone

Old sensor faulty

Resume operation

Fault DTC present

Old sensor OK/Reinstall old sensor

Go to Cause E.

Power ON

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Electrical System

Diagnostic Trouble Codes

TSP Accelerator Pedal Position A/B Out of Range High (OORH) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK - Go to Cause Not OK Correct/Repair E1.

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-19

Diagnostic Trouble Codes

Electrical System

TSP Accelerator Pedal Position A/B Data Incorrect

FAULT CODES: 12812

DTC 12812 Accelerator Pedal Position A to B

Power OFF

Wait 30 seconds

Power ON

Fault remains. Service required. Go to Cause A.

No fault

Resume operation

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Electrical System

Diagnostic Trouble Codes

TSP Accelerator Pedal Position A/B Data Incorrect (Cont) QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1 FAULT LOG CODE Review - Go to Display Menu Note: DTC 12812 can be caused by the same conditions that caused DTCs 12808 to 12811 Check VSM Fault Logs

Go to Check 1

Are these codes present?

YES See Accelerator Pedal Position A/B Out of Range Low (OORL) or Accelerator Pedal Position A/B Out of Range High (OORH)

Enter Service Password

" All VSM/MLM DTCs

Diagnostic

FAULT LOGs

VSM/MLM Fault Logs

Erase all VSM/MLM DTCs

Go to Check 1

View all VSM/MLM DTCs

( Exit Fault Log

Speedometer

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9030-20-21

Diagnostic Trouble Codes

Electrical System

TSP Accelerator Pedal Position A/B Data Incorrect (Cont) Check 2

Does Sensor APS2 Volts = Sensor APS1 Volts = DTC 12812? YES

Cause C

Does (Sensor APS2 Volts x 2) YES

Cause D

Resume Operation

Sensor APS1 Volts = > 0.60 volts for more than 2 seconds = DTC 12812? NO

Resume Operation

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Electrical System

Diagnostic Trouble Codes

TSP Accelerator Pedal Position A/B Data Incorrect (Cont) POSSIBLE CAUSES ACCELERATOR PEDAL POSITION A/B

X = Open Circuit/Fail

) = Short Circuit

CAUSES A B C D E > ?

CAUSE A Not Applicable

CAUSE B Not Applicable

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9030-20-23

Diagnostic Trouble Codes

Electrical System

TSP Accelerator Pedal Position A/B Data Incorrect (Cont) CAUSE C

If 2 = 1 = Short circuit

Find

Short circuit

If 2 = (2x1) = OK

Cause D

Find/Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. Reconnect

Use Display Diagnostics to validate

Test OK

YES

Resume Operation NO

Cause D

CAUSE D

Power OFF

Disconnect sensor. Do not discard

Install new sensor.

Fault DTC gone

Old sensor faulty

Resume operation

Fault DTC present

Old sensor OK/Reinstall old sensor

Go to Cause E.

Power ON

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9030-20-24

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Electrical System

Diagnostic Trouble Codes

TSP Accelerator Pedal Position A/B Data Incorrect (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK - Go to Cause E1.

Not OK

Correct/Repair Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-25

Diagnostic Trouble Codes

Electrical System

TSP Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL)

FAULT CODES:

Power OFF

12820

12824

DTC 12820

DTC 12824

Steering Wheel Position

Steering Axle Position

Wait 30 seconds

Power ON

POSSIBLE CAUSES STEERING WHEEL POSITION

STEERING AXLE POSITION

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C D E > ?

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9030-20-26

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Electrical System

Diagnostic Trouble Codes

TSP Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause B

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B

∞

CHECK RESISTANCE -

= Open circuit

Find

≈ 4.7K

OPEN circuit

Repair OPEN circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

≈0

- OHMS

Go to Cause D Go to Cause C

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9030-20-27

Diagnostic Trouble Codes

Electrical System

TSP Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL) (Cont) CAUSE C

CHECK RESISTANCE -

= Short circuit

Find

- OHMS

Short circuit

Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE D

Power OFF

Disconnect sensor. Do not discard

Install new sensor.

Fault DTC gone

Old sensor faulty

Resume operation

Fault DTC present

Old sensor OK/Reinstall old sensor

Go to Cause E.

Power ON

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9030-20-28

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Electrical System

Diagnostic Trouble Codes

TSP Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK - Go to Cause Not OK Correct/Repair E1.

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-29

Diagnostic Trouble Codes

Electrical System

TSP Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH)

FAULT CODES:

Power OFF

12821

12825

DTC 12821

DTC 12825

Steering Wheel Position

Steering Axle Position

Wait 30 seconds

Power ON

POSSIBLE CAUSES STEERING WHEEL POSITION

STEERING AXLE POSITION

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C C1 C2 D E > ?

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9030-20-30

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Electrical System

Diagnostic Trouble Codes

TSP Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

Go to next step.

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause C

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B Not Applicable

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9030-20-31

Diagnostic Trouble Codes

Electrical System

TSP Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH) (Cont) CAUSE C

Reconnect sensor

Power OFF

CAUSE C1

Power ON

Go to next step.

CHECK VOLTAGE

= 5 Volts = Short circuit

Find

> 5.5 volts,

Short circuit.

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical < 4.5 volts = System 2200 YRM 1369.

CAUSE C2

Go to Cause C2 OK

Go to Cause D

CHECK VOLTAGE

> 5.5 volts = Open circuit

Find

< 4.5 Volts =

OPEN circuit.

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

(continued on next page)

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9030-20-32

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Electrical System

Diagnostic Trouble Codes

TSP Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH) (Cont) CAUSE D

Power OFF

Disconnect sensor. Do not discard

Install new sensor.

Fault DTC gone

Old sensor faulty

Resume operation

Fault DTC present

Old sensor OK/Reinstall old sensor

Go to Cause E.

Power ON

Go to next step.

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9030-20-33

Diagnostic Trouble Codes

Electrical System

TSP Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK - Go to Cause Not OK Correct/Repair E1.

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-34

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Electrical System

Diagnostic Trouble Codes

TSP Steer Axle Calibration Required

FAULT CODES: 4098

DTC 4098 Steer Axle Calibration

Power OFF

Wait 30 seconds

Power ON

POSSIBLE CAUSES

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

Faulty Steer System/Faulty Sensor/New Sensor Installed VSM

STEERING AXLE CALIBRATION

CAUSES A B C D E > ?

CAUSE A Not Applicable

CAUSE B Not Applicable

CAUSE C Not Applicable

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9030-20-35

Diagnostic Trouble Codes

Electrical System

TSP Steer Axle Calibration Required (Cont) CAUSE D Calibration Process--Go to Display Menu

Enter SERVICE Password

Diagnostics

Steering Sensor

CAUSE D1 Steering Sensor Values

)* 2. )* 1.

Rotate steering wheel Rotate steering wheel

Values vary >0.5V <4.5V =

Proceed with Calibration

Values =the same = X=Steer Mechanism/Faulty Sensor

3. Check Steer Mechanism Operation

Mechanism

Cause D2

Cause D3 Go to 3

Mechanism X Go to 4

4. See /Steering System 1600 YRM 1331Steering System 1600 YRM 1363 repair.

CAUSE D2 Steer Sensor(s) Replacement

1. Power OFF

Disconnect sensor Do not discard.

Install new sensor

Power ON

Go to 2

2. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

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9030-20-36

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Electrical System

Diagnostic Trouble Codes

TSP Steer Axle Calibration Required (Cont) CAUSE D3

Enter SERVICE Password

Rotate Fully CCW

Calibration

Steering Axle

Rotate Fully CW

Cause D4

CAUSE D4

Power OFF

Power ON

Cause D5

CAUSE D5

Fault DTC gone

Old sensor faulty

Resume operation

Fault DTC present

Old sensor OK/Reinstall old sensor

Go to Cause E.

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9030-20-37

Diagnostic Trouble Codes

Electrical System

TSP Steer Axle Calibration Required (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK - Go to Cause Not OK Correct/Repair E1.

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-38

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Electrical System

Diagnostic Trouble Codes

TSP Hydraulic Temperature Sensor Out of Range High (OORL)

FAULT CODES: 12852

DTC 12852 Hydraulic Temperature

Power OFF

Wait 30 seconds

Power ON

POSSIBLE CAUSES HYDRAULIC TEMPERATURE

Fault remains. Service required. Go to Cause C.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C D E > ?

CAUSE A Not Applicable

CAUSE B Not Applicable

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9030-20-39

Diagnostic Trouble Codes

Electrical System

TSP Hydraulic Temperature Sensor Out of Range High (OORL) (Cont) CAUSE C

Disconnect sensor

Power OFF

CAUSE C1

Power ON

Go to next step.

CHECK VOLTAGE

0 Volts = Short circuit

Find

≈ 5 Volts =

Short circuit.

Go to Cause D

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

(continued on next page)

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9030-20-40

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Hydraulic Temperature Sensor Out of Range High (OORL) (Cont) CAUSE D

Power OFF

Disconnect sensor. Do not discard

Install new sensor.

Fault DTC gone

Old sensor faulty

Resume operation

Fault DTC present

Old sensor OK/Reinstall old sensor

Go to Cause E.

Power ON

Go to next step.

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9030-20-41

Diagnostic Trouble Codes

Electrical System

TSP Hydraulic Temperature Sensor Out of Range High (OORL) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-42

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Hydraulic Temperature Sensor Out of Range High (OORH)

FAULT CODES: 12853

DTC 12853 Hydraulic Temperature

Power OFF

Wait 30 seconds

Power ON

POSSIBLE CAUSES HYDRAULIC TEMPERATURE

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C C1 C2 D E > ?

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9030-20-43

Diagnostic Trouble Codes

Electrical System

TSP Hydraulic Temperature Sensor Out of Range High (OORH) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

Go to next step.

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause B

Go to Cause C

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

(continued on next page)

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9030-20-44

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Hydraulic Temperature Sensor Out of Range High (OORH) (Cont) CAUSE C

Reconnect sensor

Power OFF

CAUSE C1

Power ON

Go to next step.

CHECK VOLTAGE

= 5 Volts = Short circuit

Find

> 5.5 volts

Short circuit.

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical < 4.5 volts = System 2200 YRM 1369.

CAUSE C2

Go to Cause C2 OK

Go to Cause D

Go to Cause D.

CHECK VOLTAGE

Switched and Unswitched

< 4.5 volts = > 5.5 volts = Short circuit Find Short circuit to another voltage source. Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

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9030-20-45

Diagnostic Trouble Codes

Electrical System

TSP Hydraulic Temperature Sensor Out of Range High (OORH) (Cont) CAUSE D

Power OFF

Disconnect sensor. Do not discard

Install new sensor.

Fault DTC gone

Old sensor faulty

Resume operation

Fault DTC present

Old sensor OK/Reinstall old sensor

Go to Cause E.

Power ON

Go to next step.

(continued on next page)

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9030-20-46

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Hydraulic Temperature Sensor Out of Range High (OORH) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1.

Not OK Correct/ Repair Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-47

Diagnostic Trouble Codes

Electrical System

TSP Hydraulic Fluid Level Sensor Out Of Range Low (OORL)

FAULT CODES: 12872

DTC 12872 Hydraulic Fluid Level

Power OFF

Wait 30 seconds

Power ON

POSSIBLE CAUSES HYDRAULIC FLUID LEVEL

Fault remains. Service required. Go to Cause C.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C D E > ?

NOTE: If the CDF setting is for a sensor but the sensor is not connected, then a DTC code will be displayed. Check that the sensor is present and the harness connection is OK.

(continued on next page)

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9030-20-48

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Hydraulic Fluid Level Sensor Out Of Range Low (OORL) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

Go to next step.

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 12Volts =

Open circuit.

Go to Cause B

Repair Open Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

(continued on next page)

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9030-20-49

Diagnostic Trouble Codes

Electrical System

TSP Hydraulic Fluid Level Sensor Out Of Range Low (OORL) (Cont) CAUSE B

Power OFF

CAUSE B1

CHECK RESISTANCE -

1. ∞

= Open circuit

2. 0

= Short circuit

Find

OPEN circuit

Go to 3

≈ 4.7K

- OHMS

Go to Cause D.

Go to Cause C

3. Repair OPEN circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. Go to 4 4. Repair

Retest

Cause C1

(continued on next page)

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9030-20-50

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Hydraulic Fluid Level Sensor Out Of Range Low (OORL) (Cont) CAUSE C

1. 0

CHECK RESISTANCE -

= Short circuit

Find

≈ 4.7K

Short circuit Go to 2

- OHMS

Go to Cause D.

2. Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. Go to 3 3. Repair

Retest

Cause C1

CAUSE C1

Retest - Power ON

Go to Cause D

Is fault DTC gone? NO YES

Fault corrected

Continue operation.

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9030-20-51

Diagnostic Trouble Codes

Electrical System

TSP Hydraulic Fluid Level Sensor Out Of Range Low (OORL) (Cont) CAUSE D

Power OFF

Disconnect sensor. Do not discard

Install new sensor.

Fault DTC gone

Old sensor faulty

Resume operation

Fault DTC present

Old sensor OK/Reinstall old sensor

Go to Cause E.

Power ON

Go to next step.

(continued on next page)

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9030-20-52

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Hydraulic Fluid Level Sensor Out Of Range Low (OORL) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-53

Diagnostic Trouble Codes

Electrical System

TSP Hydraulic Fluid Level Sensor Out Of Range High (OORH)

FAULT CODES: 12873

DTC 12873 Hydraulic Fluid Level

Wait 30 seconds

Power OFF

Power ON

POSSIBLE CAUSES HYDRAULIC TEMPERATURE

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C D E > ?

CAUSE A

Power OFF

Disconnect sensor

Power ON

Go to A1.

(continued on next page)

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9030-20-54

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Hydraulic Fluid Level Sensor Out Of Range High (OORH) (Cont) CAUSE A1

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 12 Volts =

OPEN circuit.

Go to Cause C

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B Not Applicable

CAUSE C

> 4.7 Volts = Short circuit

Find

< /= 4.5 Volts = OK

Short circuit.

Go to Cause D

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE C1

Retest - Power ON

Go to Cause D

Is fault DTC gone? NO YES

Fault corrected

Continue operation.

(continued on next page)

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9030-20-55

Diagnostic Trouble Codes

Electrical System

TSP Hydraulic Fluid Level Sensor Out Of Range High (OORH) (Cont) CAUSE D

Power OFF

Disconnect sensor. Do not discard

Install new sensor.

Fault DTC gone

Old sensor faulty

Resume operation

Fault DTC present

Old sensor OK/Reinstall old sensor

Go to Cause E.

Power ON

Go to next step.

(continued on next page)

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9030-20-56

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Hydraulic Fluid Level Sensor Out Of Range High (OORH) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1.

Not OK Correct/ Repair Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-57

Diagnostic Trouble Codes

Electrical System

TSP Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL)

FAULT CODES:

12832

12840

DTC 12832

DTC 12840

Park Brake Position

Mast Tilt Position

Wait 30 seconds

Power OFF

Power ON

POSSIBLE CAUSES PARK BRAKE POSITION

MAST TILT POSITION

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C D E > ?

(continued on next page)

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9030-20-58

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

Go to next step.

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause B.

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B

∞

CHECK RESISTANCE -

= Open circuit

Find

≈ 4.7K

OPEN circuit

Repair OPEN circuit. See /Electrical System 2200 YRM 1337Electrical ≈ 0 System 2200 YRM 1369.

- OHMS

Go to Cause D Go to Cause C

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9030-20-59

Diagnostic Trouble Codes

Electrical System

TSP Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL) (Cont) CAUSE C

CHECK RESISTANCE -

= Short circuit

Find

- OHMS

Short circuit

Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE D

Power OFF

Fault DTC gone

Fault DTC present

Disconnect sensor. Do not discard

Old sensor faulty

Install new sensor.

Power ON

Go to next step.

Resume operation

Old sensor OK/Reinstall old sensor

Go to Cause E.

(continued on next page)

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9030-20-60

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-61

Diagnostic Trouble Codes

Electrical System

TSP Park Brake/Mast Tilt Position Sensor Out of Range High (OORH)

FAULT CODES:

12831

12841

DTC 12831

DTC 12841

Park Brake Position

Mast Tilt Position

Wait 30 seconds

Power OFF

Power ON

POSSIBLE CAUSES PARK BRAKE POSITION

MAST TILT POSITION

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C D E > ?

(continued on next page)

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9030-20-62

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Park Brake/Mast Tilt Position Sensor Out of Range High (OORH) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

Go to next step.

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause C.

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B Not Applicable

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9030-20-63

Diagnostic Trouble Codes

Electrical System

TSP Park Brake/Mast Tilt Position Sensor Out of Range High (OORH) (Cont) CAUSE C

Power OFF

Reconnect sensor

CAUSE C1

Power ON

Go to next step.

CHECK VOLTAGE

5 Volts = Short circuit

Find

Short circuit.

> 5.5 volts

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical < 4.5 volts = System 2200 YRM 1369.

CAUSE C2

Go to Cause C2 OK

Go to Cause D

Go to Cause D.

CHECK VOLTAGE

Switch and Unswitched

< 4.5 volts = > 5.5 volts = Short circuit Find Short circuit to another voltage source. Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

(continued on next page)

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9030-20-64

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Park Brake/Mast Tilt Position Sensor Out of Range High (OORH) (Cont) CAUSE D

Power OFF

Fault DTC gone

Fault DTC present

Disconnect sensor. Do not discard

Install new sensor.

Old sensor faulty

Power ON

Go to next step.

Resume operation

Old sensor OK/Reinstall old sensor

Go to Cause E.

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9030-20-65

Diagnostic Trouble Codes

Electrical System

TSP Park Brake/Mast Tilt Position Sensor Out of Range High (OORH) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1.

Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-66

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL)

FAULT CODES:

Power OFF

12800

12804

DTC 12800

DTC 12804

Directional Select A

Directional Select B

Wait 30 seconds

Power ON

POSSIBLE CAUSES DIRECTIONAL SELECT A/B

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C D E > ?

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9030-20-67

Diagnostic Trouble Codes

Electrical System

TSP Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

Go to next step.

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause B.

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B

∞

CHECK RESISTANCE -

= Open circuit

Find

OPEN circuit

≈ 4.7K

Repair OPEN circuit. See /Electrical System 2200 YRM 1337Electrical ≈ 0 System 2200 YRM 1369.

- OHMS

Go to Cause D Go to Cause C

(continued on next page)

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9030-20-68

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL) (Cont) CAUSE C

CHECK VOLTAGE

= Short circuit

Find

Short circuit

Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE D

Power OFF

Fault DTC gone

Fault DTC present

Disconnect Pedal or Hyd Lever. component. Do not discard

Old sensor faulty

Install new

Power ON

Go to next step.

Resume operation

Old sensor OK/Reinstall old sensor

Go to Cause E.

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9030-20-69

Diagnostic Trouble Codes

Electrical System

TSP Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK - Go to Cause E1.

Not OK

Correct/Repair Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9030-20-70

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH)

FAULT CODES:

Power OFF

12801

12805

DTC 12801

DTC 12805

Directional Select A

Directional Select B

Wait 30 seconds

Power ON

POSSIBLE CAUSES DIRECTIONAL SELECT A/B

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C C1 C2 D E > ?

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9030-20-71

Diagnostic Trouble Codes

Electrical System

TSP Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause C.

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B Not Applicable

CAUSE C

Power OFF

Reconnect sensor

Power ON

(continued on next page)

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9030-20-72

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH) (Cont) CAUSE C1

CHECK VOLTAGE

5 Volts = Short circuit

Find

> 5.5 Volts

Short circuit.

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical < 4.5 volts = System 2200 YRM 1369.

CAUSE C2

Go to Cause C2 OK

Go to Cause D

Go to Cause D.

CHECK VOLTAGE

< 4.5 volts = > 5.5 Volts = Short circuit Find Short circuit to another voltage source. Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

(continued on next page)

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9030-20-73

Diagnostic Trouble Codes

Electrical System

TSP Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH) (Cont) CAUSE D

Power OFF

Fault DTC gone

Fault DTC present

Disconnect Pedal or Hyd Lever. component. Do not discard

Old sensor faulty

Install new

Power ON

Go to next step.

Resume operation

Old sensor OK/Reinstall old sensor

Go to Cause E.

(continued on next page)

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9030-20-74

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-75

Diagnostic Trouble Codes

Electrical System

TSP Seat Sensor Out of Range Low (OORL)

FAULT CODES: 12816

DTC 12816 Seat Sensor

Wait 30 seconds

Power OFF

Power ON

POSSIBLE CAUSES SEAT SENSOR

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C D E > ?

CAUSE A

Power OFF

Disconnect sensor

Power ON

Go to next step.

(continued on next page)

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9030-20-76

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Seat Sensor Out of Range Low (OORL) (Cont) CAUSE A1

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

For Load Weigh Pressure, go to Cause C

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B

∞

CHECK RESISTANCE -

= Open circuit

Find

Repair OPEN circuit. See /Electrical System 2200 YRM 1337Electrical ≈ 0 System 2200 YRM 1369.

CAUSE C

- OHMS

≈ 4.7K

OPEN circuit

Find

CHECK RESISTANCE -

= Short circuit

For Service Brake Pressure, go to Cause B

Go to Cause D Go to Cause C

- OHMS

Short circuit

Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

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9030-20-77

Diagnostic Trouble Codes

Electrical System

TSP Seat Sensor Out of Range Low (OORL) (Cont) CAUSE D

Power OFF

Fault DTC gone

Fault DTC present

Disconnect sensor. Do not discard

Install new sensor.

Old sensor faulty

Power ON

Go to next step.

Resume operation

Old sensor OK/Reinstall old sensor

Go to Cause E.

(continued on next page)

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9030-20-78

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Seat Sensor Out of Range Low (OORL) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-79

Diagnostic Trouble Codes

Electrical System

TSP Seat Sensor Out of Range High (OORH)

FAULT CODES: 12819

DTC 12819 Seat Sensor

Wait 30 seconds

Power OFF

Power ON

POSSIBLE CAUSES LOAD WEIGH PRESSURE

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C C1 C2 D E > ?

CAUSE A

Power OFF

Disconnect sensor

Power ON

Go to next step.

(continued on next page)

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9030-20-80

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP Seat Sensor Out of Range High (OORH) (Cont) CAUSE A1

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause C

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B Not Applicable

CAUSE C

Reconnect sensor

Power OFF

CAUSE C1

Power ON

Go to next step.

CHECK VOLTAGE

5 Volts = Short circuit

Find

> 5.5 volts =

Short circuit.

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

< 4.5 volts =

Go to Cause C2 Go to Cause D

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9030-20-81

Diagnostic Trouble Codes

Electrical System

TSP Seat Sensor Out of Range High (OORH) (Cont) CAUSE C2

CHECK VOLTAGE

< 4.5 volts = > 5.5 volts = Short circuit Find Short circuit to another voltage source. Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

Go to Cause D

CAUSE D

Power OFF

Fault DTC gone

Fault DTC present

Disconnect sensor. Do not discard

Install new sensor.

Old sensor faulty

Power ON

Go to next step.

Resume operation

Old sensor OK/Reinstall old sensor

Go to Cause E.

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Electrical System

Diagnostic Trouble Codes

TSP Seat Sensor Out of Range High (OORH) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-83

Diagnostic Trouble Codes

Electrical System

TSP Battery OORH/OORL

FAULT CODES:

12545

12546

DTC 12545

DTC 12546

Battery OORH

Battery OORL

Wait 30 seconds

Power OFF

Power ON

Fault remains. Service required. Go to Cause A.

Possible Causes (OORL) Wrong Battery/Discharged Battery/Faulty Battery/ Possible Causes (OORH) Wrong Battery Installed/

CBB 4 WHEEL

No fault

Resume operation

® = High Resistance

CAUSES A B C D E > ?

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Electrical System

Diagnostic Trouble Codes

TSP Battery OORH/OORL (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

A955 G807 HIGH RESISTANCE CONNECTIONS

POSSIBLE CAUSES

) = Short Circuit

CAUSES A B C D E > ?

X = Open Circuit/Fail

CBB 3 WHEEL HIGH RESISTANCE CONNECTIONS

) = Short Circuit

CAUSES A B C D E > ?

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9030-20-85

Diagnostic Trouble Codes

Electrical System

TSP Battery OORH/OORL (Cont) CAUSE A Battery OORH/OORL

Check that correct voltage battery is installed

Perform battery maintenance, see Operating Manual

STEP A1 OORH/OORL

Power ON

Battery/Supply

Go to Diagnostic See Display Menu Flowchart

View Battery Value

STEP A2 Battery OORL NOTE: OOR Code is set if OOR condition is present for longer than 1 second. Battery Voltage 36

39.6

52.8

79.2

≈< OORL

≈ OORH

48.6

57.6

97.2

108

Nominal Fully Charged

Is battery voltage ≈ < OORL value for correct battery

STEP A3 Battery OORL

NO (√)

YES (X) Recharge battery

See Operating Manual for charge time

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Electrical System

Diagnostic Trouble Codes

TSP Battery OORH/OORL (Cont) STEP A4 Battery OORL/OORH Battery Voltage Nominal

Fully Charged

≈< OORL

≈> OORH

48.6

57.6

97.2

108

Operate truck All functions Monitor battery voltage Is battery voltage going?

< OORL or

> OORH value for correct battery

STEP A5 Battery OORH/OORL

YES (X) Inspect All Battery Connections for Corrosion/ High Resistance NO (√)

Go to Step B4

CAUSE B NOTE: High Resistance in Wiring and Connections will cause High Voltage drops (OORL) when subjected to High Current Draw NOTE: High Resistance in Wiring and Connections will cause High Voltage peaks (OORH) when subjected to High Current Regen

Disconnect battery

Set meter to lowest

scale

Check lead resistance < 0.01

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9030-20-87

Diagnostic Trouble Codes

Electrical System

TSP Battery OORH/OORL (Cont) STEP B1

CHECK RESISTANCE -

- OHMS

Battery OORH/OORL

Check resistance between the Battery (+) and (-) terminals and the Battery Connector (+) and (-) Terminals 1. > 0.01

Replace battery leads/connector terminal

2. > 0.01

Replace battery leads/connector terminal

< 0.01

Connection OK

STEP B2

Check Resistance between the Bat (+) Connector and the Contactor Stud/Bat (-) Connector and Bat (-) to System 1. > 0.01

Replace battery leads/connector terminal

2. > 0.01

Replace battery leads/connector terminal

< 0.01

Connection OK

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Electrical System

Diagnostic Trouble Codes

TSP Battery OORH/OORL (Cont) STEP B3 Battery OORH/OORL

Reconnect battery

Retest Power ON

Is DTC gone?

NO

YES

Fault Corrected

Continue operation

STEP B4 Battery OORH/OORL

Possible Battery Cell Failure

Perform Battery Cell Test

See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

If a cell failure is detected replace Battery

STEP B5

Retest Power ON

Is DTC gone?

NO

Fault Corrected

Continue operation

YES

CAUSE C Not Applicable

CAUSE D Not Applicable

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9030-20-89

Diagnostic Trouble Codes

Electrical System

TSP Battery OORH/OORL (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1

Not OK Correct/Repair

Go to Cause E1

CAUSE E1

Retest - Power ON

Is DTC gone? NO YES Go to VSM Controller Check NO

Fault corrected

Continue operation.

END FAULT

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Electrical System

Diagnostic Trouble Codes

TSP VSM 5 Volt Supply (OORL) (OORH) 13056

13057

DTC 13056

DTC 13057

5V OORL

5V OORH

FAULT CODES:

Wait 30 seconds

Power OFF

Power ON

Fault remains. Service No fault required. Go to Cause A.

Resume operation

WARNING Any VSM 5 volt powered Device will be damaged by a Short to Battery (+) condition and possibly by a Short to 12 volts (+).

WARNING All VSM 5 volt powered devices will need to be checked for correct operation and probably replaced.

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9030-20-91

Diagnostic Trouble Codes

Electrical System

TSP VSM 5 Volt Supply (OORL) (OORH) (Cont) POSSIBLE CAUSES DBB/CBB 4 WHEEL 5 VOLT SUPPLY

X = Open Circuit/Fail

) = Short Circuit

CAUSES A B C D E > ?

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9030-20-92

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Electrical System

Diagnostic Trouble Codes

TSP VSM 5 Volt Supply (OORL) (OORH) (Cont) POSSIBLE CAUSES CBB 3 WHEEL 5 VOLT SUPPLY

X = Open Circuit/Fail

) = Short Circuit

CAUSES A B C D E > ?

CAUSE A Not Applicable

CAUSE B Not Applicable

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9030-20-93

Diagnostic Trouble Codes

Electrical System

TSP VSM 5 Volt Supply (OORL) (OORH) (Cont) CAUSE C

Disconnect Accelerator Pedal sensor

Power OFF

CAUSE C1

Go to Cause C1

UNSWITCHED VOLTAGES

5 Volt OORH

≈ 0 Volts = OK

Go to Cause C2

> 0 Volts = Short Circuit

Bat (+) or 12v (+) Find

Power ON

Go to Cause C2

Short circuit.

Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. Check all 5 volt devices

CAUSE C2

Go to Cause D

SWITCHED VOLTAGES

5 Volt OORH

≈ 0 Volts = Short to bat (-) > 5.5 Volts = Short Circuit

≈ 5 Volts = Faulty Accelerator Pedal

Go to Cause C3 Bat (+) or 12v (+) Find

Go Cause D

Short circuit

Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. Check all 5 volt devices

Go to Cause D

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9030-20-94

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Electrical System

Diagnostic Trouble Codes

TSP VSM 5 Volt Supply (OORL) (OORH) (Cont) CAUSE C3 5 Volt OORL

≈ 0 Volts = Short circuit

Bat ( )

Find

Short circuit

≈ 5 Volts = Faulty Accelerator Pedal

Replace – Go Cause E

Repair Short circuit, See /Electrical System 2200 YRM 1337Electrical Go Cause E System 2200 YRM 1369. Check all 5 volt devices Reconnect Accelerator Pedal Go Cause E

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9030-20-95

Diagnostic Trouble Codes

Electrical System

TSP VSM 5 Volt Supply (OORL) (OORH) (Cont) CAUSE D

CAUSE D1

Power OFF

Disconnect next 5 volt Sensor

Do Not Discard

Go to Cause D2.

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9030-20-96

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Electrical System

Diagnostic Trouble Codes

TSP VSM 5 Volt Supply (OORL) (OORH) (Cont) CAUSE D2

Power ON

5 Volt Fault DTC gone

Old sensor faulty

Install New sensor

Resume operation

Original Fault DTC present

Old sensor OK/Reinstall old sensor

Go to Next Sensor. Repeat Cause D All Sensors tested OK. Go to Cause E

CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-97

Diagnostic Trouble Codes

Electrical System

TSP Manual Hydraulic Position Sensors Out Of Range Low (OORL) 12864

DTC 12864 Manual Hyd 3 12868

FAULT CODES:

DTC 12868 Manual Hyd 4

12856

DTC 12856 Manual Hyd 1 12860

DTC 12860 Manual Hyd 2

Power OFF

Wait 30 seconds

Power ON

POSSIBLE CAUSES MANUAL HYDRAULIC POSITION SENSOR

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C D E > ?

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9030-20-98

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Electrical System

Diagnostic Trouble Codes

TSP Manual Hydraulic Position Sensors Out Of Range Low (OORL) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

Go to next step.

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause B

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B

∞

CHECK RESISTANCE -

= Open circuit

Find

≈ 4.7K

OPEN circuit

Repair OPEN circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

≈0

- OHMS

Go to Cause D Go to Cause C

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9030-20-99

Diagnostic Trouble Codes

Electrical System

TSP Manual Hydraulic Position Sensors Out Of Range Low (OORL) (Cont) CAUSE C

= Short circuit

Find

Short circuit

Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE D

Power OFF

Fault DTC gone

Fault DTC present

Disconnect sensor. Do not discard

Install new sensor.

Old sensor faulty

Power ON

Go to next step.

Resume operation

Old sensor OK/Reinstall old sensor

Go to Cause E.

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Electrical System

Diagnostic Trouble Codes

TSP Manual Hydraulic Position Sensors Out Of Range Low (OORL) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK - Go to Cause E1.

Not OK

Correct/Repair Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-101

Diagnostic Trouble Codes

Electrical System

TSP Manual Hydraulic Position Sensor Out Of Range High (OORH) 12865

DTC 12865 Manual Hyd 3 12869

FAULT CODES:

DTC 12869 Manual Hyd 4

12857

DTC 12857 Manual Hyd 1 12861

DTC 12861 Manual Hyd 2

Power OFF

Wait 30 seconds

Power ON

POSSIBLE CAUSES ACCELERATOR PEDAL POSITION A/B

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

CAUSES A B C C1 C2 D E > ?

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9030-20-102

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Electrical System

Diagnostic Trouble Codes

TSP Manual Hydraulic Position Sensor Out Of Range High (OORH) (Cont) CAUSE A

Disconnect sensor

Power OFF

CAUSE A1

Power ON

Go to next step.

CHECK VOLTAGE

0 Volts = Open circuit

Find

≈ 5 Volts =

OPEN circuit.

Go to Cause C

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE B Not Applicable

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9030-20-103

Diagnostic Trouble Codes

Electrical System

TSP Manual Hydraulic Position Sensor Out Of Range High (OORH) (Cont) CAUSE C

Reconnect sensor

Power OFF

CAUSE C1

Power ON

Go to next step.

CHECK VOLTAGE

5 Volts = Short circuit

Find

> 5.5 Volts

Short circuit.

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE C2

< 4.5 volts =

Go to Cause C2. OK

Go to Cause D.

CHECK VOLTAGE

Switched and Unswitched

< 4.5 volts = > 5.5 Volts = Short circuit Find Short circuit to another voltage source. Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

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9030-20-104

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Electrical System

Diagnostic Trouble Codes

TSP Manual Hydraulic Position Sensor Out Of Range High (OORH) (Cont) CAUSE D

Power OFF

Fault DTC gone

Fault DTC present

Disconnect sensor. Do not discard

Install new sensor.

Old sensor faulty

Power ON

Go to next step.

Resume operation

Old sensor OK/Reinstall old sensor

Go to Cause E.

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9030-20-105

Diagnostic Trouble Codes

Electrical System

TSP Manual Hydraulic Position Sensor Out Of Range High (OORH) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? NO YES

Fault corrected

Continue operation.

END FAULT

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Electrical System

Diagnostic Trouble Codes

TSP E-Hydraulic Enable System Data Incorrect

FAULT CODES: 12332

DTC 12332 Data Incorrect

Power OFF

Wait 30 seconds

Power ON

POSSIBLE CAUSES

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

E-HYDRAULIC ENABLE SYSTEM DATA INCORRECT

No fault

Resume operation

) = Short Circuit

CAUSES A A1 A2 A3 B B1 C C1 C2 D E > ?

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9030-20-107

Diagnostic Trouble Codes

Electrical System

TSP E-Hydraulic Enable System Data Incorrect (Cont) CAUSE A Not Applicable

CAUSE A1

CHECK VOLTAGE

NOTE: Locate DC/DC Convertor - Check DC/DC Voltage Input

≈ Bat Volts =

0 Volts = Open circuit/Blown fuse

Go to Cause A2

Find OPEN circuit or SHORT circuit that blew the fuse. Repair OPEN Circuit/SHORT Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE A2

CHECK VOLTAGE

NOTE: Check DC/DC Voltage Output

0 Volts = Open circuit/DC/DC failure

Find OPEN circuit.

≈ 12 Volts =

Go to Cause A3

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. No wiring OPEN circuit. Replace DC/DC convertor.

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9030-20-108

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Electrical System

Diagnostic Trouble Codes

TSP E-Hydraulic Enable System Data Incorrect (Cont) CAUSE A3

CHECK VOLTAGE

NOTE: Occupy Seat - Operate any Hyd Function - Check Voltage out on Enable Relay

0 Volts = Open circuit/Relay Contacts

≈ 12 Volts =

Find OPEN circuit.

Go to Cause E

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. No Wiring OPEN Circuit. Replace Enable Relay.

CAUSE B

Disconnect Coil Connector

Power OFF

CAUSE B1

∞

Disconnect VSM Connector CPS2

CHECK RESISTANCE -

= Open circuit

Find

≈0

OPEN circuit.

Go to next step.

- OHMS

Go to Cause C1

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

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9030-20-109

Diagnostic Trouble Codes

Electrical System

TSP E-Hydraulic Enable System Data Incorrect (Cont) CAUSE C Not Applicable

CAUSE C1

to 1

CHECK RESISTANCE -

= Short circuit

Find

Short circuit.

- OHMS

Reconnect all connections, go to Cause E

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE C2

CHECK RESISTANCE -

= Short circuit

Find

Short circuit.

∞

- OHMS

Reconnect all connections, go to Cause E

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE D Not Applicable

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9030-20-110

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Electrical System

Diagnostic Trouble Codes

TSP E-Hydraulic Enable System Data Incorrect (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-111

Diagnostic Trouble Codes

Electrical System

TSP E-Hydraulic Coils Short To Battery Positive (STBP)

FAULT CODES: 8960

DTC 8960 Lift 8964

DTC 8964

8968

8980

DTC 8968

DTC 8980

Tilt Forward

Aux 1B

8972

8984

DTC 8972

DTC 8984

Tilt Back

Aux 2A

8978

8988

DTC 8978

DTC 8988

Aux 1A

Aux 2B

Lower

Power OFF

Wait 30 seconds

Power ON

Fault remains. Service required. Go to Cause A.

No fault

Resume operation

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Electrical System

Diagnostic Trouble Codes

TSP E-Hydraulic Coils Short To Battery Positive (STBP) (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

E-HYDRAULIC ENABLE SYSTEM DATA INCORRECT

) = Short Circuit

CAUSES A B C C1 C2 C3 C4 C5 C6 D E > ?

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9030-20-113

Diagnostic Trouble Codes

Electrical System

TSP E-Hydraulic Coils Short To Battery Positive (STBP) (Cont) CAUSE A Not Applicable

CAUSE B Not Applicable

CAUSE C

Disconnect coil connectors

Power OFF

CAUSE C1

Go to next step.

UNSWITCHED VOLTAGES

NOTE: Coil Driver Short to Unswitched Battery

Bat Volts = Short circuit

Find

≈ 0 Volts =

SHORT circuit.

Go to Cause C2

Repair SHORT Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE C2

SWITCHED VOLTAGES

NOTE: Coil Driver Short to Switched Battery

Power ON

Go to next step.

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9030-20-114

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Electrical System

Diagnostic Trouble Codes

TSP E-Hydraulic Coils Short To Battery Positive (STBP) (Cont) CAUSE C3

SWITCHED VOLTAGES

NOTE: Coil Driver Short to Switched Battery

Bat Volts = Short circuit

Find

≈ 0 Volts =

SHORT circuit

Go to Cause C4

Go to Cause C5

Repair SHORT Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE C4

SWITCHED VOLTAGES

NOTE: Short to Switched Battery

Bat Volts = Short circuit

Find

≈ 0 Volts =

SHORT circuit

Repair SHORT Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE C5

UNSWITCHED VOLTAGES

NOTE: Short to Unswitched Battery

Power OFF

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9030-20-115

Diagnostic Trouble Codes

Electrical System

TSP E-Hydraulic Coils Short To Battery Positive (STBP) (Cont) CAUSE C6

UNSWITCHED VOLTAGES

NOTE: Short to Unswitched Battery

Bat Volts = Short circuit

Find

≈ 0 Volts =

SHORT circuit

Go to Cause E

Repair Open Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE D Not Applicable

CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-116

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Electrical System

Diagnostic Trouble Codes

TSP E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC)

FAULT CODES: 13312

DTC 13312 Lift 13316

DTC 13316

13320

13332

DTC 13320

DTC 13332

Tilt Forward

Aux 1B

13324

13336

DTC 13324

DTC 13336

Tilt Back

Aux 2A

13328

13340

DTC 13328

DTC 13340

Aux 1A

Aux 2B

Lower

Power OFF

Wait 30 seconds

Power ON

Fault remains. Service required. Go to Cause A.

No fault

Resume operation

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9030-20-117

Diagnostic Trouble Codes

Electrical System

TSP E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC) (Cont) POSSIBLE CAUSES E-HYDRAULIC COILS (STBN)/(OC)

X = Open Circuit/Fail

) = Short Circuit

CAUSES A B C E > ?

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9030-20-118

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Electrical System

Diagnostic Trouble Codes

TSP E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC) (Cont) CAUSE A For causes A1, A2, and A3, go to DTC 12332 in E-Hydraulic Enable System Data Incorrect.

CAUSE B

Disconnect coil connectors

Power OFF

CAUSE B1

Go to next step.

CHECK RESISTANCE -

- OHMS

NOTE: Open Circuit - Coil Connector To VSM

∞

= Open circuit

Find

≈ 90K

OPEN circuit

Repair OPEN circuit. See /Electrical System 2200 YRM 1337Electrical ≈ 0 System 2200 YRM 1369.

= =

Go to Cause B2 Go to Cause C3

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9030-20-119

Diagnostic Trouble Codes

Electrical System

TSP E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC) (Cont) CAUSE B2

CHECK RESISTANCE -

- OHMS

NOTE: Open Circuit - Coil Connections To Coil

∞

= Open circuit

Find

≈4.5 =

OPEN circuit

± 1.5

Go to Cause C2

Repair OPEN circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. > 6 < 3 = Faulty Coil ReplaceCoil Repair OPEN circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

CAUSE C Go to Cause C1

CAUSE C1

CHECK RESISTANCE -

- OHMS

For DC/DC volt Short to Battery, go to DTC 12332 in E-Hydraulic Enable System Data Incorrect.

CAUSE C2

CHECK RESISTANCE -

- OHMS

For DC/DC volt Short to Battery, go to DTC 12332 in E-Hydraulic Enable System Data Incorrect.

CAUSE C3

CHECK RESISTANCE -

- OHMS

NOTE: Short to Bat (-) Coil Driver Connectional

= Short circuit

Find

≈ 90K

Short circuit

Go to Cause E

Repair Short circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

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9030-20-120

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Electrical System

Diagnostic Trouble Codes

TSP E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC) (Cont) CAUSE D Not Applicable

CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-121

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 CAN Communication Failure

FAULT CODES:

33025

33029

33036

33057

DTC 33025

DTC 33029

DTC 33036

DTC 33057

VSM to Display

VSM to Pump

VSM to CAN Reserved 1

Display to VSM

33026

33034

33037

DTC 33026

DTC 33034

DTC 33037

VSM to Traction 1 (Right)

VSM to MLM (DCS)

VSM to CAN Reserved 2

33027

33035

33038

DTC 33027

DTC 33035

DTC 33038

VSM to Traction 2 (Left)

VSM to Impact

VSM to CAN Reserved 3

Wait 30 seconds

Power OFF

Fault remains. Service required. Go to Quick Check.

Power ON

No fault

Resume Operation

FAULT LOG DTC Review – Go to Display Menu

Enter SERVICE Password

Diagnostics

" all VSM DTCs

Multiple VSM DTCs

Single DTC

Fault Logs

Erase VSM DTCs

DTCs Present

OFF

" DTCs

Wait 30 seconds Power OFF

Exit Fault Log

Specific Device Fault Log

Emergency Stop Switch

VSM Fault Logs

Power OFF

View all VSM DTCs

Quick Check Erase Device DTCs

Device DTCs

Recheck Single Device Fault Logs DTCs Gone

Go to Single Device TSP

Resume Operation

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 CAN Communication Failure (Cont) QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Disconnect Battery

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Locate Diagnostic Connector CPS 28

Service Connection

Short Circuit CAN Hi/CAN Lo Go to Step C1, All CAN Device DTCs

Open Circuit CAN Hi/CAN Lo Go to Cause A, Multiple CAN Device DTCs

Open Circuit CAN Hi/ CAN Lo Termination Resistor Go to Cause B, Intermittent DTCs

Circuit OK Go to Step A2, Single CAN Device DTC

CAN Hi Short Circuit Bat ( ) Go to Step C2, All CAN Device DTCs

CANbus Circuit OK Go to Step A2, Single CAN Device DTC

CAN Hi Short Circuit Bat (+) All CAN Device DTCs Go to Step C3,

CANbus Circuit OK Go to Step A2, Single CAN Device DTC

CAN Lo STB ( ), No DTC Go to Step C2, No DTC

CAN Hi Short to 12/5 (+) No DTC CAN Lo Short Circuit Bat (+) All CAN Device DTCs Go to Step C3,

SINGLE DEVICE DTC

Fault is isolated to a SINGLE CANbus Connected Device and its Supply Connections

MULTIPLE DEVICE DTCs ALL DEVICE DTCs

Faults that affect some but not all CANbus Devices

Faults that affect all of the CANbus connected devices

Typically Open Circuits

Typically Short Circuits

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9030-20-123

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 CAN Communication Failure (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

) = Short Circuit

) = No DTC

Table 9030-20-1. Main Schematic Open Circuit – Termination Resistor/CAN Hi/CAN Lo/Key Switch Supply/Device Supply/ CAUSES A, B CAN Short to – Bat (

)/12volt Bat (+)/Shorted CAN Hi to CAN Lo/Device Failure CAUSES C, D, E

CAUSES A B C D E > ?

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9030-20-124

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 CAN Communication Failure (Cont) CONNECTORS CANbus DEVICES

Table 9030-20-2. Device Connectors

VSM Cxx 1 and Cxx 2

Main Seat Cxx 52 and 54

Impact Device Cxx 148

Service Connector Cxx 28

Traction/Pump Controller Cxx 3, 4, and 5

MLM Cxx 52

Display Harness Cxx 135

Display Cxx 20

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9030-20-125

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 CAN Communication Failure (Cont) CAUSE A CAN Hi/CAN Lo Single Device DTC (Black X) vs Multiple DTCs (Red X)

1, 2, and 3 are examples of possible Causes 1. Single DTC

Indicated Device Connections/Device Fail

1. Single DTC above 2. Multiple DTCs

Step A1

Open Circuit on Device Supply (+) or Bat ( ) or Open Circuit on Sub Circuit Wiring

Fault Log

DTC/Device closest to VSM

Step A3

= Open circuit between DTC Device and VSM

3. All DTCs above

Open Circuit on Device Supply (+) Bat ( )

3. All DTCs above

Open/Short Circuit on VSM CANbus

Step B3

= Supply Failure/Open Circuit Main Supply Circuit

= Open Circuit

Step B3 – Short Circuit

Step A3

Cause C

STEP A1 CAN Hi/ CAN Lo Single Device DTC - Locate Device

1. Example Only

Single DTC

Indicated Device Connections/Device Fail

of Step A2

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 CAN Communication Failure (Cont) STEP A2

Power ON

Step A3

STEP A3 Single Device DTC Open Circuit Supply Voltage

1. Locate Device

Check connection

Not OK, Go to 4

2. = 0 Volts = Open Circuit Supply/(+) or ( ) 3. > Supply Volts

1. Connection OK

Go to 4

Go to 2

2. =Supply Volts = OK

Check for Shorts to a higher supply source

Repair

Step B1

Cause D as CAN Device may be damaged

4. Reference Main Schematic - Find/Repair Open Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Voltage Step A4

STEP A4

Retest - Power OFF Power ON

Cause B

Is fault DTC gone? YES NO

Fault corrected

Continue operation

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9030-20-127

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 CAN Communication Failure (Cont) CAUSE B

Go to Step B1

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Power OFF

STEP B1 Single Device DTC Open Circuit CAN Hi or CAN Lo

Locate Device

Check Connection

Device with Termination Resistor 1. > 120 2. = ∞

3. Replace Device

Reconnect

Go to Step B2

See Device Connectors

Locate and Disconnect

= Open Circuit Termination Resistor = Open Circuit

Connections OK

Not OK, Go to 4

1. ≈ 120

Go to 3

2. ≈ 0

Go to 4

= OK Go to 2

= OK Go to 3

Cause D

4. Find/Repair Open Circuit, See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Step B2

Recheck

Reconnect

STEP B2

Reconnect Battery

Retest - Power ON

Step B3,

Is fault DTC gone? YES NO

Fault corrected Continue operation

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 CAN Communication Failure (Cont) STEP B3

Power OFF

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Go to Step B4

STEP B4 Multi CAN Device DTCs Display > Open Circuit CAN Hi to CAN Lo

Example Only

Multiple DTCs

Fault Log

Open circuit is between DTC Device and VSM

DTC/Device closest to VSM , Step B5

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9030-20-129

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 CAN Communication Failure (Cont) STEP B5 Multi Device DTCs Open Circuit CAN Hi or CAN Lo

The above is an Example Only Disconnect VSM CPS1 > 60

to ∞

Measure

= CAN Hi/Lo Open Circuit Step B6

See Device Connectors ≈0 ≈ 60

Cause C = OK Cause C

STEP B6

The above is an Example Only Locate Device to Right or Left of Indicated Open Circuit

Disconnect

1. ∞

= CAN Hi Open Circuit

Go to 3

1. ≈ 0

= OK

Cause C

2. ∞

= CAN Lo Open Circuit

Go to 3

2. ≈ 0

= OK

Cause C

See Device Connectors

3. Find/Repair Short Circuit, See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Retest Cause C

Reconnect

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9030-20-130

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 CAN Communication Failure (Cont) CAUSE C All CAN Device DTCs Displayed > CAN Hi/CAN Lo Short Circuit together/Supply (+) or (

All DTCs

Open Circuit to VSM

)

Step B5

All DTCs

Short Circuit CAN Hi to CAN Lo

All DTCs

Short Circuit CAN Hi to (-) Supply Sources

Step C1 Step C2

All DTCs

Short Circuit CAN Lo to (+) Supply Sources

Step C3 No DTCs

No DTCs

Short Circuit CAN Lo to (–-) Supply Sources Short Circuit CAN Hi to (+) Supplies (5, 12 volt)

STEP C1 All Device DTCs Short Circuit CAN Hi to CAN Lo

Locate Service Connection 1. = 0

Measure

CAN Hi/Lo Short Circuit

See Device Connectors 1. ≈ 60

Go to 2

= OK

Step C2

2. Inspect Accessible Harness Areas for Insulation Damage then Inaccessible Harness Areas. Focus on Bend Edges and Pinch Points, Go to 3 3. Find/Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Retest Step C5

Reconnect

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9030-20-131

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 CAN Communication Failure (Cont) STEP C2 All Device DTCs Short Circuit CAN Hi to Bat (

) CAN Lo to Bat (

) will not Produce a DTC

1. 0

= CAN Hi Short Circuit. Go to 3

1. > 50K

= OK, Go to 3

2. 0

= CAN Lo Short Circuit. Go to 3

2. > 50K

= OK, Go to 3

3. Find/Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Retest, Step C5

Reconnect

STEP C3 Multiple CAN Device DTCs Displayed > (+) Supply Short Circuit to CAN Hi or CAN Lo

All DTCs

Short Circuit CAN Lo to (+) Supply Sources.

All DTCs

Short Circuit CAN Hi to (+) Supply Sources. No DTCs for a Short to (+)12 Volts or (+) 5 Volts

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 CAN Communication Failure (Cont) STEP C4 All Device DTCs Short Circuit Supply (+) to CAN Hi or CAN Lo

1. A, B, C, D, and E = 0

= CAN Hi Short Circuit, Go to 3

1. A, B, C, D, and E > 50K

= OK

, Step C5

2. A, B, C, D, and E = 0

= CAN Lo Short Circuit, Go to 3

2. A, B, C, D, and E > 50K

=OK

Step C5

3. Find/Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Retest Step C5

Reconnect

STEP C5

Reconnect Battery

Retest - Power ON

Go to Cause D

Is fault DTC gone? YES NO

Fault corrected Continue operation

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9030-20-133

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 CAN Communication Failure (Cont) CAUSE D

Disconnect Battery To Replace Motor Controller

Power OFF

Disconnect CAN Device Do Not Discard

Install New CAN Device

Power ON Step D1

Go to

STEP D1

Fault DTC gone

Old device faulty

Resume operation

Fault DTC present

Old Device OK/Reinstall Old Device

Go to Cause E.

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 CAN Communication Failure (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Step E1

Not OK Correct/Repair

Go to Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation

NO

END FAULT

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9030-20-135

Diagnostic Trouble Codes

Electrical System

TSP CBB 4 Wheel CAN Communication

FAULT CODES:

33025

33029

33036

33057

DTC 33025

DTC 33029

DTC 33036

DTC 33057

VSM to Display

VSM to Pump

VSM to CAN Reserved 1

Display to VSM

33026

33034

33037

DTC 33026

DTC 33034

DTC 33037

VSM to Traction 1 (Right)

VSM to MLM (DCS)

VSM to CAN Reserved 2

33027

33035

33038

DTC 33027

DTC 33035

DTC 33038

VSM to Traction 2 (Left)

VSM to Impact

VSM to CAN Reserved 3

Wait 30 seconds

Power OFF

Fault remains. Service required. Go to Quick Check.

Power ON

No fault

Resume Operation

FAULT LOG DTC Review – Go to Display Menu

Enter SERVICE Password

Diagnostics

" all VSM DTCs

Multiple VSM DTCs

Single DTC

Fault Logs

Erase VSM DTCs

DTCs Present

OFF

" DTCs

Wait 30 seconds Power OFF

Exit Fault Log

Specific Device Fault Log

Emergency Stop Switch

VSM Fault Logs

Power OFF

View all VSM DTCs

Quick Check Erase Device DTCs

Device DTCs

Recheck Single Device Fault Logs DTCs Gone

Go to Single Device TSP

Resume Operation

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Electrical System

Diagnostic Trouble Codes

TSP CBB 4 Wheel CAN Communication (Cont) QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Disconnect Battery

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Locate Diagnostic Connector CPS 28

Service Connection

Short Circuit CAN Hi/CAN Lo Go to Step C1, All CAN Device DTCs

Open Circuit CAN Hi/CAN Lo Go to Cause A, Multiple CAN Device DTCs

Open Circuit CAN Hi/ CAN Lo Termination Resistor Go to Cause B, Intermittent DTCs

Circuit OK Go to Step A2, Single CAN Device DTC

CAN Hi Short Circuit Bat ( ) Go to Step C2, All CAN Device DTCs

CANbus Circuit OK Go to Step A2, Single CAN Device DTC

CAN Hi Short Circuit Bat (+) All CAN Device DTCs Go to Step C3,

CANbus Circuit OK Go to Step A2, Single CAN Device DTC

CAN Lo STB ( ), No DTC Go to Step C2, No DTC

CAN Hi Short to 12/5 (+) No DTC CAN Lo Short Circuit Bat (+) All CAN Device DTCs Go to Step C3,

SINGLE DEVICE DTC

Fault is isolated to a SINGLE CANbus Connected Device and its Supply Connections

MULTIPLE DEVICE DTCs ALL DEVICE DTCs

Faults that affect some but not all CANbus Devices

Faults that affect all of the CANbus connected devices

Typically Open Circuits

Typically Short Circuits

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9030-20-137

Diagnostic Trouble Codes

Electrical System

TSP CBB 4 Wheel CAN Communication (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

) = Short Circuit

) = No DTC

Table 9030-20-3. Main Schematic Open Circuit – Termination Resistor/CAN Hi/CAN Lo/Key Switch Supply/Device Supply/ CAUSES A, B CAN Short to > Bat (

)/12volt Bat (+)/Shorted CAN Hi to CAN Lo/Device Failure CAUSES C, D, E >?

CAUSES A B C D E > ?

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9030-20-138

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Electrical System

Diagnostic Trouble Codes

TSP CBB 4 Wheel CAN Communication (Cont) CONNECTORS CANbus DEVICES

Table 9030-20-4. Device Connectors

VSM Cxx 1 and Cxx 2

Main Seat Cxx 52 and 54

Impact Device Cxx 148

Service Connector Cxx 28

Traction/Pump Controller Cxx 3, 4, and 5

MLM Cxx 52

Display Harness Cxx 135

Display Cxx 20

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9030-20-139

Diagnostic Trouble Codes

Electrical System

TSP CBB 4 Wheel CAN Communication (Cont) CAUSE A CAN Hi/CAN Lo Single Device DTC (Black X) vs Multiple DTCs (Red X)

1, 2, and 3 are examples of possible Causes 1. Single DTC

Indicated Device Connections/Device Fail

1. Single DTC above 2. Multiple DTCs

Step A1

Open Circuit on Device Supply (+) or Bat ( ) or Open Circuit on Sub Circuit Wiring

Fault Log

DTC/Device closest to VSM

Step A3

= Open circuit between DTC Device and VSM

3. All DTCs above

Open Circuit on Device Supply (+) Bat ( )

3. All DTCs above

Open/Short Circuit on VSM CANbus

Step B3

= Supply Failure/Open Circuit Main Supply Circuit

= Open Circuit

Step B3 – Short Circuit

Step A3

Cause C

STEP A1 CAN Hi/ CAN Lo Single Device DTC - Locate Device

1. Example Only

Single DTC

Indicated Device Connections/Device Fail

Step A2

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Electrical System

Diagnostic Trouble Codes

TSP CBB 4 Wheel CAN Communication (Cont) STEP A2

Power ON

Step A3

STEP A3 Single Device DTC Open Circuit Supply Voltage

NOTE: Motor Controllers Require Battery Removal. Only do this if either or both Motor Controller DTCs as Displayed NOTE: If Fault Log shows Multiple DTCs = Possible Open Circuit Supply (+) ( ) other than at the Device 1. Locate Device

Check connection

Not OK, Go to 4

2. = 0 Volts = Open Circuit Supply/(+) or ( ) 3. > Supply Volts

1. Connection OK

Go to 4

Go to 2

2. =Supply Volts = OK

Check for Shorts to a higher supply source

Repair

Step B1

Cause D as CAN Device may be damaged

4. Reference Main Schematic - Find/Repair Open Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Voltage Step A4

STEP A4

Retest - Power OFF Power ON

Cause B

Is fault DTC gone? YES NO

Fault corrected

Continue operation

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9030-20-141

Diagnostic Trouble Codes

Electrical System

TSP CBB 4 Wheel CAN Communication (Cont) CAUSE B

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Power OFF

Go to Step B1

STEP B1 Single Device DTC Open Circuit CAN Hi or CAN Lo – Motor Devices, See Step B2.

Locate Device 1. ∞

Disconnect

Check Connection

= Open Circuit CAN Device to Harness

Measure

Go to 2

Go to 1 1. ≈ 60

2. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 3. Recheck

Reconnect

= OK

CAN Device FaultyGo to Cause D

Go to 3

Step B2

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9030-20-142

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Electrical System

Diagnostic Trouble Codes

TSP CBB 4 Wheel CAN Communication (Cont) STEP B2 Single Device DTC Open Circuit CAN Hi or CAN Lo – Motor Device with Termination Resistor shown

Locate Device

Disconnect

Check Connection

1. ∞

= Open Circuit CAN Device to Harness

2. ∞

= Open Circuit

Measure

Go to 1 1. ≈ 60 /120

Go to 3

2. ≈ 0

Go to 3

3. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Recheck

Reconnect

= OK

CAN Device FaultyGo to Cause D

= OK Reconnect Device

Go to 3

Go to 4

Step B2

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9030-20-143

Diagnostic Trouble Codes

Electrical System

TSP CBB 4 Wheel CAN Communication (Cont) STEP B3 Single Device DTC Open Circuit CAN Hi or CAN Lo – Motor Device with Termination Resistor shown

Locate Device

Disconnect

Check Connection

Measure

Go to 1

1. ∞

= Open Circuit Motor Controller Loop(s)

Go to 5

1. ≈ 0

= OK

Go to 3

2. ∞

= Open Circuit Motor Controller Loop(s)

Go to 5

2. ≈ 0

= OK

Go to 3

3. ∞

= Open Circuit

3. ≈ 0

= OK Reconnect Device

4. > 120

Go to Cause D

= Open Circuit Termination Resistor

Go to Cause D

4. ≈ 120

5. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 6. Recheck

Reconnect

Go to 4

= OK Reconnect Device

Go to Step B4

Go to 6

Step B4

STEP B4

Reconnect Battery

Retest - Power ON

Is fault DTC gone? YES

NO

Fault corrected Continue operation

STEP B5

Power OFF

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Go to Step B4

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9030-20-144

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Electrical System

Diagnostic Trouble Codes

TSP CBB 4 Wheel CAN Communication (Cont) STEP B6 Multi CAN Device DTCs Display > Open Circuit CAN Hi to CAN Lo

Example Only

Multiple DTCs

Fault Log

DTC/Device closet to VSM

Open circuit is between DTC Device and VSM

Step B5

STEP B7 Multi Device DTCs Open Circuit CAN Hi or CAN Lo

The above is an Example Only Disconnect VSM CPS1 > 60 B6

to ∞

Measure

See Device Connectors

= Termination Resistor/CAN Hi/Lo Open Circuit Step

≈ 60

= OK

Cause C

> 60 to ∞ = Termination Resistor/CAN Hi/Lo Open Circuit Step Cause C B6 ≈ 0

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9030-20-145

Diagnostic Trouble Codes

Electrical System

TSP CBB 4 Wheel CAN Communication (Cont) STEP B8

Disconnect Termination Resistor Connector Cxx 42 1. = 120

= Faulty Connections/Wiring/ to Termination Resistor or Faulty Termination Resistor

2. >120

= Faulty Connections/Wiring/ Pump Controller

Go to 3

Step B7

3. Measure Termination Resistor 4. >120

= Faulty Resistor

Replace

Reconnect

Retest

4. = 120

Step B7

STEP B9

The above is an Example Only Locate Device to Right or Left of Indicated Open Circuit

Disconnect

1. ∞

= CAN Hi Open Circuit

Go to 3

1. ≈ 0

= OK

Cause C

2. ∞

= CAN Lo Open Circuit

Go to 3

2. ≈ 0

= OK

Cause C

See Device Connectors

3. Find/Repair Short Circuit, See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Retest Cause C

Reconnect

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9030-20-146

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Electrical System

Diagnostic Trouble Codes

TSP CBB 4 Wheel CAN Communication (Cont) CAUSE C All CAN Device DTCs Displayed > CAN Hi/CAN Lo Short Circuit together/Supply (+) or (

All DTCs

Open Circuit to VSM

All DTCs

Short Circuit CAN Hi to CAN Lo

All DTCs

Short Circuit CAN Hi to (-) Supply Sources

Step C2

All DTCs

Short Circuit CAN Lo to (+) Supply Sources

Step C3 No DTCs

)

Step B5 Step C1 No DTCs

Short Circuit CAN Lo to (–-) Supply Sources Short Circuit CAN Hi to (+) Supplies (5, 12 volt)

STEP C1 All Device DTCs Short Circuit CAN Hi to CAN Lo

Locate Service Connection 1. = 0

Measure

CAN Hi/Lo Short Circuit

See Device Connectors 1. ≈ 60

Go to 2

= OK

Step C2

Reconnect

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9030-20-147

Diagnostic Trouble Codes

Electrical System

TSP CBB 4 Wheel CAN Communication (Cont) STEP C2 All Device DTCs Short Circuit CAN Hi to Bat (

) CAN Lo to Bat (

) will not Produce a DTC

1. 0

= CAN Hi Short Circuit. Go to 3

1. > 50K

= OK, Go to 3

2. 0

= CAN Lo Short Circuit. Go to 3

2. > 50K

= OK, Go to 3

3. Find/Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Retest, Step C5

Reconnect

STEP C3 Multiple CAN Device DTCs Displayed > (+) Supply Short Circuit to CAN Hi or CAN Lo

All DTCs

Short Circuit CAN Lo to (+) Supply Sources.

All DTCs

Short Circuit CAN Hi to (+) Supply Sources. No DTCs for a Short to (+)12 Volts or (+) 5 Volts

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Electrical System

Diagnostic Trouble Codes

TSP CBB 4 Wheel CAN Communication (Cont) STEP C4 All Device DTCs Short Circuit Supply (+) to CAN Hi or CAN Lo

1. A, B, C, D, and E = 0

= CAN Hi Short Circuit, Go to 3

1. A, B, C, D, and E > 50K

= OK

, Step C5

2. A, B, C, D, and E = 0

= CAN Lo Short Circuit, Go to 3

2. A, B, C, D, and E > 50K

=OK

Step C5

3. Find/Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Retest Step C5

Reconnect

STEP C5

Reconnect Battery

Retest - Power ON

Go to Cause D

Is fault DTC gone? YES NO

Fault corrected Continue operation

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9030-20-149

Diagnostic Trouble Codes

Electrical System

TSP CBB 4 Wheel CAN Communication (Cont) CAUSE D

Disconnect Battery To Replace Motor Controller

Power OFF

Disconnect CAN Device Do Not Discard

Install New CAN Device

Power ON Step D1

Go to

STEP D1

Fault DTC gone

Old device faulty

Resume operation

Fault DTC present

Old Device OK/Reinstall Old Device

Go to Cause E.

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Electrical System

Diagnostic Trouble Codes

TSP CBB 4 Wheel CAN Communication (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Step E1

Not OK Correct/Repair

Go to Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation

NO

END FAULT

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9030-20-151

Diagnostic Trouble Codes

Electrical System

TSP DBB 4 Wheel CAN Communication

FAULT CODES:

33025

33029

33036

33057

DTC 33025

DTC 33029

DTC 33036

DTC 33057

VSM to Display

VSM to Pump

VSM to CAN Reserved 1

Display to VSM

33026

33034

33037

DTC 33026

DTC 33034

DTC 33037

VSM to Traction 1 (Right)

VSM to MLM (DCS)

VSM to CAN Reserved 2

33027

33035

33038

DTC 33027

DTC 33035

DTC 33038

VSM to Traction 2 (Left)

VSM to Impact

VSM to CAN Reserved 3

Wait 30 seconds

Power OFF

Fault remains. Service required. Go to Quick Check.

Power ON

No fault

Resume Operation

FAULT LOG DTC Review – Go to Display Menu

Enter SERVICE Password

Diagnostics

Multiple VSM DTCs

all VSM DTCs

Single DTC

Fault Logs

Erase VSM DTCs

Specific Device Fault Log

Emergency Stop Switch DTCs Present

OFF

" DTCs

Wait 30 seconds Power OFF

VSM Fault Logs

Exit Fault Log

View all VSM DTCs

Power OFF

Quick Check Erase Device DTCs

Device DTCs

Recheck Single Device Fault Logs DTCs Gone

Go to Single Device TSP

Resume Operation

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Electrical System

Diagnostic Trouble Codes

TSP DBB 4 Wheel CAN Communication (Cont) QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Disconnect Battery

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Locate Diagnostic Connector CPS 28

Service Connection

Short Circuit CAN Hi/CAN Lo Go to Step C1, All CAN Device DTCs

Open Circuit CAN Hi/CAN Lo Go to Cause A, Multiple CAN Device DTCs

Open Circuit CAN Hi/ CAN Lo Termination Resistor Go to Cause B, Intermittent DTCs

Circuit OK Go to Step A2, Single CAN Device DTC

CAN Hi Short Circuit Bat ( ) Go to Step C2, All CAN Device DTCs

CANbus Circuit OK Go to Step A2, Single CAN Device DTC

CAN Hi Short Circuit Bat (+) All CAN Device DTCs Go to Step C3,

CANbus Circuit OK Go to Step A2, Single CAN Device DTC

CAN Lo STB ( ), No DTC Go to Step C2, No DTC

CAN Hi Short to 12/5 (+) No DTC CAN Lo Short Circuit Bat (+) All CAN Device DTCs Go to Step C3,

SINGLE DEVICE DTC

Fault is isolated to a SINGLE CANbus Connected Device and its Supply Connections

MULTIPLE DEVICE DTCs ALL DEVICE DTCs

Faults that affect some but not all CANbus Devices

Faults that affect all of the CANbus connected devices

Typically Open Circuits

Typically Short Circuits

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9030-20-153

Diagnostic Trouble Codes

Electrical System

TSP DBB 4 Wheel CAN Communication (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

) = Short Circuit

) = No DTC

Table 9030-20-5. Main Schematic Open Circuit – Termination Resistor/CAN Hi/CAN Lo/Key Switch Supply/Device Supply/ CAUSES A, B CAN Short to – Bat (

)/12volt Bat (+)/Shorted CAN Hi to CAN Lo/Device Failure CAUSES C, D, E

CAUSES A B C D E > ?

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Electrical System

Diagnostic Trouble Codes

TSP DBB 4 Wheel CAN Communication (Cont) CONNECTORS CANbus DEVICES

Table 9030-20-6. Device Connectors

VSM Cxx 1 and Cxx 2

Main Seat Cxx 52 and 54

Impact Device Cxx 148

Service Connector Cxx 28

Traction/Pump Controller Cxx 3, 4, and 5

MLM Cxx 52

Display Harness Cxx 135

Display Cxx 20

CAUSE A CAN Hi/CAN Lo Single Device DTC (Black X) vs Multiple DTCs (Red X)

1, 2, and 3 are examples of possible Causes 1. Single DTC

Indicated Device Connections/Device Fail

1. Single DTC above 2. Multiple DTCs

Step A1

Open Circuit on Device Supply (+) or Bat ( ) or Open Circuit on Sub Circuit Wiring

Fault Log

DTC/Device closest to VSM

Step A3

= Open circuit between DTC Device and VSM

3. All DTCs above

Open Circuit on Device Supply (+) Bat ( )

3. All DTCs above

Open/Short Circuit on VSM CANbus

Step B3

= Supply Failure/Open Circuit Main Supply Circuit

= Open Circuit

Step B3 – Short Circuit

Step A3

Cause C

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9030-20-155

Diagnostic Trouble Codes

Electrical System

TSP DBB 4 Wheel CAN Communication (Cont) STEP A1 CAN Hi/ CAN Lo Single Device DTC - Locate Device

1. Example Only

Single DTC

Indicated Device Connections/Device Fail

STEP A2

Power ON

STEP A3 Single Device DTC Open Circuit Supply Voltage

1. Locate Device

Check connection

Not OK, Go to 4

2. = 0 Volts = Open Circuit Supply/(+) or ( ) 3. > Supply Volts

Go to 4

1. Connection OK

Go to 2

2. =Supply Volts = OK

Check for Shorts to a higher supply source

Repair

Step B1

Cause D as CAN Device may be damaged

4. Reference Main Schematic - Find/Repair Open Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Voltage Step A4

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Electrical System

Diagnostic Trouble Codes

TSP DBB 4 Wheel CAN Communication (Cont) STEP A4

Retest - Power OFF Power ON

Fault corrected

Is fault DTC gone? YES NO

Continue operation

CAUSE B

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Power OFF

STEP B1 Single Device DTC Open Circuit CAN Hi or CAN Lo

Locate Device

Check Connection

Device with Termination Resistor 1. > 120

Connections OK

Not OK, Go to 6 Locate and Disconnect

= Open Circuit Termination Resistor

Go to 5

Reconnect

See Device Connectors 1. ≈ 120

= OK Go to 2

2. = ∞

= Open Circuit

Go to 5

2. ≈ 0

= OK Go to 3

3. = ∞

= Open Circuit

Go to 6

3. ≈ 0

= OK Reconnect Device

4. Motor Controller ID Loop(s) = ∞ 5. Replace Device

= Open Circuit

Go to 6

Go to Step B2

4. Reference Main Schematic ≈ 0

= OK Reconnect Device

Cause D

6. Find/Repair Open Circuit, See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

Recheck

Reconnect

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9030-20-157

Diagnostic Trouble Codes

Electrical System

TSP DBB 4 Wheel CAN Communication (Cont) STEP B2

Reconnect Battery

Retest - Power ON

Is fault DTC gone? YES

NO

Fault corrected Continue operation

STEP B3

Power OFF

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

STEP B4 Multi CAN Device DTCs Display > Open Circuit CAN Hi to CAN Lo

Example Only

Multiple DTCs

Fault Log

DTC/Device closet to VSM

Open circuit is between DTC Device and VSM

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Electrical System

Diagnostic Trouble Codes

TSP DBB 4 Wheel CAN Communication (Cont) STEP B5 Multi Device DTCs Open Circuit CAN Hi or CAN Lo

The above is an Example Only Disconnect VSM CPS1 > 60

to ∞

Measure

See Device Connectors ≈0

= CAN Hi/Lo Open Circuit

Cause C

≈ 60

= OK

Cause C

4. Find/Repair Short Circuit, See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Retest

Recheck

STEP B6

The above is an Example Only Locate Device to right or Left of Indicated Open Circuit 1. ∞

= CAN Hi Open Circuit

Go to 3

1. ≈0

= OK Cause C

2. ∞

= CAN Hi Open Circuit

Go to 3

2. ≈0

= OK Cause C Reconnect

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9030-20-159

Diagnostic Trouble Codes

Electrical System

TSP DBB 4 Wheel CAN Communication (Cont) CAUSE C All CAN Device DTCs Displayed > CAN Hi/CAN Lo Short Circuit together/Supply (+) or (

All DTCs

Open Circuit to VSM

)

Step B5

All DTCs

Short Circuit CAN Hi to CAN Lo

All DTCs

Short Circuit CAN Hi to (-) Supply Sources

Step C1 Step C2

All DTCs

Short Circuit CAN Lo to (+) Supply Sources

Step C3 No DTCs

No DTCs

Short Circuit CAN Lo to (–) Supply Sources Short Circuit CAN Hi to (+) Supplies (5, 12 volt)

STEP C1 All Device DTCs Short Circuit CAN Hi to CAN Lo

Locate Service Connection 1. = 0

Measure

CAN Hi/Lo Short Circuit

Go to 2

See Device Connectors 1. ≈ 60

= OK

Step C2

2. Inspect easily Accessible Harness Areas for Insulation Damage then Inaccessible Harness Areas. Focus on Bend Edges and Pinch Points, 3. Find/Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Retest

Reconnect

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Electrical System

Diagnostic Trouble Codes

TSP DBB 4 Wheel CAN Communication (Cont) STEP C2 All Device DTCs Short Circuit CAN Hi to Bat (

) CAN Lo to Bat (

) will not Produce a DTC

1. 0

= CAN Hi Short Circuit. Go to 3

1. > 50K

= OK, Go to 3

2. 0

= CAN Lo Short Circuit. Go to 3

2. > 50K

= OK, Go to 3

3. Find/Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Retest, Step C5

Reconnect

STEP C3 Multiple CAN Device DTCs Displayed > (+) Supply Short Circuit to CAN Hi or CAN Lo

All DTCs

Short Circuit CAN Lo to (+) Supply Sources.

All DTCs

Short Circuit CAN Hi to (+) Supply Sources. No DTCs for a Short to (+)12 Volts or (+) 5 Volts

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9030-20-161

Diagnostic Trouble Codes

Electrical System

TSP DBB 4 Wheel CAN Communication (Cont) STEP C4 All Device DTCs Short Circuit Supply (+) to CAN Hi or CAN Lo

1. A, B, C, D, and E = 0

= CAN Hi Short Circuit, Go to 3

1. A, B, C, D, and E > 50K

= OK

2. A, B, C, D, and E = 0

= CAN Lo Short Circuit, Go to 3

2. A, B, C, D, and E > 50K

=OK

3. Find/Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Recheck Retest

Reconnect

STEP C5

Reconnect Battery

Retest - Power ON

Go to

Is DTC gone? YES NO

Fault corrected Continue operation

Install New CAN Device

Power ON

CAUSE D

Disconnect Battery To Replace Motor Controller

Power OFF

Disconnect CAN Device Do Not Discard

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Electrical System

Diagnostic Trouble Codes

TSP DBB 4 Wheel CAN Communication (Cont) STEP D1

Fault DTC gone

Old device faulty

Resume operation

Fault DTC present

Old Device OK/Reinstall Old Device

CAUSE E

Power OFF

Inspect VSM Connections

Go to Step E1

Not OK Correct/Repair

Go to Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation

NO

END FAULT

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9030-20-163

Diagnostic Trouble Codes

Electrical System

TSP MLM Failure

FAULT CODES:

QUICK CHECK

21830

21836

DTC 21830

DTC 21836

MLM EEPROM Write Error

MLM Sensor 3 Out of Range

21834

21837

DTC 21834

DTC 21837

MLM Sensor 1 Out of Range

MLM Sensor 4 Out of Range

21835

25344

DTC 21835

DTC 25344

MLM Sensor 2 Out of Range

MLM Checksum Error

X = Open Circuit/Fail

) = Short Circuit

DTC 21834

MLM Sensor 1 Out of Range

Cause D

DTC 21835

MLM Sensor 2 Out of Range

Cause D

DTC 21836

MLM Sensor 3 Out of Range

Cause D

DTC 21837

MLM Sensor 4 Out of Range

Cause D

DTC 25344

MLM Checksum Error

DTC 33034 Display

Cause A

DTC 21830

MLM EEPROM Write Error

DTC 33034 Display

Cause A

Check 1

Push in Emergency Stop

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Release Emergency Stop

FAULT LOG CODE Review - Go to Display Menu

Enter Service Password

Diagnostic

FAULT LOGs

VSM/MLM Fault Logs

View all VSM/MLM DTCs

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Electrical System

Diagnostic Trouble Codes

TSP MLM Failure (Cont)

" All VSM/MLM DTCs

Erase all VSM/MLM DTCs

( Exit Fault Log

Power OFF

Check 2

Push in Emergency Stop

Enter Service Password

" VSM/MLM DTCs

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Diagnostic

FAULT LOGs

Wait 30 seconds

VSM/MLM Fault Logs

Compare VSM/MLM DTCs Check 1 & 2

Release Emergency Stop

View all VSM/MLM DTCs

Erase all VSM/MLM DTCs

MLM 21834, 21835, 21836, & 21837

Power OFF

Cause D

33034 VSM DTC Only

Power OFF

Cause A

Exit Fault Log

No DTCs

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9030-20-165

Diagnostic Trouble Codes

Electrical System

TSP MLM Failure (Cont)

No Fault

Resume Operation

CAUSE A

Table 9030-20-7. Main Schematic

STEP A1 MLM Open Circuit Supply Voltage

1. Locate Device

Check Connections

2. =0 Volts = Open Circuit 3. > Supply Volts

Not OK Go to 4

Supply/(+) or ( )

Go to 4

Go to 2

2. = Supply Volts= OK

Check for Shorts to a Higher Supply Source

4. Reference Table 9030-20-7, Page 9030-20-166 2200 YRM 1369 ReCheck Voltage

1. Connections OK

Repair

Step A2

Cause D as MLM may be damaged.

- Find/Repair OPEN Circuit See /Electrical System 2200 YRM 1337Electrical System

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Electrical System

Diagnostic Trouble Codes

TSP MLM Failure (Cont) STEP A2 MLM Open Circuit CAN Hi/CAN Lo

1. Locate Device 2. > 60

Check Connections

= Open Circuit

Not OK Go to 4

CAN Hi/CAN Lo

Go to 4

3. Reference Table 9030-20-7, Page 9030-20-166 System 2200 YRM 1369 Go to 4 4. ReCheck

1. Connections OK

Go to 2

2. CAN Hi/CAN Lo Connections = OK

Cause D

- Find/Repair OPEN Circuit See /Electrical System 2200 YRM 1337Electrical

Repeat Check 2

CAUSE B Not Applicable

CAUSE C Not Applicable

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9030-20-167

Diagnostic Trouble Codes

Electrical System

TSP MLM Failure (Cont) CAUSE D

Power OFF 1369

Remove and Replace MLM PCB Cassette Assembly

Check Replacement MLM

Version

See Label Information

See /Electrical System 2200 YRM 1337Electrical System 2200 YRM

Step D2

STEP D1

1. Go to TRD/Axcess Online /Software. Replacement Cassette Software Version the Latest Version 2. NO

Download the latest Application

3. YES

Test New Installation

Install on truck

See 4

Step D2

4. WARNING: Keyswitch must be OFF during reprogramming

STEP D2

Power ON

? DTCs gone

DTCs Still Present

Original MLM Cassette faulty

Resume operation

Original MLM Cassette OK/Reinstall Original Cassette

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Electrical System

Diagnostic Trouble Codes

TSP MLM Failure (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

END FAULT

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9030-20-169

Diagnostic Trouble Codes

Electrical System

TSP MLM Incorrect Lever Installed FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

4112

4114

4116

DTC 4112

DTC 4114

DTC 4116

Incorrect Lever 1 Installed

Incorrect Lever 3 Installed

Incorrect Lever 5 Installed

4113

4115

DTC 4113

DTC 4115

Incorrect Lever 2 Installed

Incorrect Lever 4 Installed

) = Short Circuit

Check 1 Is Truck Lever Hardware Configuration Correct for the Repair Function(s)? Standard

Remove Lever(s)

Dual Function

Clamp

Monentary

(RTST)

Check Base Information

If Incorrect Install Correct Lever(s) Check 2 ?DTC for Lever 1 or Lever 2 Standard Lever Installation

Enter Service Password Reset Timer to Zero

Truck Setup

Review RTST Setup Procedures

Timer should be set to zero?

Truck Setup

RTST

? Timer Value = 0 for Standard Levers

See Display Menu Flowchart for next step

Check 3

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Electrical System

Diagnostic Trouble Codes

TSP MLM Incorrect Lever Installed (Cont) Push in Emergency Stop

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Release Emergency Stop

DTC FAULT LOG CODE Review - Go to Display Menu

Enter Service Password

Erase all VSM/MLM DTCs Same DTCs Return

Diagnostic

FAULT LOGs

Exit Fault Log

VSM/MLM Fault Logs

Power OFF/Power ON

Configuration File Incorrect

View all VSM/MLM DTCs

No DTCs

Resume Operation

Go to Cause E

CAUSE A Not Applicable

CAUSE B Not Applicable

CAUSE C Not Applicable

CAUSE D Not Applicable

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9030-20-171

Diagnostic Trouble Codes

Electrical System

TSP MLM Incorrect Lever Installed (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

END FAULT

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Electrical System

Diagnostic Trouble Codes

TSP VSM 12 Volts Supply OORL/OORH 13060

13061

DTC 13060

DTC 13061

VSM 12V OORL

VSM 12V OORH

FAULT CODES:

Power OFF

Wait 30 seconds

Power ON

POSSIBLE CAUSES

Fault remains. Service required. Go to Cause A.

X = Open Circuit/Fail

No fault

Resume operation

) = Short Circuit

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9030-20-173

Diagnostic Trouble Codes

Electrical System

TSP VSM 12 Volts Supply OORL/OORH (Cont) DBB/CBB 4 WHEEL VSM 12 VOLT SUPPLY

CAUSES A B C D E > ?

The addition of Non Approved 12 Volt Devices other than those listed on the schematics may cause an OORL condition

WARNING No Display Fault Code will be visible for a Short To Battery(+) [STB(+)] OORH condition as the Display will be Inoperative For a STB (+) Fault Codes will only be visible on the PC Service Tool Any VSM 12 volt powered Device that is turned on, will be damaged by a STB(+) condition, except for the Display All VSM 12 volt powered devices will need to be checked for correct operation and probably replaced

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Electrical System

Diagnostic Trouble Codes

TSP VSM 12 Volts Supply OORL/OORH (Cont) POSSIBLE CAUSES CBB 3 WHEEL VSM 12 VOLT SUPPLY

X = Open Circuit/Fail

) = Short Circuit

CAUSES A B C D E > ?

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9030-20-175

Diagnostic Trouble Codes

Electrical System

TSP VSM 12 Volts Supply OORL/OORH (Cont) CONNECTORS

Table 9030-20-8. Device Connectors

VSM Cxx 1 & 2

Hydraulic Level Cxx 70

Cxx 94 & 156

Display Cxx 20 &135

MLM Cxx 52

Cxx 95 & 157

Impact Device Cxx 148

CAUSE A Not Applicable

CAUSE B Not Applicable

CAUSE C

Power OFF

Disconnect Connector Cxx 135 and Install Breakout

Go to Step C1

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Electrical System

Diagnostic Trouble Codes

TSP VSM 12 Volts Supply OORL/OORH (Cont) STEP C1

1. ≈ 0 Volts

UNSWITCHED VOLTAGES

Step C4

2. ≈ 12 Volts

Power ON

3. ≈ Bat Volts = Short Circuit to Unswitched Bat (+)

Go to 2

Go to 4

4. Find/Repair Short Circuit, See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 ReCheck Voltage Reconnect Go to 5 5. Check correct operation of all 12 volt Devices except Display

STEP C2

Cause D

SWITCHED VOLTAGES

1. ≈ 12 Volts

≈ 12 Volts

2. ≈ Bat Volts = Short Circuit to Switch Bat (+)

Step C3, Cause C

Go to 3

3. Find/Repair Short Circuit, See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Reconnect Go to 4 ReCheck Voltage 4. Check correct operation of all 12 volt Devices except Display

Cause D

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9030-20-177

Diagnostic Trouble Codes

Electrical System

TSP VSM 12 Volts Supply OORL/OORH (Cont) STEP C3

1. Disconnect VSM CPS1 2. ≈ 12 Volts = Short Circuit

DC/DC 12 Volts (+), Go to 3

3. Find/Repair Short Circuit, See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 ReCheck Voltage Fault Remains Reconnect Go to 4 Check correct operation of all 12 volt Devices except Display

Cause D

STEP C4 OORL

1. ≈ 0 Volts = Short Circuit

Bat (-)

Find/Repair Short Circuit

Go to 2

2. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 ReCheck Voltage Fault Remains Reconnect Cxx 135 Cause D

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Electrical System

Diagnostic Trouble Codes

TSP VSM 12 Volts Supply OORL/OORH (Cont) STEP C5 OORL – No 12 volt Device Operation

1. ≈ 0 Volts = No 12 volt Device operation

No Fault Code

This will not Cause a Fault Code

2. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 ReCheck Voltage Fault Remains Reconnect Cxx 135 Cause D

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9030-20-179

Diagnostic Trouble Codes

Electrical System

TSP VSM 12 Volts Supply OORL/OORH (Cont) CAUSE D

1. Shorted Devices that are switched on by a control device will not cause a problem until operated by the control device. E,g.. Motor Controller Fans 2. 3 Wheel Fans are not supplied with 12 volts 3. Only approved 12 volt devices are allowed to be connected to this supply

STEP D1

Power OFF

Disconnect 12 volt Device

Do Not Discard

Go to Step D2, Cause D

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Electrical System

Diagnostic Trouble Codes

TSP VSM 12 Volts Supply OORL/OORH (Cont) STEP D2

12 Volt Fault DTC gone

Original Fault DTC present

Old device faulty

Old device faulty New Device

Install

Old Device OK/Reinstall Old Device

Resume operation

Go to Next Device, Repeat Cause D All Devices Tested OK, go to Cause E

CAUSE E

Power OFF

Inspect VSM Connections

Go to Step E1.

Not OK Correct/Repair

Go to Step E1.

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-181

Diagnostic Trouble Codes

Electrical System

TSP Display Internal Failure 22032

12935

22531

DTC 22032

DTC 12935

DTC 22531

22538

DTC 22538

Display EEPROM Checksum Error

Display Internal LCD Backlight

Display

Display Button 7

Arrow

8705

22539 22532

22033

DTC 22033

DTC 8705

DTC 22532

DTC 22539

Display Internal LCD Heater

Display Button 1

Display Button 8

Display Cell Write Error 12936

22540 22533

33056

DTC 33056

FAULT CODES:

DTC 12936

DTC 22533

DTC 22540

Display Internal LCD Heater

Display Button 2

Display Button 9

Display Internal CAN Failure 12937

22541 22534

33057

DTC 33057 Display Communications Error with VSM

DTC 12937

DTC 22534

DTC 22541

Display Internal LCD Heater

Display Button 3

Display Button 0

22528 22535

8704

DTC 22528

DTC 22535

Display Button *

Display Button 4

DTC 8704 Display Internal LCD Backlight

22529 22536

12934

DTC 22529

DTC 22536

Display Button #

Display Button 5

DTC 12934 Display Internal LCD Backlight

22530 22537

DTC 22530

DTC 22537

Display

Display Button 6

Arrow

FAULT LOG CODE Review – Go To Display Review QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Table 9030-20-9. Display Internal Failure Fault DTCs DTC 22032

Display EEPROM Checksum Error

Cause D

DTC 22033

Display Cell Write Error

Cause D

DTC 33056

Display Internal CAN Failure

Cause D

DTC 33057

Display Communications Error with VSM

DTC 8704

Display Internal LCD Backlight

STB ( )/Current OORH

Cause D

DTC 12934

Display Internal LCD Backlight

STB (+)

Cause D

DTC 12935

Display Internal LCD Backlight

Open Circuit

Cause D

DTC 8705

Display Internal LCD Heater

STB ( )/Current OORH

Cause D

DTC 12936

Display Internal LCD Heater

STB (+)

Cause D

DTC 12937

Display Internal LCD Heater

Open Circuit

Cause D

DTC 22528

Display Button *

Button Stuck

Cause D

DTC 22529

Display Button #

Button Stuck

Cause D

DTC 22530

Display

Button Stuck

Cause D

DTC 22531

Display

Button Stuck

Cause D

DTC 22532

Display Button 1

Button Stuck

Cause D

DTC 22533

Display Button 2

Button Stuck

Cause D

DTC 22534

Display Button 3

Button Stuck

Cause D

DTC 22535

Display Button 4

Button Stuck

Cause D

DTC 22536

Display Button 5

Button Stuck

Cause D

Arrow Arrow

See CAN Communication TSPs

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Electrical System

Diagnostic Trouble Codes

TSP Display Internal Failure (Cont) Table 9030-20-9. Display Internal Failure Fault DTCs (Continued) DTC 22537

Display Button 6

DTC 33034 Display

Cause D

DTC 22538

Display Button 7

Button Stuck

Cause D

DTC 22539

Display Button 8

Button Stuck

Cause D

DTC 22540

Display Button 9

Button Stuck

Cause D

DTC 22541

Display Button 0

Button Stuck

Cause D

Note: No Display Visible

Use PC Service Tool

Note: No DTC on PC Service Tool

Cause D

Possible Key Switch Failure

Cause D

QUICK CHECK (Continued) Check 1

Power OFF

Wait 30 seconds

Fault remains Service required Go to Check 2

Power ON

No fault

Resume operation

QUICK CHECK (Continued) Check 2

Disconnect Battery

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

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9030-20-183

Diagnostic Trouble Codes

Electrical System

TSP Display Internal Failure (Cont) Check 2

Fault Remains Service Required

Power ON

No Fault

Resume Operation

QUICK CHECK (Continued) Check 3

Enter SERVICE Password

Diagnostics

all Display DTCs

FAULT LOGs

Erase all Display DTCs

Display FAULT LOGs

Exit Fault Log

View all Display DTCs

Power OFF

Cause D

CAUSE A Not Applicable

CAUSE B Not Applicable

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Electrical System

Diagnostic Trouble Codes

TSP Display Internal Failure (Cont) CAUSE C Not Applicable

CAUSE D

1. No Display/No PC DTCs

Possible Keyswitch Failure

2. Keyswitch Mechanical Operation Indicates Binding/No Turn 3. YES

Replace Keyswitch Barrel

Step D1

4. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

STEP D1

Retest - Power ON

Step D2

Does Display Turn On? Is DTC gone? YES NO

Fault corrected

Continue operation.

STEP D2

Power OFF

Disconnect Display

Do not Discard

Step D3

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9030-20-185

Diagnostic Trouble Codes

Electrical System

TSP Display Internal Failure (Cont) STEP D3

1. Download the latest Display Application Version

Install NEW Display

Install NEW Application Software

Go to 2

2. See Axcess Online, Software Resources for your truck, (Installing Application Software)

Power ON

DTC Gone

Original Display Faulty

New DTC Present

Return Faulty Display

Dealer

Factory

Failure Analysis

Resume Operation

DTC TSP

?? Reprogramming

END FAULT

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Electrical System

Diagnostic Trouble Codes

TSP Display Failure – Keyswitch Relay Output 9041

12941

DTC 9041

DTC 12941

Display Keyswitch Output

12940

DTC 12940

Display Keyswitch Output FAULT CODES:

FAULT LOG CODE Review – Go To Display Review QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

DTC 9041

Display Keyswitch Output

STB ( )/Current OORH

Cause C

DTC 12940

Display Keyswitch Output

STB (+)

Cause C

DTC 12941

Display Keyswitch Output

Open Circuit

Cause C

Note: No Display Visible

Use PC Service Tool

Note: No DTC on PC Service Tool

Cause D

Possible Key Switch Failure

Cause D

QUICK CHECK (Continued) Check 1

Power OFF

Wait 30 seconds

Fault remains Service required Go to Check 2

Power ON

No fault

Resume operation

QUICK CHECK (Continued) Check 2

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9030-20-187

Diagnostic Trouble Codes

Electrical System

TSP Display Failure – Keyswitch Relay Output (Cont) Check 2 Disconnect Battery

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Fault Remains Service Required

Power ON

Reconnect Battery

No Fault

Resume Operation

QUICK CHECK (Continued) Check 3

Enter SERVICE Password

Diagnostics

all Display DTCs

FAULT LOGs

Erase all Display DTCs

Display FAULT LOGs

Exit Fault Log

View all Display DTCs

Power OFF

Cause D

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Electrical System

Diagnostic Trouble Codes

TSP Display Failure – Keyswitch Relay Output (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Display Cxx 20

Key Switch Relay Connector Cxx 208

Display Cxx 135

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9030-20-189

Diagnostic Trouble Codes

Electrical System

TSP Display Failure – Keyswitch Relay Output (Cont) CAUSE A DTC 12941 Key Switch Relay OC

Remove Display and Disconnect Display Connector 1. > 100

to ∞

= High Resistance/Open Circuit

2. < ≈60

to 0

= Short Circuit

Measure

Go to Step A2

Cause C

Go to 1 1. ≈80

= OK

Step A5

2. ≈80

= OK

Step A5

1. ≈80

= OK

Step A3

2. ≈80

= OK

Step A3

STEP A1

Remove 12 Volt Relay

Measure

Go to 1

1. > 100

to ∞

= High Resistance/Open Circuit

2. < ≈60

to 0

= Short Circuit

Go to 3

3. Relay Coil OPEN/SHORT Circuit

Replace Relay

ReCheck

Step A1

Reconnect Display

Step A4

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Electrical System

Diagnostic Trouble Codes

TSP Display Failure – Keyswitch Relay Output (Cont) STEP A2

Measure 1. ∞

Go to 1

= High Resistance/Open Circuit

1. ≈0

Go to 2

= OK

Step A4

2. Find/Repair OPEN Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Reconnect Step A4

ReCheck

Step A1

STEP A3

Retest - Power OFF Power ON

Step A4

Is fault DTC gone? YES NO

Fault corrected

Continue operation

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9030-20-191

Diagnostic Trouble Codes

Electrical System

TSP Display Failure – Keyswitch Relay Output (Cont) STEP A4

CAUTION Do not backprobe VSM connector if Breakout Connectors are available. See Step A6 for Alternative to 3. 1. Turn Key Switch ON 2. 0 Volts

Measure Volts at 1, 2, and 3

Open Circuit Fuse/Wiring/Relay Contacts

Go to 2 Go to 3

2. ≈ Bat (+) Volts = OK

Step A6

3. Find/Repair OPEN Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 A5 Reconnect Step A6

ReCheck Volts

Step

STEP A5

Turn Key Switch OFF 1. = ∞

Disconnect Relay and VSM CPS 2

Open Circuit Wiring

Go to 2

Measure

Go to 1 1. ≈ 0

= OK

Step A6

2. Find/Repair OPEN Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Reconnect Step A6

ReCheck

Step A1

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Electrical System

Diagnostic Trouble Codes

TSP Display Failure – Keyswitch Relay Output (Cont) STEP A6

Retest - Power OFF Power ON

Cause C

Is fault DTC gone? YES NO

Fault corrected

Continue operation

CAUSE B Not Applicable

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9030-20-193

Diagnostic Trouble Codes

Electrical System

TSP Display Failure – Keyswitch Relay Output (Cont) CAUSE C

1. Turn Key Switch OFF

Push Emergency Stop

2. ≈ Bat (+) Volts = Short to Unswitched Bat (+) 3. Release Emergency Stop

Remove Display and Disconnect Go to 6

Measure Volts

2. 0 Volts = OK

Go to 3

4. 0 Volts = OK

Step C1

Go to 2

Go to 4

4. ≈ 12 Volts = Short to VSM 12 Volt Supply

Go to 6

5. ≈ Bat (+) Volts = Short to Switched Bat (+)

Go to 6

6. Find/Repair Short Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

ReCheck Volts

Reconnect

STEP C1

1. Turn Key Switch OFF 2. < ≈60

= Short Circuit

Measure Go to 3

Go to 2 2. ≈ 80

= OK

Cause D

3. Find/Repair Short Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Cause D

ReCheck

Reconnect

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Electrical System

Diagnostic Trouble Codes

TSP Display Failure – Keyswitch Relay Output (Cont) CAUSE D

1. No Display/No PC DTCs

Possible Keyswitch Failure

2. Keyswitch Mechanical Operation Indicates Binding/No Turn 3. YES

Replace Keyswitch Barrel

Step D1

4. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

STEP D1

Retest - Power ON

Step D2

Does Display Turn On? Is DTC gone? YES NO

Fault corrected

Continue operation.

STEP D2

Power OFF

Disconnect Display

Do not Discard

Step D3

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9030-20-195

Diagnostic Trouble Codes

Electrical System

TSP Display Failure – Keyswitch Relay Output (Cont) STEP D3

1. Download the latest Display Application Version

Install NEW Display

Install NEW Application Software

Go to 2

2. See Axcess Online, Software Resources for your truck, (Installing Application Software)

Power ON

DTC Gone

Original Display Faulty

New DTC Present

Return Faulty Display

Dealer

Factory

Failure Analysis

Resume Operation

DTC TSP

?? Reprogramming

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Electrical System

Diagnostic Trouble Codes

TSP Display Failure – Keyswitch Relay Output (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Step E1.

Not OK Correct/Repair

Go to Step E1.

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is DTC gone?

NO

Fault corrected

Continue operation.

YES

END FAULT

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9030-20-197

Diagnostic Trouble Codes

Electrical System

TSP VSM Controller Check

FAULT CODES:

21760

21762

21764

21766

DTC 21760

DTC 21762

DTC 21764

DTC 21766

VSM BOOT_BLOCK Checksum failure

VSM APPLICATION_SOFTWARE Checksum failure/Error

VSM EEPROM Checksum failure/Error

VSM EEPROM Cell failure Write Error

21761

21792

DTC 21761

DTC 21792

CDF_Checksum_failure

VSM Serial Number Error

Wait 30 seconds

Power OFF

QUICK CHECK

Power ON

X = Open Circuit/Fail

Fault remains. No fault Service required. Go to Quick Check.

Resume operation

) = Short Circuit

Check 1

Disconnect Battery

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

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Electrical System

Diagnostic Trouble Codes

TSP VSM Controller Check (Cont)

Power ON

Fault remains, Service required

Go to Check 2

No fault

Resume operation

Check 2

Enter Service Password

all VSM DTCs

VSM Versions

Diagnostic

FAULT LOGs

Erase all VSM DTCs

VSM Fault Logs View all VSM DTCs

( Exit Fault Log

" Hardware/Software Versions ( Exit Versions

Go to next step

Truck Status

Power OFF

Go to Next Step

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9030-20-199

Diagnostic Trouble Codes

Electrical System

TSP VSM Controller Check (Cont) QUICK CHECK (Continued) DTCs 21792

Step E2 VSM has been installed from another truck

DTCs 21792

Step E2 Display has been installed from another truck

DTCs 21761

Step E4, Step E2

Reprogram CDF

DTCs 21762

Step E5, Step E2

Reprogram Application Software

DTCs 21760, 21764, 21766

Step E5, Step E2

Factory Issued VSM Required

STEP E2

Scroll to Password symbol

Press *

Enter 5 Digit Password

Press *

Scroll to Truck Serial #

? Displayed Serial Number = the Truck Serial Number?

YES

Scroll to Truck Symbol. Press *

Press *

NO Find/Replace with Correct VSM. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. Repair Complete. Step E3

Step E3

? Displayed Serial Number for VSM and Display are BLANK?

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9030-20-200

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Electrical System

Diagnostic Trouble Codes

TSP VSM Controller Check (Cont) STEP E3

Retest - Power ON

Is fault DTC gone? YES NO

Go to Step E4.

Fault corrected

Continue operation.

STEP E4

1. DTC 21761 2. Go to Axcess Online 3. Test

Step E7

Software

Download new CDF

Install on Truck

Go to 3

Resume Operation – Not OK Step E6

STEP E5

1. DTC 21761 2. Go to Axcess Online 3. Test

Step E7

Software

Download the latest Application Software

Install on Truck

Go to 3

Resume Operation – Not OK Step E6

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9030-20-201

Diagnostic Trouble Codes

Electrical System

TSP VSM Controller Check (Cont) STEP E6

DTCs 21760, 21762, 21764, and 21766 1. Replacement Approval –Contact Yale Resident Service. 2. Remove and replace faulty VSM with new VSM. See Electrical System 2200 YRM 1337 or Electrical System 2200 YRM 1369. 3. Return faulty VSM to dealer. 4. Retest new installed VSM. Go to Step E7.

STEP E7

Retest - Power ON

Go to Step E4.

Is DTC gone? NO YES

Fault corrected

Continue operation.

DTC LOGS: DTC logs should only be cleared once the data is " by the Service Tech. See Display Menu Flowchart – Clearing DTCs.

END FAULT

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Electrical System

Diagnostic Trouble Codes

TSP Display Failure – Temperature/Buzzer 12928

12929

12938

DTC 12928

DTC 12929

DTC 12938

Display Temperature Sensor (Freezer Option Only)

Display Buzzer Output

DTC 9040

Display Buzzer Output

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

12939

DTC 12939

9040

) = Short Circuit

) = No DTC

DTC 12928

Display Temperature Sensor (Freezer Option Only)

OORL Open Circuit

Cause A

DTC 12929

Display Temperature Sensor (Freezer Option Only)

OORH

Cause A

DTC 9040

Display Buzzer Output

STB ( )/Current OORH

Code Not Active

DTC 12938

Display Buzzer Output

STB (+)

Code Not Active

DTC 12939

Display Buzzer Output

Open Circuit

Code Not Active

QUICK CHECK (Continued) Check 1

Power OFF

Wait 30 seconds

Fault remains Service required Go to

Power ON

No fault

Resume operation

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9030-20-203

Diagnostic Trouble Codes

Electrical System

TSP Display Failure – Temperature/Buzzer (Cont) QUICK CHECK (Continued) FAULT LOG CODE Review – Go to Display Menu

Enter SERVICE Password

Diagnostics

all Display DTCs

POSSIBLE CAUSES

FAULT LOGs

Display FAULT LOGs

Erase all Display DTCs

X = Open Circuit/Fail

Exit Fault Log

) = Short Circuit

View all Display DTCs

Power OFF

) = No DTC

CAUSES A B C D > ?

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9030-20-204

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Electrical System

Diagnostic Trouble Codes

TSP Display Failure – Temperature/Buzzer (Cont) CAUSE A DTC 12929 Temperature Sensor OORH

Remove Display and Disconnect Temperature Sensor 1. > 5 volts = Short to

Measure Volts

Go to 2

Go to 1 1. < 5 volts = OK

Step A1

2. Find/Repair Short Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 ReCheck Cause A Reconnect Display Step A3

STEP A1 DTC 12928 Temperature Sensor STB (

) OORL

Disconnect connector 135

Go to 1

1. ≈0

Measure

= Short Circuit to Bat ( )

Go to 2

1. =∞

= OK

Step A2

2. Find/Repair Short Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 ReCheck Reconnect Step A3

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9030-20-205

Diagnostic Trouble Codes

Electrical System

TSP Display Failure – Temperature/Buzzer (Cont) STEP A2 DTC 12928 Temperature Sensor Open Circuit OORL

Remove Display and Disconnect Display Connector 1. =∞

= Open Circuit

Disconnect Temperature Sensor 1. ≈0

Go to 2

= OK

Measure

at 1 and 2

Go to 1

Cause D

2. Find/Repair OPEN Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 ReCheck Cause A Reconnect

STEP A3

Retest - Power OFF Power ON

Is fault DTC gone?

NO

YES

CAUSE B There are no active DTCs displayed for Buzzer Failure. Please refer to the Troubleshooting Electrical Symptoms for Diagnostics.

CAUSE C Not Applicable

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9030-20-206

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Electrical System

Diagnostic Trouble Codes

TSP Display Failure – Temperature/Buzzer (Cont) CAUSE D Device Failure NOTE: The Temperature Sensor is Only used on Freezer configured Displays.

NOTE: The Temperature Sensor is tied to the wiring Harness behind the Display.

NOTE: The Temperature Sensor is NOT RESISTIVE and cannot be analyzed using a DMM.

Power OFF

Remove Display

Disconnect sensor. Do not discard

Install new sensor.

Fault DTC gone

Original sensor faulty

Resume operation

Fault DTC present

Original sensor OK/Reinstall old sensor

Go to Step D1.

Power ON

STEP D1

Power OFF

Disconnect Display

Do not Discard

Step D2

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9030-20-207

Diagnostic Trouble Codes

Electrical System

TSP Display Failure – Temperature/Buzzer (Cont) STEP D2

1. Download the latest Display Application Version

Install NEW Display

Install NEW Application Software

Go to 2

2. See Axcess Online, Software Resources for your truck, (Installing Application Software)

STEP D3

Power ON

DTC Gone

Original Display Faulty

New DTC Present

Return Faulty Display

Dealer

Factory

Failure Analysis

Resume Operation

DTC TSP

?? Reprogramming

END FAULT

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Electrical System

Diagnostic Trouble Codes

TSP Contactor/Relay/Valve Coil Short to Battery Positive (STBP)

FAULT CODES:

Power OFF

9000

9012

9026

9036

DTC 9000

DTC 9012

DTC 9026

DTC 9036

Diverter Valve

Acc 2 Relay

Spare 1 Relay

2nd Contactor

9004

9016

9028

DTC 9004

DTC 9016

DTC 9028

E Hyd Enable

Forward Relay

Spare 2 Relay

9008

9020

9032

DTC 9008

DTC 9020

DTC 9032

Clamp Solenoid (Optional)

Reverse Relay

Main Contactor

Wait 30 seconds

Power ON

Fault remains. Service required. Go to Cause C.

No fault

Resume operation

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9030-20-209

Diagnostic Trouble Codes

Electrical System

TSP Contactor/Relay/Valve Coil Short to Battery Positive (STBP) (Cont) POSSIBLE CAUSES CONTACTOR/RELAY/VALVE COIL (STBP)

X = Open Circuit/Fail

) = Short Circuit

CAUSES A B C D E > ?

CAUSE A Not Applicable

CAUSE B Not Applicable

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Electrical System

Diagnostic Trouble Codes

TSP Contactor/Relay/Valve Coil Short to Battery Positive (STBP) (Cont) CAUSE C

Unplug/Disconnect Contactor/Relay/Valve Coil Indicated DTC Connection to VSM

Power OFF

STEP C1

UNSWITCHED VOLTAGES

NOTE: Short Circuit to Unswitched Bat (+) Contactor/Relay/Valve Coil Connection to VSM

Bat Volts = Short circuit

Find

≈ 0 Volts =

SHORT circuit.

Repair SHORT Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. See Schematic for Connection information

STEP C2

Power ON

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9030-20-211

Diagnostic Trouble Codes

Electrical System

TSP Contactor/Relay/Valve Coil Short to Battery Positive (STBP) (Cont) STEP C3

SWITCHED VOLTAGES

NOTE: Short Circuit to Switched Bat (+) – Contactor/Relay/Valve Coil Connection to VSM

Bat Volts = Short circuit

Find

SHORT circuit

≈ 0 Volts =

Repair SHORT Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. See Schematic for Connection information

STEP C4

Power OFF

Reconnect Contactor/Relay/Valve Coil Connections to VSM

CAUSE D Not Applicable

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Electrical System

Diagnostic Trouble Codes

TSP Contactor/Relay/Valve Coil Short to Battery Positive (STBP) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-213

Diagnostic Trouble Codes

Electrical System

TSP Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC)

FAULT CODES:

Power OFF

13352

13364

13376

13388

DTC 13352

DTC 13364

DTC 13376

DTC 13388

Diverter Valve

Acc 2 Relay

Spare 1 Relay

2nd Contactor

13356

13368

13380

DTC 13356

DTC 13368

DTC 13380

E Hyd Enable

Motion Relay

Spare 2 Relay

13360

13372

13384

DTC 13360

DTC 13372

DTC 13384

Acc 1 Relay

Reverse Relay

Main Contactor

Wait 30 seconds

Power ON

Fault remains. Service required. Go to Cause A.

No fault

Resume operation

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Electrical System

Diagnostic Trouble Codes

TSP Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC) (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

CONTACTOR/RELAY/VALVE COILS STBN/(OC)

) = Short Circuit

CAUSES A B C D E > ?

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9030-20-215

Diagnostic Trouble Codes

Electrical System

TSP Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC) (Cont) Relay/Coil Function

Coil Voltage

Coil Resistance ( )

Key Switch

Motion Direction

320

Reverse Direction

320

Brake Light

320

Diverter Valve

320

E Hyd Enable

320

Man Hyd Enable x 2

Clamp

CAUSE A NOTE: Prior to performing any checks, Service Technician should verify to see if the Motion relay option or Diverter valve option is activated. (See Truck Setup Display menu- Motion Alarm/Diverter Valve). If neither device is part of the truck hardware then the function should be TURNED OFF to prevent false DTC conditions.

Unplug/Disconnect Contactor/Relay/Valve Coil Indicated DTC Connection to VSM

Power OFF

STEP A1

CHECK RESISTANCE -

- OHMS

Open Circuit – Contactor/Relay/Valve Coil Connection to VSM

∞

= Open Circuit

Find

Open circuit

≈ Function K ≈0

= OK Go to Cause C

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

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Electrical System

Diagnostic Trouble Codes

TSP Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC) (Cont) CAUSE B

CHECK RESISTANCE -

- OHMS

NOTE: Open Circuit – Contactor/Relay/Valve Coil Connections to Coil

∞

= Open Circuit

Find

≈ xx

Open circuit

See Schematics =OK

Repair OPEN Circuit in wiring or Replace Open Circuit Coil/Relay See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. > xx

= Faulty Coil

Replace Coil

See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

STEP B1

CHECK RESISTANCE -

- OHMS

Open Circuit – Bat (+) Connections to Contactor/Relay/Valve Coil

∞

= Open Circuit

Find

≈0

Open circuit

= OK Go to Cause E

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

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9030-20-217

Diagnostic Trouble Codes

Electrical System

TSP Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC) (Cont) CAUSE C NOTE: STBN – Contactor/Relay/Valve Coil Connection to VSM

≈0

= Short Circuit

Find

Short circuit

≈ Function K

= OK Go to Cause E

Repair Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369.

STEP C1

Power OFF

Reconnect Contactor/Relay/Valve Coil Connections to VSM

CAUSE D Not Applicable

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Electrical System

Diagnostic Trouble Codes

TSP Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC) (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest – Power ON

NO Go to VSM Controller Check

Is DTC gone?

NO

Fault corrected

Continue operation.

YES

END FAULT

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9030-20-219

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Contactor Failure 21569

DTC 21569 Contactor Open 21570

DTC 21570 Contactor Closed

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? No Operation? POSSIBLE CAUSES DTC 21569 Contactor Open

Low Battery/Open Circuit Connections Go to 1, 2, and 3

Cause A

DTC 21570 Contactor Closed

Short Circuit Connections Go to 2 and 3

Cause C

DTC 21569/21570 Contactor Coil

Open/Short Circuit Connections Go to 2 and 3

Cause A/Cause C

1. Go to Battery OORH/OORL 2. Go to Contactor/Relay/Valve Coil Short to Battery Positive (STBP) 3. Go to Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC)

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9030-20-220

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Contactor Failure (Cont) Check 2

Disconnect Battery

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Power ON

Fault Remains Service Required

No Fault

Resume Operation

Check 4

Power ON

Go to Diagnostics

Battery/Supply

View Bat Value

Go to Display Menu Flowchart

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9030-20-221

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Contactor Failure (Cont) Check 5 Battery OORL NOTE: OOR Code is set if OOR condition is present for longer than 1 second. Battery Voltage 36

39.6

52.8

79.2

≈< OORL

≈ OORH

48.6

57.6

97.2

108

Nominal Fully Charged

Is battery voltage ≈ < OORL value for correct battery NO

Is Bat Voltage ≈< OORL value for Correct Battery

YES

Battery OORH/OORL

FAULT LOG Review - Go to Display Menu

Enter Service Password

Diagnostic

Diagnostics

FAULT LOGs

all Motor DTCs

Motor Fault Log(s)

( Exit Fault Log

View all Motor DTCs

Truck Status

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9030-20-222

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Contactor Failure (Cont)

Motor Versions

"Hardware/Software Versions ( Exit Versions

Power OFF

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9030-20-223

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Contactor Failure (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

MOTOR CONTROLLER CONTACTOR FAILURE

) = Short Circuit

X = No DTC

CAUSES A B C D E > ?

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9030-20-224

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Contactor Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

CAUSE A

Power OFF

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

STEP A1 For any Fault DTC

Locate Device

Inspect ALL Wiring/Connections

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9030-20-225

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Contactor Failure (Cont) STEP A2

1. Inspect Contactor Top and Bottom Contacts for Pitting/Corrosion/Dirt Build-Up

Go to 2

2. Replace Contactor if Pitting/Corrosion is Observed 3. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Check all Connections

Reconnect Battery

Go to 4

Step A3

STEP A3

Retest - Power ON

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

STEP A4

CHECK RESISTANCE -

Disconnect Battery and Sound Horn to Discharge Capacitors. YRM 1342 Set DMM to Lowest

- OHMS

Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100

Check Lead Resistance < 0.01

Note: If the Resistance is > 0.01

then record this as the Zero

Value

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Contactor Failure (Cont) STEP A5

CHECK RESISTANCE -

- OHMS

Contactor Open

1. >10

@ 25 °C (77 °F) = Faulty PTC

5 0

2. > Zero Value +0.01 = High Resistance 3. ∞

= Open Circuit

Cause C

Go to 5

4. Repeat 2 & 3 on other Motor Controllers

Go to 5

5. Find/Repair High Resistance Open Circuit

Go to 7

6. Replace PTC(s)

1. <10

= OK

Go to 2

2. ≈0

= OK

Go to 4

3. ≈0

= OK

Go to 4

Go to 7

7. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 8. Recheck

Reconnect

Test

Cause C

CAUSE B Not Applicable

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9030-20-227

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Contactor Failure (Cont) CAUSE C Contactor Closed

1. 0

= Shorted PTC/Welded Contacts

2. Disconnect PTC 3. ∞

Go to 2

1. >4

<10

= OK

Cause D

Recheck

= Shorted PTC Go to 4

4. Replace PTC(s)

= Welded Contacts

Go to 5

Go to 6

5. Replace Contactor

Go to 6

6. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 7. Recheck

Reconnect

Test

STEP C1

Retest - Power ON

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

CAUSE D

Power OFF

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

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9030-20-228

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Contactor Failure (Cont) STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

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9030-20-229

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Contactor Failure (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

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9030-20-230

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Capacitor Failure 12592

DTC 12592 Capacitor Charge

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? Function Failure/Reduced Performance/Uncommanded Continuous Operation? POSSIBLE CAUSES

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9030-20-231

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Capacitor Failure (Cont) 1. Motor Controller Connections/Wiring High Resistance?

Cause A

2. Motor Controller(s) Failure?

Cause D

Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

FAULT LOG Review - Go to Display Menu

Enter SERVICE Password

Diagnostic

FAULT LOGs

Motor Fault Log(s)

View all Motor DTCs

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9030-20-232

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Capacitor Failure (Cont)

all Motor DTCs

( Exit Fault Log

Truck Status

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection Motor Versions

"Hardware/Software Versions ( Exit Versions

Power OFF

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9030-20-233

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Capacitor Failure (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

MOTOR CONTROLLER CAPACITOR FAILURE

) = Short Circuit

) = No DTC

CAUSES A B C D E > ?

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9030-20-234

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Capacitor Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

CAUSE A

Power OFF

STEP A1 For any Fault DTC

Locate Device

Inspect ALL Wiring/Connections See

CAUSE B Not Applicable

CAUSE C Not Applicable

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9030-20-235

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Capacitor Failure (Cont) CAUSE D

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Capacitor Failure (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES NO

Fault corrected

Continue operation.

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is " by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

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9030-20-237

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Speed Sensor Failure 29456

DTC 29456 Sensor Fault

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

?No Traction/Hydraulic Operation? POSSIBLE CAUSES 1. Speed Sensor/Motor Controller Connections/Wiring? 2. Speed Sensor Failure? 3. Motor Controller(s) Failure ? 4. Motor Failure ?

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Speed Sensor Failure (Cont) Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

Check 4 FAULT LOG Review - Go to Display Menu

Enter Service Password

Diagnostic

FAULT LOGs

Motor Fault Log(s)

View all Motor DTCs

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9030-20-239

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Speed Sensor Failure (Cont)

all Motor DTCs

Motor Versions

( Exit Fault Log

Truck Status

"Hardware/Software Versions ( Exit Versions

Power OFF

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection Diagnostics Speed Sensor Analysis – Use to Validate Correct Sensor Operation after Repairs

NOTE: If Motor Operation is Disabled then no speed will be displayed

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9030-20-240

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Speed Sensor Failure (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

WHEEL MOTOR SPEED SENSOR FAILURE

) = Short Circuit

) = No DTC

CAUSES A B C D E > ?

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9030-20-241

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Speed Sensor Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

Speed Sensor Motor Connector Cxx 146, 152, and 153

CAUSE A

Power OFF

STEP A1 For any Fault DTC

Locate Device

Inspect ALL Wiring/Connections

Disconnect Cxx XXX as indicated from the Fault Logs

Power ON

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Speed Sensor Failure (Cont) STEP A2

CHECK VOLTAGE

Speed Sensor Supply

1. 0 Volts = Open/Short Circuit

Step A3

1 ≈ 12 Volts = OK

2. Bat Volts = Short to Bat (+)

Cause B

2. ≈ 12 Volts = OK

STEP A3

Power OFF

CHECK RESISTANCE -

Step A3 Step A3

Step A5 Step A5

- OHMS

Disconnect Cxx 3, 4, or 5 as indicated from the Fault Logs

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9030-20-243

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Speed Sensor Failure (Cont) STEP A4

CHECK RESISTANCE -

- OHMS

Speed Sensor Connections

1. 0

= Short Circuit

Go to 4

1≈∞

= OK

Go to 2

2. ∞

= Open Circuit

Go to 4

2. ≈ 0

= OK

Go to 3

3. ∞

= Open Circuit

Go to 4

3. ≈ 0

= OK

Cause B

4. Find/Repair Short/Open Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 5. Recheck

Reconnect

STEP A5

Use Display Diagnostics to validate

Test OK

CHECK RESISTANCE -

YES

Resume Operation No

Cause B

- OHMS

Speed Sensor Connections

1. ∞

= Open Circuit

Go to 3

1. ≈ 0

= OK

Go to 2

2. ∞

= Open Circuit

Go to 3

2. ≈ 0

= OK

Cause B

3. Find/Repair Open Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Recheck

Reconnect

Use Display Diagnostics to validate

Test OK

YES

Resume Operation No

Cause B

(continued on next page)

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9030-20-244

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Speed Sensor Failure (Cont) CAUSE B

CHECK RESISTANCE -

- OHMS

Speed Sensor Connections

1. 0

= Short Circuit

Go to 6

1. ≈ ∞

= OK

Go to 2

2. 0

= Short Circuit

Go to 6

2. ≈ ∞

= OK

Go to 3

3. 0

= Short Circuit

Go to 6

3. ≈ ∞

= OK

Go to 4

4. 0

= Short Circuit

Go to 6

4. ≈ ∞

= OK

Go to 5

5. 0

= Short Circuit

Go to 6

5. ≈ ∞

= OK

Cause C

6. Find/Repair Short Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 7. Recheck

Reconnect

Use Display Diagnostics to validate

Test OK

YES

Go to 7

Resume Operation No

Cause C

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9030-20-245

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Speed Sensor Failure (Cont) CAUSE C

CHECK RESISTANCE -

- OHMS

Sensor Failure

Power OFF

Remove/Replace Motor Speed Sensor

See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

Step C1

STEP C1

Power ON

DTCs Gone

Original Sensor Faulty

Resume Operation

DTCs Present

Original Sensor OK/Reinstall Original Sensor

Cause D

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9030-20-246

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Speed Sensor Failure (Cont) CAUSE D

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

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9030-20-247

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Speed Sensor Failure (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

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9030-20-248

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Speed Sensor Failure 25104

DTC 25104 Sensor Fault 29456

DTC 29456 Sensor Fault

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

?No Traction/Hydraulic Truck Operation? POSSIBLE CAUSES 1. Speed Sensor/Motor Controller Connections/Wiring? 2. Speed Sensor Failure? 3. Motor Controller(s) Failure ? 4. Motor Failure ?

WARNING The CBB Truck requires the removal of the battery to access the Controllers and Motors

(continued on next page)

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9030-20-249

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Speed Sensor Failure (Cont) Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

Check 4 FAULT LOG Review - Go to Display Menu

Enter Service Password

Diagnostic

FAULT LOGs

Motor Fault Log(s)

View all Motor DTCs

(continued on next page)

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9030-20-250

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Speed Sensor Failure (Cont)

all Motor DTCs

Motor Versions

( Exit Fault Log

Truck Status

"Hardware/Software Versions ( Exit Versions

Power OFF

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection Diagnostics Speed Sensor Analysis – Use to Validate Correct Sensor Operation after Repairs

NOTE: If Motor Operation is Disabled then no speed will be displayed

(continued on next page)

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9030-20-251

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Speed Sensor Failure (Cont) POSSIBLE CAUSES 1.5 – 2.0 TON CBB SCHEMATIC

X = Open Circuit/Fail

) = Short Circuit

) = No DTC

CAUSES A B C D E > ?

(continued on next page)

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9030-20-252

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Speed Sensor Failure (Cont) 2.2 – 3.5 TON DBB SCHEMATIC

CAUSES A B C D E > ?

(continued on next page)

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9030-20-253

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Speed Sensor Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

Speed Sensor Motor Connector Cxx 146, 152, and 153

CAUSE A

Power OFF

STEP A1 For any Fault DTC

Locate Device

Inspect ALL Wiring/Connections

Disconnect Cxx XXX as indicated from the Fault Logs

Power ON

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9030-20-254

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Speed Sensor Failure (Cont) STEP A2

CHECK VOLTAGE

Speed Sensor Supply

1. 0 Volts = Open/Short Circuit

Step A3

1 ≈ 12 Volts = OK

2. Bat Volts = Short to Bat (+)

Cause B

2. ≈ 12 Volts = OK

Step A3 Step A3

Step A5 Step A5

STEP A3

Power OFF

Disconnect Cxx 3, 4, or 5 as indicated from the Fault Logs

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9030-20-255

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Speed Sensor Failure (Cont) STEP A4

CHECK RESISTANCE -

- OHMS

Speed Sensor Connections

1. 0

= Short Circuit

Go to 4

1≈∞

= OK

Go to 2

2. ∞

= Open Circuit

Go to 4

2. ≈ 0

= OK

Go to 3

3. ∞

= Open Circuit

Go to 4

3. ≈ 0

= OK

Cause B

4. Find/Repair Short/Open Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 5. Recheck

Reconnect

STEP A5

Use Display Diagnostics to validate

Test OK

CHECK RESISTANCE -

YES

Resume Operation NO

Cause B

- OHMS

Speed Sensor Connections

1. ∞

= Open Circuit

Go to 3

1. ≈ 0

= OK

Go to 2

2. ∞

= Open Circuit

Go to 3

2. ≈ 0

= OK

Cause B

3. Find/Repair Open Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Recheck

Reconnect

Use Display Diagnostics to validate

Test OK

YES

Resume Operation NO

Cause B

(continued on next page)

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9030-20-256

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Speed Sensor Failure (Cont) CAUSE B

CHECK RESISTANCE -

- OHMS

Speed Sensor Connections

1. 0

= Short Circuit

Go to 6

1. ≈ ∞

= OK

Go to 2

2. 0

= Short Circuit

Go to 6

2. ≈ ∞

= OK

Go to 3

3. 0

= Short Circuit

Go to 6

3. ≈ ∞

= OK

Go to 4

4. 0

= Short Circuit

Go to 6

4. ≈ ∞

= OK

Go to 5

5. 0

= Short Circuit

Go to 6

5. ≈ ∞

= OK

Cause C

6. Find/Repair Short Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 7. Recheck

Reconnect

Use Display Diagnostics to validate

Test OK

YES

Go to 7

Resume Operation NO

Cause C

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9030-20-257

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Speed Sensor Failure (Cont) CAUSE C

CHECK RESISTANCE -

- OHMS

Sensor Failure

Power OFF

Remove/Replace Motor Speed Sensor

See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

Step C1

STEP C1

Power ON

DTCs Gone

Original Sensor Faulty

Resume Operation

DTCs Present

Original Sensor OK/Reinstall Original Sensor

Cause D

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9030-20-258

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Speed Sensor Failure (Cont) CAUSE D

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

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9030-20-259

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Speed Sensor Failure (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9030-20-260

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Auto Brake Failure 8786

DTC 8786 Brake Coil Shorted 12834

DTC 12834 Aux Driver Short to Bat (-) Brake Coil Open Circuit 12835

DTC 12835

FAULT CODES:

QUICK CHECK

Aux Driver Open Circuit Excess Current

X = Open Circuit/Fail

) = Short Circuit

Check 1

?Brake does not Release when Traction is Commanded? POSSIBLE CAUSES DTC 12834

Aux Driver Short to Bat (-) Brake Coil Open Circuit

DTC 12835

Aux Driver Open Circuit Excess Current

No Current/> 5 amps driver current

Cause A

DTC 8786

Brake Coil Shorted

> 5.3 amps driver current

Cause A

Driver Failure

Cause D

Motor Controllers Failure?

Cause A

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9030-20-261

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Auto Brake Failure (Cont) Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

Check 4 FAULT LOG Review - Go to Display Menu

Enter Service Password

Diagnostic

FAULT LOGs

Motor Fault Log(s)

View all Motor DTCs

(continued on next page)

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9030-20-262

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Auto Brake Failure (Cont)

all Motor DTCs

Motor Versions

( Exit Fault Log

Truck Status

"Hardware/Software Versions ( Exit Versions

Power OFF

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection Diagnostics Speed Sensor Analysis – Use to Validate Correct Sensor Operation after Repairs

Note: If Motor Operation is Disabled then no speed will be displayed

(continued on next page)

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9030-20-263

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Auto Brake Failure (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

WHEEL MOTOR AUTO BRAKE FAILURE

) = Short Circuit

X = No DTC

CAUSES A B C D E > ?

(continued on next page)

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9030-20-264

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Auto Brake Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

Auto Brake Motor Connectors Cxx 24 and 26

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9030-20-265

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Auto Brake Failure (Cont) CAUSE A For any Fault DTC

Locate Device

Inspect ALL Wiring/Connections

Disconnect Cxx and Cxx 3 or 4 as indicated from the Fault Logs

Power ON

STEP A1 Auto Brake Short Circuit to Bat (+)

1. Short to Bat (+)

Go to 2

1 0 Volts = OK

2. Short to Bat (+)

Go to 3

2. 0 Volts = OK

3. Recheck

Reconnect

Test

No DTCs

YES

Resume Operation No

Go to 2 Step A2

Step A2

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9030-20-266

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Auto Brake Failure (Cont) STEP A2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Power OFF

STEP A3

CHECK RESISTANCE -

- OHMS

Auto Brake Coil Open/Short Circuit

1. <15

> 45

= Faulty Coil

2. Replace Auto Brake 3. Recheck

Go to 2

1 >15

< 45

= OK Coil

Go to Step A4

See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

Reconnect

Test

No DTCs

YES

Resume Operation No

Step A4

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9030-20-267

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Auto Brake Failure (Cont) STEP A4

CHECK RESISTANCE -

- OHMS

Auto Brake Connections Open/Short Circuit

1. 0

= Short Circuit

Go to 4

1. ≈ ∞

= OK

Go to 2

2. ∞

= Open Circuit

Go to 4

2. ≈ 0

= OK

Go to 3

3. ∞

= Open Circuit

Go to 4

3. ≈ 0

= OK

Cause D

4. Find/Repair Short/Open Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 5. Recheck

Reconnect

Test

No DTCs

YES

Resume Operation No

Cause D

CAUSE B Not Applicable

CAUSE C Not Applicable

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9030-20-268

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Auto Brake Failure (Cont) CAUSE D

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Controller

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

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9030-20-269

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Auto Brake Failure (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9030-20-270

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Power Mosfet Failure 65513

DTC 65513 Power MOS Shorted

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? No Traction/Hydraulics Truck Operation ? Possible Causes Motor Controller(s) Failure ?

Cause D

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9030-20-271

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Power Mosfet Failure (Cont) Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

FAULT LOG Review - Go to Display Menu

Enter SERVICE Password

Diagnostic

FAULT LOGs

Motor Fault Log(s)

View all Motor DTCs

(continued on next page)

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9030-20-272

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Power Mosfet Failure (Cont)

all Motor DTCs

Motor Versions

( Exit Fault Log

Truck Status

"Hardware/Software Versions ( Exit Versions

Power OFF

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9030-20-273

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Power Mosfet Failure (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

MOTOR CONTROLLER POWER MOSFET FAILURE

) = Short Circuit

) = No DTC

CAUSES A B C D E > ?

(continued on next page)

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9030-20-274

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Power Mosfet Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

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9030-20-275

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Power Mosfet Failure (Cont) CAUSE A Not Applicable

CAUSE B Not Applicable

CAUSE C Not Applicable

CAUSE D

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

(continued on next page)

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9030-20-276

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Power Mosfet Failure (Cont) STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

STEP D3

Retest - Power ON

Is fault DTC gone? YES NO

Fault corrected

Continue operation.

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9030-20-277

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Power Mosfet Failure (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

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9030-20-278

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor/Motor Controller Failure 12576

DTC 12576 Motor Voltage Not OK

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? No Traction/Hydraulic Truck Operation ? POSSIBLE CAUSES Motor to Motor Controller Connections/Wiring

High Resistance?

Cause A

Motor Windings Failure Open Circuit?

Cause A

Motor Windings Short to Frame?

Cause C

Motor Controller(s) Failure?

Cause D

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9030-20-279

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor/Motor Controller Failure (Cont) Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

FAULT LOG Review - Go to Display Menu

Enter Service Password

Diagnostic

FAULT LOGs

Motor Fault Log(s)

View all Motor DTCs

(continued on next page)

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9030-20-280

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor/Motor Controller Failure (Cont)

all Motor DTCs

Motor Versions

( Exit Fault Log

Truck Status

"Hardware/Software Versions ( Exit Versions

Power OFF

NOTE: Fault Logs will indicate which Motor/Motor Controller has the Faulty Component/Connection

(continued on next page)

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9030-20-281

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor/Motor Controller Failure (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

MOTOR/MOTOR CONTROLLER FAILURE

) = Short Circuit

) = No DTC

CAUSES A B C D E > ?

(continued on next page)

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9030-20-282

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Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor/Motor Controller Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

CAUSE A

Power OFF

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

STEP A1

For any Fault DTC Locate Device Inspect ALL Wiring/Connections for Open Circuits/Corrosion/Bridging between adjacent Terminals

(continued on next page)

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9030-20-283

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor/Motor Controller Failure (Cont) STEP A2

1. Set DMM to Lowest

Check Lead Resistance <0.01

Note: If the Resistance is >0.01

then record this as the Zero

STEP A3

Value

Step A3

CHECK RESISTANCE -

- OHMS

Motor Coils

Disconnect Motor connections W, V, U on Motor System indicated in Fault Log 1. Measure

Go to 2

2. Measure

Go to 3

3. Measure

Go to 4

4. 1 ≠ 2 ≠ 3 = > 0.01 5. Motor Faulty

+ Zero Value

Go to 5

4. 1 = 2 = 3 < 0.01

+ Zero Value

Step A4

Replace Motor Go to 6

6. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 7. Recheck

Reconnect

Test

?DTCs? YES

Step A4

Resume Operation

(continued on next page)

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9030-20-284

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor/Motor Controller Failure (Cont) STEP A4

CHECK RESISTANCE -

- OHMS

Motor Coils

Disconnect Motor connections W, V, U on Controller 1. Measure

Go to 2

2. Measure

Go to 3

3. Measure

Go to 4

4. 1 ≠ 2 ≠ 3 > 0.01

+ Zero Value

5. Wiring/Connector(s) Faulty

Go to 5

4. 1 = 2 = 3 < 0.01

+ Zero Value

Cause C

Replace Go to 6

6. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 7. Recheck

Reconnect

Test

?DTCs? YES

Cause C

Resume Operation

CAUSE B Not Applicable

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9030-20-285

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor/Motor Controller Failure (Cont) CAUSE C Motor Windings to Motor Case

Measure

between Case and any Motor Terminal

1. < 500K

Go to 2

2. Short to Case

1. > 500K

Replace Motor

Cause D

Go to 3

3. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Recheck

Reconnect

Test

?DTCs? YES

Cause D

Resume Operation

CAUSE D

Power OFF

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

(continued on next page)

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9030-20-286

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor/Motor Controller Failure (Cont) STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

(continued on next page)

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9030-20-287

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor/Motor Controller Failure (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

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9030-20-288

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Failure 65280

DTC 65280 Controller Failure

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? Function Failure/Reduced Performance/Uncommanded Continuous Operation? POSSIBLE CAUSES

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9030-20-289

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Failure (Cont) 1. Motor Controller Connections/Wiring High Resistance?

Cause A

2. Motor Controller(s) Failure?

Cause D

Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

FAULT LOG Review - Go to Display Menu

Enter SERVICE Password

Diagnostic

FAULT LOGs

Motor Fault Log(s)

View all Motor DTCs

(continued on next page)

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9030-20-290

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Failure (Cont)

all Motor DTCs

( Exit Fault Log

Truck Status

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection Motor Versions

"Hardware/Software Versions ( Exit Versions

Power OFF

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9030-20-291

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Failure (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

MOTOR CONTROLLER CAPACITOR FAILURE

) = Short Circuit

) = No DTC

CAUSES A B C D E > ?

(continued on next page)

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9030-20-292

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

CAUSE A

Power OFF

STEP A1 For any Fault DTC

Locate Device

Inspect ALL Wiring/Connections See

CAUSE B Not Applicable

CAUSE C Not Applicable

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9030-20-293

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller Failure (Cont) CAUSE D

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

(continued on next page)

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9030-20-294

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller Failure (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES NO

Fault corrected

Continue operation.

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is " by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

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9030-20-295

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Failure 8976

DTC 8976 AC Current – Over Current 9024

DTC 9024 AC Current – Short Circuit

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? No Traction/Hydraulic Truck Operation ? POSSIBLE CAUSES Motor to Motor Controller Connections/Wiring

High Resistance?

Cause A

Motor Windings Failure Open Circuit?

Cause A

Motor Windings Short to Frame?

Cause C

Motor Controller(s) Failure?

Cause D

WARNING The CBB Truck requires the removal of the battery to access the Controllers and Motors

(continued on next page)

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9030-20-296

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor/Motor Controller Failure (Cont) Check 2

Disconnect Battery

Sound Horn to Discharge Capacitors

Wait 30 seconds

Reconnect Battery

Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

FAULT LOG Review - Go to Display Menu

Enter Service Password

Diagnostic

FAULT LOGs

Motor Fault Log(s)

View all Motor DTCs

(continued on next page)

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9030-20-297

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Failure (Cont) "

all Motor DTCs

Motor Versions

( Exit Fault Log

Truck Status

"Hardware/Software Versions ( Exit Versions

Power OFF

NOTE: Fault Logs will indicate which Motor/Motor Controller has the Faulty Component/Connection

(continued on next page)

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9030-20-298

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor/Motor Controller Failure (Cont) POSSIBLE CAUSES 1.5 – 2.0 TON CBB SCHEMATIC

X = Open Circuit/Fail

) = Short Circuit

) = No DTC

CAUSES A B C D E > ?

(continued on next page)

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9030-20-299

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Failure (Cont) 2.2 – 3.0 TON DBB SCHEMATIC

CAUSES A B C D E > ?

(continued on next page)

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9030-20-300

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor/Motor Controller Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

CAUSE A

Power OFF

Disconnect Battery

Sound Horn to Discharge Capacitors

STEP A1

For any Fault DTC Locate Device Inspect ALL Wiring/Connections for Open Circuits/Corrosion/Bridging between adjacent Terminals

(continued on next page)

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9030-20-301

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Failure (Cont) STEP A2

1. Set DMM to Lowest

Check Lead Resistance <0.01

Note: If the Resistance is >0.01

then record this as the Zero

STEP A3

Value

Step A3

CHECK RESISTANCE -

- OHMS

Motor Coils

Disconnect Motor connections W, V, U on Motor System indicated in Fault Log 1. Measure

Go to 2

2. Measure

Go to 3

3. Measure

Go to 4

4. 1 ≠ 2 ≠ 3 = > 0.01 5. Motor Faulty

+ Zero Value

Go to 5

4. 1 = 2 = 3 < 0.01

Cause B

Replace Motor Go to 6

6. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 7. Recheck

+ Zero Value

Reconnect

Test

?DTCs? YES

Cause B

Go to 7

Resume Operation

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9030-20-302

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor/Motor Controller Failure (Cont) CAUSE B

CHECK RESISTANCE -

- OHMS

Motor/Controller Connections

Disconnect Motor connections W, V, U on Controller 1. Measure

Go to 2

2. Measure

Go to 3

3. Measure

Go to 4

4. 1./2./3. 0

Go to 5

5. Wiring/Connector(s) Faulty

4. 1./2./3. ∞ Replace Go to 6

6. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 7. Recheck

Reconnect

Cause C

Test

?DTCs? YES

Cause C

Go to 7

Resume Operation

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9030-20-303

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Failure (Cont) CAUSE C Motor Windings to Motor Case

Measure

between Case and any Motor Terminal

1. < 500K

Go to 2

2. Short to Case

1. > 500K

Replace Motor

Go to 3

3. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Recheck

Reconnect

Test

Cause D

?DTCs? YES

Cause D

Go to 4

Resume Operation

CAUSE D

Power OFF

Disconnect Battery

Sound Horn to Discharge Capacitors

(continued on next page)

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9030-20-304

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor/Motor Controller Failure (Cont) STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

(continued on next page)

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9030-20-305

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Failure (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9030-20-306

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller CAN Communication Failure 65527

DTC 65527 No CAN Communication

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? No Traction/Hydraulic Truck Operation ? POSSIBLE CAUSES Motor Controller Connections/Wiring Open/Short Circuit Motor Controller(s) Failure?

A955 – G807 CAN Communication Failure Cause D

Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

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9030-20-307

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller CAN Communication Failure (Cont) Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

FAULT LOG Review - Go to Display Menu

Enter Service Password

all Motor DTCs

Diagnostic

FAULT LOGs

( Exit Fault Log

Motor Fault Log(s)

View all Motor DTCs

Truck Status

(continued on next page)

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9030-20-308

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller CAN Communication Failure (Cont) Motor Versions

"Hardware/Software Versions ( Exit Versions

Power OFF

NOTE: Fault Logs will indicate which Motor/Motor Controller has the Faulty Component/Connection

(continued on next page)

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9030-20-309

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller CAN Communication Failure (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

MOTOR CONTROLLER CAN COMMUNICATION FAILURE

) = Short Circuit

) = No DTC

CAUSES A B C D E > ?

(continued on next page)

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9030-20-310

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller CAN Communication Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

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9030-20-311

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller CAN Communication Failure (Cont) CAUSE A See A955 – G807 CAN Communication Failure

CAUSE B Not Applicable

CAUSE C Not Applicable

CAUSE D

WARNING Do not do Cause D until Cause A is complete.

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

(continued on next page)

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9030-20-312

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP A955 – G807 Motor Controller CAN Communication Failure (Cont) STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

STEP D3

Retest - Power ON

Is fault DTC gone? YES NO

Fault corrected

Continue operation.

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9030-20-313

Diagnostic Trouble Codes

Electrical System

TSP A955 – G807 Motor Controller CAN Communication Failure (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9030-20-314

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller CAN Communication Failure 33024

DTC 33024 CAN Communication Failure

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? No Traction/Hydraulic Truck Operation ? POSSIBLE CAUSES 1. Motor Controller Connections/Wiring – Open/Short Circuit

Go to 1a or 1b

1a. CAN Communication Failure. See CBB 4 Wheel CAN Communication 1b. CAN Communication Failure. See DBB 4 Wheel CAN Communication 2. Motor Controller(s) Failure?

Cause D

WARNING The CBB Truck requires the removal of the battery to access the Controllers and Motors

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9030-20-315

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller CAN Communication Failure (Cont) Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

(continued on next page)

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9030-20-316

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller CAN Communication Failure (Cont) Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

FAULT LOG Review - Go to Display Menu

Enter Service Password

all Motor DTCs

Diagnostic

FAULT LOGs

( Exit Fault Log

Motor Fault Log(s)

View all Motor DTCs

Truck Status

(continued on next page)

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9030-20-317

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller CAN Communication Failure (Cont) Motor Versions

"Hardware/Software Versions ( Exit Versions

Power OFF

NOTE: Fault Logs will indicate which Motor/Motor Controller has the Faulty Component/Connection

(continued on next page)

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9030-20-318

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller CAN Communication Failure (Cont) POSSIBLE CAUSES 1.5 – 2.0 CBB SCHEMATIC

X = Open Circuit/Fail

) = Short Circuit

CAUSES A B C D E > ?

(continued on next page)

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9030-20-319

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller CAN Communication Failure (Cont) 2.2 – 3.0 DBB SCHEMATIC

CAUSES A B C D E > ?

(continued on next page)

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9030-20-320

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller CAN Communication Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

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9030-20-321

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller CAN Communication Failure (Cont) CAUSE A See CBB 4 Wheel CAN Communication or DBB 4 Wheel CAN Communication

CAUSE B Not Applicable

CAUSE C Not Applicable

CAUSE D

WARNING Do not do Cause D until Cause A is complete.

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

(continued on next page)

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9030-20-322

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller CAN Communication Failure (Cont) STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

STEP D3

Retest - Power ON

Is fault DTC gone? YES NO

Fault corrected

Continue operation.

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9030-20-323

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller CAN Communication Failure (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9030-20-324

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Electrical System

Diagnostic Trouble Codes

TSP Travel Direction Select Incorrect

FAULT CODES:

12802

DTC 12802 Direction Select Data Incorrect – Direction Signals Incorrect

Power OFF

Wait 30 seconds

Power ON

POSSIBLE CAUSES

Fault remains. Service required. Go to Cause C.

X = Open Circuit/Fail

TRAVEL DIRECTION SELECT INCORRECT

No fault

Resume operation

) = Short Circuit

CAUSES A B C D E > ?

CAUSE A Not Applicable

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9030-20-325

Diagnostic Trouble Codes

Electrical System

TSP Travel Direction Select Incorrect (Cont) CAUSE B Not Applicable

CAUSE C

Disconnect sensor

Power OFF

STEP C1

CHECK RESISTANCE -

= Short circuit

Find

≈ 9K

Short circuit.

- OHMS

Go to Cause D.

Repair OPEN Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369. Recheck

Reconnect

Test OK

YES

Resume Operation NO

Recheck

Reconnect

Use Display Diagnostics to validate

Cause D

Test OK

YES

Resume Operation NO

Cause D

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Electrical System

Diagnostic Trouble Codes

TSP Travel Direction Select Incorrect (Cont) CAUSE D

Power OFF

Reconnect sensor

Power ON

Step D1

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9030-20-327

Diagnostic Trouble Codes

Electrical System

TSP Travel Direction Select Incorrect (Cont) STEP D1

1. Measure Pedal Neutral Voltage DS2 and DS1 ? DS2 (1.13V ± 2%) volts ≈ ½ DS1 (2.25V ± 2%) volts?

YES

Go to 2 NO

Go to 3

2. Select FORWARD Position – Foot DCS or Man Hyd DCS and Measure voltage at points 1 & 2 ? DS2 (1.8 ← →2.1)volts ≈ ½ DS1(3.6 ← →4.1)volts ?

YES

Go to Step D2 NO

Go to Step D3

Note: >4.9 Volts Go to Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH) Note: <0.31 Volts Go to Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL)

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Electrical System

Diagnostic Trouble Codes

TSP Travel Direction Select Incorrect (Cont) STEP D2

CHECK VOLTAGE

1. Select REVERSE Position – Foot DCS or Man Hyd DCS and Measure voltage at points 1 & 2 2. ? DS2 (0.9 ← →1.4)volts ≈ ½ DS1(0.4 ← →0.7)volts ?

YES

Go to Cause E NO

Go to Step D3

Note >4.9 Volts Go to Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH) Note <0.31 Volts Go to Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL)

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9030-20-329

Diagnostic Trouble Codes

Electrical System

TSP Travel Direction Select Incorrect (Cont) STEP D3

CHECK VOLTAGE

Power OFF

Fault DTC gone

Fault DTC present

Reconnect sensor

Old sensor faulty

Power ON

Go to next step.

Resume operation

Old sensor OK/Reinstall old sensor

Go to Cause E.

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9030-20-330

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Electrical System

Diagnostic Trouble Codes

TSP Travel Direction Select Incorrect (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-331

Diagnostic Trouble Codes

Electrical System

TSP Travel Direction Select Data Incorrect – 2 Sources

FAULT CODES:

12806

DTC 12806 Direction Select – Data Incorrect 2 + Direction Devices Installed

Power OFF

Wait 30 seconds

Power ON

Fault remains. Service required. Go to Cause C.

No fault

Resume operation

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Electrical System

Diagnostic Trouble Codes

TSP Travel Direction Select Data Incorrect – 2 Sources (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

TRAVEL DIRECTION SELECT DATA INCORRECT

) = Short Circuit

CAUSES A B C D E > ?

WARNING The Fault DTC will be displayed if more than one Direction Control Device is installed.

CAUSE A Not Applicable

CAUSE B Not Applicable

CAUSE C Not Applicable

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9030-20-333

Diagnostic Trouble Codes

Electrical System

TSP Travel Direction Select Data Incorrect – 2 Sources (Cont) CAUSE D

Power OFF

Locate and Disconnect Incorrect Direction Selection Device

Step D1

For MLM see /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

STEP D1

Retest - Power ON

Go to Cause E

Is fault DTC gone? NO YES

Fault corrected

Continue operation.

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9030-20-334

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Electrical System

Diagnostic Trouble Codes

TSP Travel Direction Select Data Incorrect – 2 Sources (Cont) CAUSE E

Power OFF

Inspect VSM Connections

Go to Cause E1. Not OK Correct/Repair

Go to Cause E1.

CAUSE E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone?

Fault corrected

Continue operation.

NO YES

END FAULT

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9030-20-335

Diagnostic Trouble Codes

Electrical System

TSP Direction Select Data Incorrect - No DCS Source

12807

DTC 12807 Direction Select Data Incorrect - No DCS Source

FAULT CODES:

Wait 30 seconds

Power OFF

QUICK CHECK

Power ON

X = Open Circuit/Fail

Fault remains. Service required. Go to Cause A.

No fault

Resume operation

) = Short Circuit

Check 1

1. Is there any other DCS devices installed except the armrest DCS? 2. YES

Check 2 NO

Go to 3

3. Is DCS installed on the armrest? YES

Check 2 NO

Obtain and Install DCS

Go to 4

4. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 5. Test new DCS

Function OK/DTC gone

YES

Resume Operation NO

Check 2

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9030-20-336

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Electrical System

Diagnostic Trouble Codes

TSP Direction Select Data Incorrect - No DCS Source (Cont) Check 2

Push in Emergency Stop

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Release Emergency Stop

FAULT LOG CODE Review - Go to Display Menu

Enter Service Password

Diagnostic

" All VSM/MLM DTCs

FAULT LOGs

VSM/MLM Fault Logs

Erase all VSM/MLM DTCs

View all VSM/MLM DTCs

( Exit Fault Log

NOTE: ?DTC 33034 ?

Fault Code A955 – G807 CAN Communication Failure

NOTE: ?DTC 12807 ?

Cause A

Power OFF

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9030-20-337

Diagnostic Trouble Codes

Electrical System

TSP Direction Select Data Incorrect - No DCS Source (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

DIRECTION SELECT DATA INCORRECT - NO DCS SOURCE

) = Short Circuit

CAUSES A B C D E > ?

CAUSE A DCS Wiring/Connections

1. Push In Emergency Stop 2. NOTE: Do not remove PCB Cassette to Remove DCS 3. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Disconnect DCS from harness 5. Release Emergency Stop

STEP A1

CHECK VOLTAGE

MLM Open Circuit CAN Hi/CAN Lo

1. 0 Volts

Step A2

1. ≈ 5 Volts

Step A3

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Electrical System

Diagnostic Trouble Codes

TSP Direction Select Data Incorrect - No DCS Source (Cont) STEP A2

CHECK VOLTAGE

1. Disconnect Cassette Connector as Indicated 2. 0 Volts

Faulty MLM Cassette

Measure Volts ≈ 5 Volts

Cause D

Step A3

STEP A3

Disconnect Cassette Connector as Indicated

Measure

1. ∞

OPEN Circuit

Go to 4

1. 0

Go to 2

2. ∞

OPEN Circuit

Go to 4

2. 0

Go to 3

3. ∞

OPEN Circuit

Go to 4

3. 0

Step A4

4. Find/Repair OPEN Circuit

Go to 5

5. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 6. Recheck

Reconnect

Test OK

No DTCs

YES

Resume Operation No

Step A4

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9030-20-339

Diagnostic Trouble Codes

Electrical System

TSP Direction Select Data Incorrect - No DCS Source (Cont) STEP A4

CHECK RESISTANCE -

- OHMS

1. 0

Short Circuit

Go to 3

1. ∞

Go to 2

2. 0

Short Circuit

Go to 3

2. ∞

Cause C

3. Find/Repair Short Circuit

Go to 5

5. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 6. Recheck

Reconnect

Test OK

No DTCs

YES

Resume Operation No

Cause C

CAUSE B Not Applicable

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Electrical System

Diagnostic Trouble Codes

TSP Direction Select Data Incorrect - No DCS Source (Cont) CAUSE C

Reconnect Cassette Connector and DCS as Indicated

Select FOWARD Position

Measure Volts

1. Does FORWARD Voltage DS1 = 3.25V ± 0.25 V? NO: Replace DSC

See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

YES: Select REVERSE Position NO: Replace DSC YES

Measure Volts

Does REVERSE Voltage DSC1 = 1.75V ± 0.25 V?

See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

Replace PCB Cassette

Cause D

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9030-20-341

Diagnostic Trouble Codes

Electrical System

TSP Direction Select Data Incorrect - No DCS Source (Cont) CAUSE D

Power OFF 1369

Remove and Replace MLM PCB Cassette Assembly

Check Replacement MLM

Version

See Label Information

See /Electrical System 2200 YRM 1337Electrical System 2200 YRM

Step D1

STEP D1

1. Go to TRD/Axcess Online /Software. Replacement Cassette Software Version the Latest Version 2. NO

Download the latest Application

3. YES

Test New Installation

Install on truck

Step D2

STEP D2

Power ON

? DTCs gone

DTCs Still Present

Original MLM Cassette faulty

Resume operation

Original MLM Cassette OK/Reinstall Original Cassette

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Electrical System

Diagnostic Trouble Codes

TSP Direction Select Data Incorrect - No DCS Source (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is " by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

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9030-20-343

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure 16912

DTC 16912 Motor Temperature High 17168

DTC 17168 Controller/Heatsink Temperature High 25105

DTC 25105

FAULT CODES:

QUICK CHECK

Temperature Sensor Failure

X = Open Circuit/Fail

) = Short Circuit

Check 1

? Over Temperature Icon Displayed at Power ON? POSSIBLE CAUSES 1. Sensor(s) – Motor/Motor Controller – Connections/Wiring?

Cause A

2. Sensor(s) Failure?

Cause A

3. Motor Controller(s) Hardware Failure?

Cause D

Note: Hydraulic Oil Over Temperature and Sensor Issues see Fault Code Hydraulic Temperature Sensor Out of Range High (OORL) Fault Code Hydraulic Temperature Sensor Out of Range High (OORH)

? Over Temperature Icon Displayed during Operation/Reduced Performance/Function Failure? POSSIBLE CAUSES 1. Motor/Motor Controller/Hydraulic Fluid Overheating?

Aggressive Operation?

2. Sensor – Motor/Motor Controller/Hyd Tank – Connections/Wiring?

Cause A

3. Sensor(s) Failure?

Cause A

4. Motor Controller(s) Failure ?

Cause D

WARNING The CBB Truck requires the removal of the battery to access the Controllers and Motors (continued on next page)

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9030-20-344

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont) Table 9030-20-10. CBB Temperature Control Chart Table Note: For further assistance on Silicon Temperature Sensor readings, see Table 9030-10-1, Page 9030-10-21 CBB Temperature Control Chart Table Application

Performance Cutback Start

Performance Cutback Finish

°C

°F

°C

°F

Traction Motor

155

311

165

329

Traction Controller

176

115

239

Pump Motor

155

311

165

329

Pump Controller

176

194

Hyd Fluid

203

115

239

Fan ON °C

°F

140

122

Table 9030-20-11. DBB Temperature Control Chart Table Note: For further assistance on Silicon Temperature Sensor readings, see Table 9030-10-1, Page 9030-10-21 DBB Temperature Control Chart Table Application

Performance Cutback Start

Performance Cutback Finish

°C

°F

°C

°F

Traction Motor

140

284

165

329

Traction Controller

167

185

Pump Motor

155

311

165

329

Fan ON °C

°F

140

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9030-20-345

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont) Table 9030-20-11. DBB Temperature Control Chart Table (Continued) Pump Controller

176

203

Hyd Fluid

203

110

230

122

Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Power ON

Fault Remains Service Required

No Fault

Resume Operation

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont) Check 4

Reduced Performance

Check Display Icons

Motor/Motor Controller Temperature Icon On 1. Check fan operation

Are fans operating?

2. Temp Sensor/Controller to Motor connection

A955 – G807 Motor Controller Fan Failure YES

Open Circuit

Cause A

3. Use the following steps for viewing Motor Temperature Note: The Motor Temperature ICON will be displayed for any Over Temperature of Traction 1/Traction 2, Pump Motor and their associated Controllers plus Hydraulic Fluid Note: The Diagnostics Display Menu Flowchart will show which device is overheating See Check 5 Note: The Service Tech may need to operate the truck for an extended time on a 20% grade to have this Over temperature icon(s) display again after it has been first reported

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9030-20-347

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont) Check 5 Diagnostics Temperature Analysis – Go to Display Menu Flowchart

Enter Service Password

Diagnostics

Motor

Traction1/Traction2/Pump

Motor/Controller Data

Fan(s) Operation Temperature Threshold: Traction = 55°C (131°F) Pump = 65°C (149°F) Reduced Performance: Traction = 80°C (176°F) Pump = 80°C (176°F)

Motor

Motor Controller

Invalid Temperature Signal (Traction/Pump Motor(s) Only): Sensor Connections/Sensor Open Circuit

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont)

Return to Diagnostics Menu Check 6 Fault Log DTC – Go to Display Menu Flowchart

Enter Service Password

all Motor Codes

Motor Versions

Diagnostic

FAULT LOGs

( Exit Fault Log

Motor Fault Log(s)

View all Motor DTCs

Truck Status

"Hardware/Software Versions ( Exit Versions

Power OFF

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9030-20-349

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont) POSSIBLE CAUSES CBB SCHEMATIC

X = Open Circuit/Fail

) = Short Circuit

X = No DTC

CAUSES A B C D E > ?

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9030-20-350

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont) DBB SCHEMATIC

CAUSES A B C D E > ?

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9030-20-351

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

Fan Motor Connector Cxx 146, 154, and 155

CAUSE A

Power OFF

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

Go to Step A1

STEP A1 For any Fault DTC

Locate Device

Inspect ALL Wiring/Connections

A DMM Temperature probe can also be used to determine which device is overheating

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont) STEP A2

CHECK RESISTANCE -

- OHMS

Motor Temperature Sensor

1. Disconnect Motor Connector

Measure

as indicated

Note: For temperature sensor readings, see Table 9030-10-1, Page 9030-10-21. At xxx deg 2. <300 3. >2800

sensor

to 0

≈ match Temperature Chart 340

= Motor Sensor Short Circuit

to ∞

-40°C (25°F) to 2791

@ 300°C (572°F)

Go to 8

= Motor Sensor Open Circuit/High Resistance Connection

Go to 8

4. Reconnect Motor Connector 5. Disconnect Controller Connector 6. <300 7. >2800

to 0

= Short Circuit

to ∞

Measure

as indicated

Go to 9

= Open Circuit/High Resistance Connection

8. Replace Motor

See Table 9030-10-1, Page 9030-10-21

Go to 9

Go to 10

9. Find/Repair Harness OPEN/SHORT Circuit

Go to 10

10. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 11. Recheck

Reconnect

Go to 11

Resume Operation

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9030-20-353

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont) STEP A3 Motor Temperature Sensor (Controller Check)

1. Disconnect Motor Temperature Sensor Connector from suspect Controller 2. Connect a ¼ watt resistor (>3300

to <10,000 ) as shown

3. Reconnect Battery and all other Connectors 4. Does Over Temperature ICON Appear? 5. YES: Go to 7 6. NO: Controller is Faulty

Cause D

7. Repeat Resistor Test on other Controllers 8. Temperature ICON is Displayed?

YES: Controller tested OK, Go to 9

NO: Controller tested Faulty

Cause D

9. Reconnect other Motor Temperature Sensors

CAUSE B Not Applicable

CAUSE C Not Applicable

CAUSE D

Power OFF

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

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9030-20-354

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont) STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

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9030-20-355

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor/Motor Controller Temperature Sensor Failure (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

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9030-20-356

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller Current Sensor Failure 21008

DTC 21008 Current Sensor Offset Calibration Error

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? No Traction/Hydraulics Truck Operation ? Possible Causes Motor Controller(s) Failure ?

Cause D

WARNING The CBB Truck requires the removal of the battery to access the Controllers and Motors

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9030-20-357

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller Current Sensor Failure (Cont) Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

FAULT LOG Review - Go to Display Menu

Enter SERVICE Password

Diagnostic

FAULT LOGs

Motor Fault Log(s)

View all Motor DTCs

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9030-20-358

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller Current Sensor Failure (Cont)

all Motor DTCs

Motor Versions

( Exit Fault Log

Truck Status

"Hardware/Software Versions ( Exit Versions

Power OFF

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9030-20-359

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller Current Sensor Failure (Cont) CAUSE A Not Applicable

CAUSE B Not Applicable

CAUSE C Not Applicable

CAUSE D

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

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9030-20-360

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller Current Sensor Failure (Cont) STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

STEP D3

Retest - Power ON

Is fault DTC gone? YES NO

Fault corrected

Continue operation.

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9030-20-361

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller Current Sensor Failure (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

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9030-20-362

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Electrical System

Diagnostic Trouble Codes

TSP Hydraulic Calibration Required 4096

DTC 4096 Hydraulic Calibration Required

FAULT CODES:

FAULT LOG CODE Review – Go To Display Review

Fault Remains Service Required

Power ON

No Fault

Resume Operation

Calibration Process - Go to Display Menu

Enter Service Password

Diagnostics

Hydraulic Input

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9030-20-363

Diagnostic Trouble Codes

Electrical System

TSP Hydraulic Calibration Required (Cont) Hydraulic Lever Sensor Input Values

Hydraulic Levers at Center position

< ± 2.5% =

Hydraulic Levers at Center position

> ± 2.5% = X = Faulty Lever Mechanism

Proceed with Calibration Repair, Go to 3

3. Manual Hydraulics Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 or Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439. Calibration Process - Go to Display Menu

Calibration Menu This Hydraulic Calibration Display Menu is viewable to those logged in with a supervisor or service level password. E-Hydraulics and Manual Hydraulics Threshold Calibration: For Display Menu graphics see following pages. 1. Access Calibration Menu

Press

Press*

Scroll to Hydraulic Calibration

2. Move the lever for function 1 in the A direction until the forks begin to visibly move in the A Direction. Press* The VSM will record the setting and the Display will automatically step to the next Calibration step. E.g. 1A 1B

2B.

Note: Calibration reading outside of the allowable engineering tolerances = X across the graphic. Press any key to return to the A direction graphic for the valve under calibration. Repeat calibration steps. 3. Last Calibration completed.

Display transitions back to the Calibration Maintenance Menu List.

Manual-Hydraulic: For Display Menu graphics see following pages. 1. Access Calibration Menu

Press

Scroll to Manual Hydraulic Valve

Press*

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Electrical System

Diagnostic Trouble Codes

TSP Hydraulic Calibration Required (Cont) 2. Move the Lift Lever first to the end of mechanical travel in one direction and then to the other end Press* Repeat for the other Levers. When all levers have been calibrated Press the Scroll Left Button to return to the previous Menu. Note: If the calibration reading is outside of the allowable engineering tolerances the Display will display an ‘X’ across the graphic. Wait 3 seconds Press* Repeat the calibration for this Lever. Calibration Process - Go to Display Menu

Calibration

Hydraulic Valve Threshold

Hydraulic Valve Threshold - Manual and E-Hydraulic

Operate Indicated Control until Hyd movement is observed

Repeat for each Function

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9030-20-365

Diagnostic Trouble Codes

Electrical System

TSP Hydraulic Calibration Required (Cont) X = Calibration Failure

Repeat Calibration

to Reset

WARNING: X = MLM Lever operated in the wrong direction. Repeat Calibration Manual Hydraulic Valve

)* Lift/Lower

) * H Next Lever

X = Calibration Fail ,

FAULT DTC LOGS: DTC logs should only be cleared once the data is Clearing DTCs.

3 seconds ) * Repeat Calibration

by the Service Tech. See Display Menu Flowchart -

CAUSE A End of Task

END FAULT

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller 15 – 5 Volt Internal Failure 20753

DTC 20753 15 Volt Supply Low Voltage 20755

DTC 20755 5 Volt Supply Low/High Voltage

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? No Traction/Hydraulics Truck Operation ? Possible Causes 20753/20755

Motor Controller(s) Failure ?

Cause D

WARNING The CBB Truck requires the removal of the battery to access the Controllers and Motors

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9030-20-367

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller 15 – 5 Volt Internal Failure (Cont) Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

FAULT LOG Review - Go to Display Menu

Enter SERVICE Password

Diagnostic

FAULT LOGs

Motor Fault Log(s)

View all Motor DTCs

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller 15 – 5 Volt Internal Failure (Cont)

all Motor DTCs

Motor Versions

( Exit Fault Log

Truck Status

"Hardware/Software Versions ( Exit Versions

Power OFF

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection

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9030-20-369

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller 15 – 5 Volt Internal Failure (Cont) CAUSE A Not Applicable

CAUSE B Not Applicable

CAUSE C Not Applicable

CAUSE D

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller 15 – 5 Volt Internal Failure (Cont) STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3

Step D3 Factory

Failure Analysis

?? Reprogramming

STEP D3

Retest - Power ON

Is fault DTC gone? YES NO

Fault corrected

Continue operation.

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9030-20-371

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller 15 – 5 Volt Internal Failure (Cont) CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller DC Bus Low/High 12576

12818

DTC 12576

DTC 12818

DC Bus Charging Timeout

DC Bus Hi – Hardware Detected

12817

DTC 12817

12833

DTC 12833

DC Bus Hi – Software Detected

DC Bus Low – Hardware/Software

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? No Operation ? POSSIBLE CAUSES DTC 12576 DC Bus Charging Timeout

Low Battery/High ® Connections

DTC 12817 DC Bus Hi – Software Detected

Brake Torque Settings

DTC 12818 DC Bus Hi – Hardware Detected

High ® Connections

Go to 3 and 4

DTC 12833 DC Bus Low – Hardware/Software

High ® Connections

Go to 3

Go to 1, 2, and 3

Go to 4

Cause A Cause C Cause A/Cause C Cause B

1. Go to OORL. See Battery OORH/OORL 2. PTC Failure?

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9030-20-373

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) 3. Motor/Motor Controller Battery Connections/Wiring – High ®/Contactor Contacts? 4. Commanded Braking Torque (Regen) is set too High for Battery Condition Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

Check 4

Power ON

Go to Diagnostics

Battery/Supply

View Bat Value

Go to Display Menu Flowchart

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) Check 5 Battery OORL/OORH as measured by the Motor Controllers NOTE: OOR fault is set if OOR condition is present for longer than 1 second. NOTE: Both Motor control and VSM OOR faults may appear due to the different thresholds levels Battery Voltage 36

39.6

52.8

79.2

≈< OORL

≈ OORH

110

Nominal Fully Charged

Is battery voltage ≈ < OORL value for correct battery? YES Battery OORH/OORL Return to this Fault after Battery OORH/OORL/Retest is complete. NO Check 6 FAULT LOG Review - Go to Display Menu

Enter Service Password

Diagnostic

Diagnostics

FAULT LOGs

all Motor DTCs

Motor Fault Log(s)

( Exit Fault Log

View all Motor DTCs

Truck Status

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9030-20-375

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont)

Motor Versions

"Hardware/Software Versions ( Exit Versions

Status

Truck Diagnostics)*

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

) = Short Circuit

® = High Resistance Connections 1.5 – 2.0 CBB SCHEMATIC

CAUSES A B C D E > ?

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9030-20-377

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) ® = High Resistance Connections 2.2 – 3.0 DBB SCHEMATIC

CAUSES A B C D E > ?

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

CAUSE A

Power OFF

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

STEP A1 NOTE: ® Battery or Battery to Motor Controller Power Connections all DTC Faults are possible NOTE: High Current drawn from the battery through ® = Voltage drops = OORL NOTE: High Current sent to the battery through ® = Voltage increases = OORH

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9030-20-379

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) STEP A2 For any Fault DTCs

Locate Devices

Inspect ALL Wiring/Connections

STEP A3

1. Inspect Contactor Top and Bottom Contacts for Pitting/Corrosion/Dirt Build-Up

Go to 2

2. Replace Contactor if Pitting/Corrosion is Observed/ Clean out any Dirt Build up 3. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Check all Connections

Reconnect Battery

Go to 4

Step A4

STEP A4

Retest - Power ON

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) STEP A5

Disconnect Battery and Sound Horn to Discharge Capacitors. YRM 1342 . Set DMM to Lowest

scale

Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100

Check Lead Resistance < 0.01

Note: If the Resistance is > 0.01

then record this as the Zero

STEP A6

Value

Step A6

CHECK RESISTANCE -

- OHMS

PTC Failure

1. >10

@ 25 °C (77 °F) = Faulty PTC

2. Replace PTC(s)

Go to 2

1. <10

Go to 2

Go to 3

3. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Recheck

= OK

Reconnect

Go to 4

Step A7

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9030-20-381

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) STEP A7

Retest - Power ON

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

CAUSE B

Enter SERVICE Password

Diagnostics

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) STEP B1

Scroll

Indicated Motor with Fault DTC

View Voltage

Voltage

STEP B2

Battery Voltage 36

39.6

52.8

79.2

≈ < OORL

≈ > OORH

110

Nominal Fully Charged

1. Ensure that the Battery has been fully charged

Check Battery connections are clean and secure.

2 Operate Truck with Maximum Acceleration in Forward Direction 3. Completely release acceleration pedal

Regen Braking Only

" "

Maximum Voltage Maximum Voltage

4. Do Minimum and Maximum Voltages exceed the OORL or OORH thresholds? 5. YES

Step B3 NO

Resume Operation

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9030-20-383

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) STEP B3

1. Elevate Truck drive wheels. Use only approved support methods See Operating Manual 2. All Hydraulic Functions need to be free to be operated.

STEP B4

CHECK VOLTAGE

1. Connect DMM

Position 1

Measure Battery Volts at the Contactor terminals

2. Operate Traction and Hoist Hydraulics against Relief Valve

" DMM/Display Volts

2a. Display Volts < DMM Volts < Controller Minimum?

® Connections

2b. Display Volts = DMM Volts > Controller Minimum?

Change DMM to Position 2

3. Operate Traction and Hoist Hydraulics against Relief Valve

Value Compare

Go to 2a

Go to 4 Repeat Step2?

" DMM/Display Volts

3a. Display Volts < DMM Volts < Controller Minimum?

® Contactor Contacts

3b. Display Volts = DMM Volts > Controller Minimum?

Go to 4?

Compare

Go to 3a

Go to 4

4. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

Go to 5?

5. Recheck Volts Test Truck DTC Faults? YES Step B3 NO Resume Operation

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) STEP B5

CHECK VOLTAGE

1. Connect DMM

Measure Battery Volts at the Connector terminals

2. Operate Traction and Hoist Hydraulics against Relief Valve

Value

" DMM/Display Volts

2a. Display Volts < DMM Volts < Controller Minimum?

® Connections

2b. Display Volts = DMM Volts > Controller Minimum?

Go to 3

Compare

Go to 2a

Go to 3

3. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

Go to 4

4. Recheck Volts Test Truck DTC Faults? YES Step B6 NO Resume Operation

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9030-20-385

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) STEP B6

CHECK VOLTAGE

1. Connect DMM as shown

Measure Battery Volts at the Battery terminals

2. Operate Truck Traction and Hoist Hydraulics against Relief Valve

Value

" Lowest Battery Voltage

Compare

Go to 3

3. Battery Voltage < Controller Minimum? 4. YES Battery internal Resistance is too high 5. NO

Battery Maintenance check/Replace Battery(s)

Go to 6

Cause D

3. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

Go to 7

4. Recheck Volts Test Truck DTC Faults? YES Cause C NO Resume Operation

CAUSE C Battery OORL/OORH as measured by the Motor Controllers NOTE: OOR DTC is set if OOR condition is present for longer than 1 second.

NOTE: Both Motor control and VSM OOR DTCs may appear due to the different thresholds levels Battery Voltage 36

39.6

52.8

79.2

≈ < OORL

≈ > OORH

110

Nominal Fully Charged

An OORH DTC can occur if the Regen braking setting is too high

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) STEP C1 REGEN BRAKE SETTING – must be completed before making adjusted.

Enter Service Password

Truck Setup

Scroll to Braking Setup

Braking Setup

)* To Select

Scroll to Regen Function

Enter Lower Value Using Number Buttons

STEP C2

Battery Voltage 36

39.6

52.8

79.2

≈ < OORL

≈ > OORH

110

Nominal Fully Charged

1. Ensure that the Battery has been fully charged

Check Battery connections are clean and secure.

2 Operate Truck with Maximum Acceleration in Forward Direction 3. Completely release acceleration pedal

Regen Braking Only

" "

Maximum Voltage Maximum Voltage

4. Do Maximum Voltages exceed the OORH thresholds? 5. Yes

Repeat Step C1 until no fault exist.

Resume Operation

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9030-20-387

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) CAUSE D

Power OFF

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342 .

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Controller DC Bus Low/High (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES NO

Fault corrected

Continue operation.

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is " by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

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9030-20-389

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Aux Driver Failure 21520

DTC 21520 Aux Driver Current High

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

It is recommended that the Display or PC Service Tool diagnostics be used as much as possible to determine the potential Motor. Motor Controller failure before starting as analysis using the CAUSE procedures, CBB Motor Controller Access requires Battery removal CBB Auto Brake Access requires Battery removal DBB Motor Controller Connector Access is very difficult. Use a Break-Out Harness kit DBB/CBB Motor Controller Component Access requires Battery removal Check 1

POSSIBLE SYMPTOMS No/ Reduced Traction - Auto Brake Does not Release/Fan(s) do not Operate at Key ON POSSIBLE CAUSES DTC 21520

Aux Driver Short to Bat (+)

> 1 amp driver current

Cause A

DTC 21520

Brake Coil (DBB)/Fan Short Circuit

> 1 amp driver current

Cause A/Cause C

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Aux Driver Failure (Cont) Motor Controller(s) Failure ?

Driver Failure

Cause D

Also see, Observed Symptom - Auto Brake Does not Release/Fan(s) do Not Operate at Key ON Check 2

Power ON

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9030-20-391

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Aux Driver Failure (Cont) YES NO

Go to Check 3

Cause A

Observed Symptoms - Fans do Not Operate

Cause C

Check 3

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 4

Fault Remains Service Required

Power ON

No Fault

Resume Operation

Check 5 FAULT LOG Review - Go to Display Menu

Enter Service Password

Diagnostic

FAULT LOGs

Motor Fault Log(s)

View all Motor DTCs

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Aux Driver Failure (Cont)

all Motor DTCs

Motor Versions

( Exit Fault Log

Truck Status

"Hardware/Software Versions ( Exit Versions

Power OFF

NOTE: Fault Logs will indicate which Motor/Motor Controller has the faulty Component/Connection

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9030-20-393

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Aux Driver Failure (Cont) POSSIBLE CAUSES 1.5 – 2.0 CBB SCHEMATIC

X = Open Circuit/Fail

) = Short Circuit

) = No DTC

CAUSES A B C D E > ?

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Aux Driver Failure (Cont) 2.2 – 3.0 DBB SCHEMATIC

CAUSES A B C D E > ?

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9030-20-395

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Aux Driver Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

Fan Connector Cxx 94, 95, 156, and 153

Auto Brake Motor Connector Cxx 15, 16, 17, 193, and 194

CAUSE A For any Fault DTC

Locate Device

Inspect ALL Wiring/Connections

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Aux Driver Failure (Cont) STEP A1

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Power OFF

STEP A2

CHECK RESISTANCE -

- OHMS

Auto Brake Short Circuit to Bat (+)

1. < 24

Short to Bat (+)

CBB go to 2. DBB

Step A3

1 > 24

Cause C

2. Find/Repair Short/Open Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 3. Recheck

Reconnect

Test OK

YES

Resume Operation NO

Cause C

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9030-20-397

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Aux Driver Failure (Cont) STEP A3

CHECK RESISTANCE -

- OHMS

DBB Auto Brake Diode/Coil Short Circuit

Disconnect Coil, Measure 1. 0

= Short Diode

2. < 26

> 30

1∞

Go to 2

= Faulty Coil

3. Replace Diode Pack.

Go to 4

= OK

2. > 26

< 30

Cause C

Go to 5

5. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

CAUSE B

= OK

Go to 5

4. Replace Auto Brake Coil Assy.

5. Recheck

Go to 2

Reconnect

Test OK

YES

Resume Operation NO

Go to 6

Cause C

CHECK RESISTANCE -

- OHMS

Not Applicable

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Aux Driver Failure (Cont) CAUSE C

CHECK RESISTANCE -

- OHMS

Fan Short Circuit

Disconnect Fans Measure 1. < 24

Shorted Fan

Go to 2.

1. > 24

Go to 2.

2. < 24

Shorted Fan

Go to 2.

1. > 24

Go to Step C1.

2. Replace Fan. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 3. Recheck

Reconnect

Test OK

STEP C1

YES

Resume Operation NO

Go to 3

Cause D

CHECK RESISTANCE -

- OHMS

Fan Harness Short Circuit

1. < 24

Shorted Circuit

Go to 3.

1. > 24

Go to Cause D.

2. Find Short Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 3. Recheck

Reconnect

Test OK

YES

Resume Operation NO

Go to 3

Cause D

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9030-20-399

Diagnostic Trouble Codes

Electrical System

TSP CBB/DBB Motor Aux Driver Failure (Cont) CAUSE D

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

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Electrical System

Diagnostic Trouble Codes

TSP CBB/DBB Motor Aux Driver Failure (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES NO

Fault corrected

Continue operation.

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is " by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END FAULT

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9030-20-401

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

9030-20-402

Electrical System

Observed Symptoms

Group 30

Observed Symptoms TSP No Display/No Truck Operation None

DTC None No Display/No Truck Operation

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

X = No DTC

Symptom 1 No Display/No Truck Operation

Power ON

No Display

No truck Operation

Check 1 Battery Voltage 36

39.6

52.8

79.2

≈< OORL

≈ OORH

48.6

57.6

97.2

108

Nominal Fully Charged

1. Check Emergency Disconnect Button is Released 2. Check Battery Connections/Wiring 3. Check Battery Voltage 4. Battery Voltage OK

See Table

YES Check 2

See Battery Service Manual for Battery Charging Instruction

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9030-30-1

Observed Symptoms

Electrical System

TSP No Display/No Truck Operation (Cont) Check 2

1. Use PC Service Tool to Check for DTCs 2. ? DTCs

YES

VSM OK

3. ? DTCs

NO Check 3

Check Display Power Connections

Cause C

A935/K160

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Electrical System

Observed Symptoms

TSP No Display/No Truck Operation (Cont) 4 Wheel CBB

4 Wheel DBB

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9030-30-3

Observed Symptoms

Electrical System

TSP No Display/No Truck Operation (Cont) Connectors

VSM Cxx 1 and Cxx 2

Display Cxx 20 and 135

For further information showing VSM/Display/Fuse location see Check 3 CAUTION:A Open Circuit Fuse Indicates a Short Circuit in the Wiring Locate the Short before replacing the fuse

1. Is Key Switch Turning without binding?

YES Go to 2

2. Check VSM/Display Power/Fuses/Connections/Wiring

NO Go to 3 for Replacement Instructions Cause A

3. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Repair/Replace

Reconnect

Test

Go to Check 4

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Electrical System

Observed Symptoms

TSP No Display/No Truck Operation (Cont) Check 4

Retest - Power ON

Does Display Turn ON? Is fault DTC gone? YES NO

Fault corrected

Continue operation.

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9030-30-5

Observed Symptoms

Electrical System

TSP No Display/No Truck Operation (Cont) CAUSE A

Disconnect Battery and Sound Horn to Discharge Capacitors. YRM 1342 . Disconnect VSM Reconnect Battery

STEP A1

Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100

CHECK VOLTAGE

VSM Power Connections

Disconnect VSM connector CPS2 and check for Battery Volts 1. <18 Volts = Flat Battery 2. 0 Volts = Open Circuit

1. Battery Volts = OK, Go to 2 Step A2

2. Battery Volts = OK, Go to 3

3. 0 Volts =

1Fuse

Cause B

3. Battery Volts = OK, Go to 4

4. 0 Volts =

1Fuse

Cause B

4. Battery Volts = OK, Go to 5

5. 0 Volts = Open Circuit

Go to 7

5. Battery Volts = OK, Go to 6

6. 0 Volts = Open Circuit

Go to 7

6. Battery Volts = OK, Cause C

7. Open Circuit

Find/Repair Open Circuit, Go to 8

8. Find/Repair Open Circuit See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 9. Recheck Volts at (+) 5 & 6 (-) 2

Battery Voltage Present? YES

Cause B Resume Operation No

Step A2

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Electrical System

Observed Symptoms

TSP No Display/No Truck Operation (Cont) STEP A2

CHECK RESISTANCE -

- OHMS

VSM Power Connections Open Circuit

Disconnect Battery

Check for

1. ∞

= Open Circuit, Go to 3

1. 0

= OK, Go to 2

2. ∞

= Open Circuit, Go to 3

2. 0

= OK, Cause B

3. Find/Repair Open Circuit, Go to 4 4. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 5. Recheck

at 1 & 2

Reconnect Battery

Test

? YES

Go to 6

Resume Operation No

Battery Voltage Present? Yes

Go back to 3

Resume Operation

Cause B

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9030-30-7

Observed Symptoms

Electrical System

TSP No Display/No Truck Operation (Cont) CAUSE B

CHECK RESISTANCE -

- OHMS

VSM Power Connections 1Fuse (Short Circuit)

1. 0

= Short Circuit

Go to 3

1. ∞

2. 0

= Short Circuit

Go to 3

2. ≈ ∞

= OK = OK

Go to 2 Step B2

3. Find/Repair Short, Circuit Go to 4 4. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

Step B2

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9030-30-8

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Electrical System

Observed Symptoms

TSP No Display/No Truck Operation (Cont) STEP B1

CHECK RESISTANCE -

- OHMS

VSM Power Connections Open Circuit

Replace Fuse(s)

Reconnect Battery

1. Battery Volts Present? Yes

Go to 2

2. Battery Volts Present? Yes

Go to 3

3. Disconnect Battery

Check Volts

4. Reconnect VSM

Go to 1

5. Reconnect Battery, Step B2

STEP B2

Retest - Power ON

Cause C

Does Display Turn ON? Is fault DTC gone? YES NO

Fault corrected

Continue operation.

CAUSE C DISPLAY Connection Failure See A955 – G807 CAN Communication Failure, CBB 4 Wheel CAN Communication, and DBB 4 Wheel CAN Communication

END SYMPTOM

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9030-30-9

Observed Symptoms

Electrical System

TSP A955 – G807 Motor Controller Fan Failure None

DTC None A955 – G807 Motor Controller Fan Failure

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? Function Failure/Reduced Performance/Uncommanded Continuous Operation? POSSIBLE CAUSES 1. Fan/Motor Controller Connections/Wiring ? 2. Fan Motor Failure ? 3. Motor Controller(s) Failure ?

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Electrical System

Observed Symptoms

TSP A955 – G807 Motor Controller Fan Failure (Cont) Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

Check 3

Power ON

Fault Remains Service Required

No Fault

Resume Operation

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9030-30-11

Observed Symptoms

Electrical System

TSP A955 – G807 Motor Controller Fan Failure (Cont) Check 4

Reduced Performance

Check Display Icons

Motor/Motor Controller Temperature Icon On 1. Check fan operation

Are fans operating?

2. Temp Sensor/Sensor Connection

Cause A YES

Go to 2

Open Circuit

3. Use the following steps for viewing Motor Temperatures Fan(s) Operation Temperature Threshold

Traction = 55°C (131°F) Pump = 65°C (149°F)

Reduced Performance:

Traction = 80°C (176°F) Pump = 80°C (176°F)

Temperature > Operation Threshold

No Fan Operation = Faulty Fan/Fan Connections

Check 5 Diagnostics Temperature Analysis – Go to Display Menu Flowchart

Enter Service Password

Diagnostics

Motor

Traction1/Traction2/Pump

Motor/Controller Data

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Electrical System

Observed Symptoms

TSP A955 – G807 Motor Controller Fan Failure (Cont) FAULT LOG Review - Go to Display Menu

Enter Service Password

all Motor DTCs

Motor Versions

Diagnostic

FAULT LOGs

( Exit Fault Log

Motor Fault Log(s)

View all Motor DTCs

Truck Status

"Hardware/Software Versions ( Exit Versions

Power OFF

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9030-30-13

Observed Symptoms

Electrical System

TSP A955 – G807 Motor Controller Fan Failure (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

) = Short Circuit

X = No DTC

CAUSES A B C D E > ?

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Electrical System

Observed Symptoms

TSP A955 – G807 Motor Controller Fan Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

Fan Motor Connector Cxx 156, 157, 595A, 595B

CAUSE A

Power OFF

STEP A1 For any Fault DTC

Locate Device

Inspect ALL Wiring/Connections

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9030-30-15

Observed Symptoms

Electrical System

TSP A955 – G807 Motor Controller Fan Failure (Cont) STEP A2

CHECK VOLTAGE

Fan Operation

Disconnect Fan(s) and connect DMM as indicated 1. 0 Volts = Open Circuit (Fuse)

1 ≈ Bat Volts = OK Go to 2

Step A6

2. 0 Volts = Open Circuit

Go to 4

2. ≈ Bat Volts = OK Go to 3

3. 0 Volts = Open Circuit

Go to 4

3. ≈ Bat Volts = OK Go to Step A3

4. Find/Repair Open Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 5. Recheck

Reconnect

Retest

STEP A3

Step A5

CHECK RESISTANCE -

- OHMS

Fan Operation

Disconnect Relevant Controller and connect DMM as indicated 1. ∞

= Open Circuit

Go to 3

1≈0

2. ∞

= Open Circuit

Go to 3

2. ≈ 0

= OK Go to 2 = OK Go to Step A4

3. Find/Repair Open Circuit. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Recheck

Reconnect

Retest

Step A5

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Electrical System

Observed Symptoms

TSP A955 – G807 Motor Controller Fan Failure (Cont) STEP A4

CHECK RESISTANCE -

- OHMS

Fan Operation

1. ∞

= Open Circuit

Go to 3

< 150

Cause C

1 ≈ 200 to 260

2. ∞

= Open Circuit

Go to 3

< 150

Cause C

2. ≈ 200 to 260

= OK Go to 2 = OK Go to Step A5

3. Find/Repair Open Circuit/Replace Fan See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Recheck

Reconnect

Retest

Step A5

STEP A5 Fan Operation Test

1. Connect Fan(s) Circuit to Bat (-) as shown 2. Fan(s) Do not operate 3. Replace Fan

5. Fan(s) operate

Go to 3

Retest with Jumper wire

4. Reconnect Controller

Go to 2 2. Fan(s) operate

Go to 4

Operate Truck (Traction/Hydraulics) for at least 10 minute

Resume Operation

6. Fan(s) Do not operate

Cause D

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9030-30-17

Observed Symptoms

Electrical System

TSP A955 – G807 Motor Controller Fan Failure (Cont) STEP A6

CHECK RESISTANCE -

- OHMS

Fan Operation from Step A1

1. Remove Fuse 2. 0

∞

Measure

= Short Circuit

= Fuse Open Circuit

Go to 2

Go to 3

3. Find/Repair Short Circuit

Go to 4

4. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 5. Replace Fuse

Reconnect Controller

6. Fan(s) operate

Resume Operation

7. Fan(s) Do not operate

Go to 5

Operate Truck (Traction/Hydraulics) for at least 10 minute

Cause D

CAUSE B Not Applicable

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Electrical System

Observed Symptoms

TSP A955 – G807 Motor Controller Fan Failure (Cont) CAUSE C Fan Operation

1. Remove Fuse

Measure

2. Find/Repair Short Circuit

= Short Circuit

Go to 2

Go to 3

3. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. From Step A3 0 to 150

= Fan Short Circuit

Go to 6

Go to 5

5. Replace Fan

See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369

6. Replace Fuse

Reconnect Controller

7. Fan(s) operate

Resume Operation

8. Fan(s) Do not operate

Go to 6

Operate Truck (Traction/Hydraulics) for at least 10 minute

Cause D

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9030-30-19

Observed Symptoms

Electrical System

TSP A955 – G807 Motor Controller Fan Failure (Cont) STEP C1

CHECK RESISTANCE -

- OHMS

Fan Operation (Continuous)

1. Remove Fuse

Measure

2. Find/Repair Short Circuit

= Short Circuit

Go to 2

Go to 3

3. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 4. Replace Fuse

Reconnect Controller

5. Fans Operate Continuously at Power ON

Go to 4

Operate Truck (Traction/Hydraulics) for at least 10 minute Faulty Controller

Cause D

6. Fans operate briefly and then don’t operate until at least 1 minute of Operation

Resume Normal Operation

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Electrical System

Observed Symptoms

TSP A955 – G807 Motor Controller Fan Failure (Cont) CAUSE D

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

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9030-30-21

Observed Symptoms

Electrical System

TSP A955 – G807 Motor Controller Fan Failure (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is

" by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END SYMPTOM

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Electrical System

Observed Symptoms

TSP A955 – G807 Motor/Motor Controller Temperature Sensor Failure None

DTC None A955 – G807 Motor/Motor Controller Temperature Sensor Failure

FAULT CODES:

QUICK CHECK

X = Open Circuit/Fail

) = Short Circuit

Check 1

? Over Temperature Icon Displayed at Power ON? POSSIBLE CAUSES 1. Sensor(s) – Motor/Motor Controller – Connections/Wiring?

Cause A

2. Sensor(s) Failure?

Cause A

3. Motor Controller(s) Hardware Failure?

Cause D

Note: Hydraulic Oil Over Temperature and Sensor Issues seeHydraulic Temperature Sensor Out of Range High (OORL) /Hydraulic Temperature Sensor Out of Range High (OORH)

? Over Temperature Icon Displayed during Operation/Reduced Performance/Function Failure? POSSIBLE CAUSES 1. Motor/Motor Controller/Hydraulic Fluid Overheating?

Aggressive Operation?

2. Sensor – Motor/Motor Controller/Hyd Tank – Connections/Wiring?

Cause A

3. Sensor(s) Failure?

Cause A

4. Motor Controller(s) Failure ?

Cause D

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9030-30-23

Observed Symptoms

Electrical System

TSP A955 – G807 Motor/Motor Controller Temperature Sensor Failure (Cont) Note: For further assistance on Silicon Temperature Sensor readings, see Table 9030-10-1, Page 9030-10-21 Temperature Control Chart Table Application

Performance Cutback Start

Performance Cutback Finish

°C

°F

°C

°F

Traction Motor

165

329

185

365

Traction Controller

176

115

239

Pump Motor

145

293

160

320

Pump Controller

176

115

239

Hyd Fluid

185

100

212

Fan ON °C

°F

149

131

Check 2

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Wait 30 seconds

Reconnect Battery

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Electrical System

Observed Symptoms

TSP A955 – G807 Motor/Motor Controller Temperature Sensor Failure (Cont) Check 3

Fault Remains Service Required

Power ON

No Fault

Resume Operation

Check 4

Reduced Performance

Check Display Icons

Motor/Motor Controller Temperature Icon On 1. Check fan operation

Are fans operating?

2. Temp Sensor/Controller to Motor connection

A955 – G807 Motor Controller Fan Failure YES

Open Circuit

Cause A

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9030-30-25

Observed Symptoms

Electrical System

TSP A955 – G807 Motor/Motor Controller Temperature Sensor Failure (Cont) Check 5 Diagnostics Temperature Analysis – Go to Display Menu Flowchart

Enter Service Password

Diagnostics

Motor

Traction1/Traction2/Pump

Motor/Controller Data

Fan(s) Operation Temperature Threshold: Traction = 55°C (131°F) Pump = 65°C (149°F) Reduced Performance: Traction = 80°C (176°F) Pump = 80°C (176°F)

Motor

Motor Controller

Invalid Temperature Signal (Traction/Pump Motor(s) Only): Sensor Connections/Sensor Open Circuit

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Electrical System

Observed Symptoms

TSP A955 – G807 Motor/Motor Controller Temperature Sensor Failure (Cont)

Return to Diagnostics Menu Check 6 Fault Log DTC – Go to Display Menu Flowchart

Enter Service Password

all Motor Codes

Motor Versions

Diagnostic

FAULT LOGs

( Exit Fault Log

Motor Fault Log(s)

View all Motor DTCs

Truck Status

"Hardware/Software Versions ( Exit Versions

Power OFF

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9030-30-27

Observed Symptoms

Electrical System

TSP A955 – G807 Motor/Motor Controller Temperature Sensor Failure (Cont) POSSIBLE CAUSES

X = Open Circuit/Fail

) = Short Circuit

X = No DTC

CAUSES A B C D E > ?

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9030-30-28

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Electrical System

Observed Symptoms

TSP A955 – G807 Motor/Motor Controller Temperature Sensor Failure (Cont) CONNECTORS

VSM Cxx 1 and Cxx 2

Traction/Pump Controller Cxx 3, 4, and 5

Fan Motor Connector Cxx 156, 157, 595A, and 595B

CAUSE A

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

STEP A1 For any Fault DTC

Locate Device

Inspect ALL Wiring/Connections

A DMM Temperature probe can also be used to determine which device is overheating

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9030-30-29

Observed Symptoms

Electrical System

TSP A955 – G807 Motor/Motor Controller Temperature Sensor Failure (Cont) STEP A2

CHECK RESISTANCE -

- OHMS

Motor Temperature Sensor

1. Disconnect Motor Connector

Measure

as indicated

Note: For temperature sensor readings, see Table 9030-10-1, Page 9030-10-21. At xxx deg 2. <300 3. >2800

sensor

to 0

≈ match Temperature Chart 340

= Motor Sensor Short Circuit

to ∞

@ -40°C (25°F) to 2791

@ 300°C (572°F)

Go to 8

= Motor Sensor Open Circuit/High Resistance Connection

Go to 8

4. Reconnect Motor Connector 5. Disconnect Controller Connector 6. <300 7. >2800

to 0

= Short Circuit

to ∞

Measure

as indicated

Go to 9

= Open Circuit/High Resistance Connection

8. Replace Motor

See Temperature Sensor Chart

Go to 9

Go to 10

9. Find/Repair Harness OPEN/SHORT Circuit

Go to 10

10. See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 11. Recheck

Reconnect

Go to 11

Resume Operation

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Electrical System

Observed Symptoms

TSP A955 – G807 Motor/Motor Controller Temperature Sensor Failure (Cont) STEP A3 Motor Temperature Sensor (Controller Check)

1. Disconnect Motor Temperature Sensor Connector from suspect Controller 2. Connect a ¼ watt resistor (>3300

to <10,000 ) as shown

3. Reconnect Battery and all other Connectors 4. Does Over Temperature ICON Appear? 5. YES: Go to 7 6. NO: Controller is Faulty

Cause D

7. Repeat Resistor Test on other Controllers 8. Temperature ICON is Displayed?

YES: Controller tested OK, Go to 9

NO: Controller tested Faulty

Cause D

9. Reconnect other Motor Temperature Sensors

CAUSE B Not Applicable

CAUSE C Not Applicable

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9030-30-31

Observed Symptoms

Electrical System

TSP A955 – G807 Motor/Motor Controller Temperature Sensor Failure (Cont) CAUSE D

Disconnect Battery and Sound Horn to Discharge Capacitors. Depending on your lift truck, go to Frame 100 YRM 1329 or Frame 100 YRM 1342.

Power OFF

STEP D1

Remove and Replace Faulty Motor Controller See /Electrical System 2200 YRM 1337Electrical System 2200 YRM 1369 Check Replacement Controller

Version

See Label Information

Step D2

STEP D2

1. Go to TRD/Axcess Online /Software. ?? Is Replacement Controller Application Software Version the Latest Version 2. NO 3. YES

Download the latest Application Test New Installation

4. Return Faulty Display

Dealer

Install on truck

Step D3 Factory

Failure Analysis

?? Reprogramming

(continued on next page)

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9030-30-32

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Observed Symptoms

TSP A955 – G807 Motor/Motor Controller Temperature Sensor Failure (Cont) STEP D3

Retest - Power ON

Is fault DTC gone? YES NO

Fault corrected

Continue operation.

CAUSE E

Power OFF

Inspect VSM Connections

OK Step E1

Not OK Correct/Repair

Step E1

STEP E1

Retest - Power ON

NO Go to VSM Controller Check

Is fault DTC gone? YES

Fault corrected

Continue operation.

NO

DTC LOGS: DTC logs should only be cleared once the data is " by the Service Tech. See Display Menu Flowchart - Clearing DTCs.

END SYMPTOM

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9030-30-33

Observed Symptoms

Electrical System

Horn Failure DIAGRAMS

WIRE # 005 (RED) = HORN SUPPLY WIRE # 045 (WHITE) = SIGNAL GROUND WIRE # 124 (BLACK) = HORN GROUND Horn Schematic CONNECTOR(S)

Connector CPS4

Connector CPS9

Connector CPS10 Connector CPS8

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9030-30-34

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Observed Symptoms

Horn Failure(Cont)

Connector CPS15 POSSIBLE CAUSE A. B. C. D.

FUSE BLOWN IN PDM OPEN CIRCUIT IN WIRING HARNESS HORN FAILURE VSM FAILURE

COMPONENT OPERATIONAL CHECK PROCEDURE OR ACTION: 1. Open engine cover to gain access to battery and Power Distribution Module (PDM). See Operating Manual. 2. Examine connections between battery and PDM.

Are connections correct and secure? YES: Go to Cause A. NO: Connect cables, as required. Depending on your lift truck, see Electrical System 2200 YRM 1369, or Electrical System 2200 YRM 1337. CAUSE A - FUSE BLOWN IN PDM PROCEDURE OR ACTION: 1. At the PDM, open access cover. 2. Using DMM, measure voltage on both sides of fuse F6 (+) with respect to ground (-).

Is voltage on one side of fuse less than 0.5 Vdc? YES: Check wiring harness for shorts between wires 005 and 124 or 005 and the vehicles frame. Repair or Replace wiring harness. Depending on your lift truck, see Wire Harness Repair 2200 YRM 1128, or Fuse 6 is blown, replace blown fuse. NO: Fuse 6 is OK. Go to Cause B.

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9030-30-35

Observed Symptoms

Electrical System

Horn Failure (Cont) CAUSE B - OPEN CIRCUIT IN WIRING HARNESS NOTE: If DTC 524213-4 appears, go to Wire Harness Repair 2200 YRM 1128 PROCEDURE OR ACTION: 1. Disconnect horn at CPS 89. 2. Using DMM, measure voltage between Pin B and Pin C on CPS 89.

Is battery voltage present? YES: Go to Step 3. NO: Check wiring harness for shorts between wires 005 and 124 for open circuit. Repair or Replace wiring harness. Depending on your lift truck, see Wire Harness Repair 2200 YRM 1128. 3. Change DMM to ohms scale. Verify DMM zero reading. Is the reading approximately 28 ? YES: Go to Step 4. NO: Wire 045 has a short to ground in the wiring harness. Repair/Replace wiring harness. Depending on your lift truck, see Wire Harness Repair 2200 YRM 1128. NOTE: Do not disconnect wiring harness at horn button. 4. Remove only horn button from top of steering wheel. Ensure that wire is still connected. 5. Set DMM to volts scale. 6. Measure voltage on both sides of horn button terminals with respect to ground (-). Is battery voltage present? YES: Go to Step 7. NO: Go to Step 8. 7. Connect DMM to slip ring wires. During voltage measurement, rotate steering wheel from lock-to-lock position to test the entire slip ring surface. Is battery voltage present? YES: Repair or Replace slip ring assembly. Go to Steering Column Repair. NO: Wire 025 and 109 has open circuit in wiring harness. Repair/Replace wiring harness. Depending on your lift truck, see Wire Harness Repair 2200 YRM 1128. 8. Push horn button. Does DMM voltage go to zero? YES: Go to Cause C. NO: Replace horn button. CAUSE C - HORN FAILURE PROCEDURE OR ACTION: 1. Connect horn at CPS 89. 2. Using a jumper wire to short circuit, connect Pin A and Pin C at CPS 89. Does DMM voltage go to zero? YES: Go to Cause D. NO: Replace horn.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9030-30-36

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Observed Symptoms

Horn Failure (Cont) CAUSE D - VSM FAILURE PROCEDURE OR ACTION: 1. Replace VSM. Depending on your lift truck, see Electrical System 2200 YRM 1369, or Electrical System 2200 YRM 1337. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

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9030-30-37

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

9030-30-38

Electrical System

Icons and Graphics

Group 55

Icons and Graphics Icon Glossary INTRODUCTION TO ICONS An icon is a symbol that conveys a unique meaning without words, such as an arrow. The Operating Screen on this lift truck presents information to an operator solely through the use of symbols which are mostly icons, along with some numbers and a few text characters. Icons make it possible to simultaneously display up to 12 kinds of information graphically in a Symbols/Icons

small space. In addition, the use of icons reduces the difficulty of communicating with operators who speak different languages. The following table, are icons used during the Diagnostic Troubleshooting Procedures. For further details on displays and icons, see User Interface, Supervisor 2200 YRM 1335 or User Interface, Service Technician 2200 YRM 1336. Definition Display FAULT Panel

Password Screen

System Power OFF

System Power ON / Display RUN Screen

PC Service Tool

Vehicle System Manager

Confidential/Proprietary - Do Not Copy or Duplicate

9030-55-1

Icons and Graphics

Symbols/Icons

Electrical System

Definition Operator Password

Supervisor Password

Service Password

Service Required / Fault Code

Digital Multimeter

Operate the Indicated Button / Key / Device

Look For / Find

Garbage / Junk / Rubbish Receptacle

Operator Presence

Park Brake

9030-55-2

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Symbols/Icons

Icons and Graphics

Definition Wait 30-Seconds

Work Lights

Battery

Battery Disconnect

Reconnect Battery

Locate Diagnostic Connector

Sound Horn to Discharge Capacitors

Fork Truck

Travel Direction

Confidential/Proprietary - Do Not Copy or Duplicate

9030-55-3

Icons and Graphics

Symbols/Icons

Electrical System

Definition Mast Tilt Position

Push in Emergency Stop

Release Emergency Stop

Accelerator Pedal

Buzzer / Audible Warning Device

Contactor

DCS – Directional Control Selector

E-Hydraulic

Hydraulic Temperature

Load Weigh Pressure

9030-55-4

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Symbols/Icons

Icons and Graphics

Definition Manual-Hydraulic

MLM Lever

MLM PCB Cassette

Pump Motor

Service Brake Pressure

Steering Wheel Position

Steering Axle Position

Traction Motor

Accelerator Sensor

Hydraulic Temperature Sensor

Load Weight Pressure Sensor

Confidential/Proprietary - Do Not Copy or Duplicate

9030-55-5

Icons and Graphics

Symbols/Icons

Electrical System

Definition Manual Hydraulic Position Sensor

Motor Speed Sensor

Operator Presence Sensor

Park Brake/Mast Tilt Sensor

Steering Axle/Wheel Sensor

Temperature Sensor

Travel Direction Foot Pedal Sensor

Travel Direction Manual Hydraulic Sensor

Failure / Cause / Occurence Failure A / Cause A / Occurence A

Shorted Connection / Fault e.g.C

Resistor e.g. Value = 1.1KOhms

Fuse – xx Amps

9030-55-6

Confidential/Proprietary - Do Not Copy or Duplicate

Electrical System

Symbols/Icons

Icons and Graphics

Definition Emergency Disconnect

Coil – Relay / Contactor / Valve Contactor/Relay//Valve Coil

Switch – Normally Open

Switch – Normally Closed High Resistance Okay / Correct

" #

Record Software Repair Faulty Component Go to Next Step

Go to Next Step

Go to Next Cause

Display arrow Left Display arrow Right Go to next step

Confidential/Proprietary - Do Not Copy or Duplicate

9030-55-7

Icons and Graphics

Electrical System

Symbols/Icons

Definition

Display Scroll UP/DOWN Push Buttons Lift / Lower Hydraulic Lever(s)

≠

Not Equal Ohms

≈ ∞ ? = < > 1

9030-55-8

Approximately Infinite Value Question / Questionable Operation Equal / Compare to Less Than Greater Than Dead - Destroyed – Beyond Redemption

Confidential/Proprietary - Do Not Copy or Duplicate

SECTION 9035

DRIVE AXLE/UNIT TABLE OF CONTENTS Group 10 - Principles of Operation Drive Axle ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (A955) ............................................. Description .......................................................................................................................................... Principles of Operation........................................................................................................................ Drive Units ........................................................................................................................................ Brakes ............................................................................................................................................... Drive Axle ERC22-35VG (ERC40-70VG) (A968)ERC16-20VA ERC030-040VA (A969)....................... Description .......................................................................................................................................... Dry Brake System ............................................................................................................................... General ............................................................................................................................................. Master Cylinder................................................................................................................................. Parking Brake.................................................................................................................................... Automatic Park Brake........................................................................................................................ Foot Directional Control Pedal ............................................................................................................ Description ........................................................................................................................................ Principles of Operation...................................................................................................................... Group 30 - Observed Symptoms One Drive Wheel Will Not Move ............................................................................................................ Noise During Operation That Is Not Normal ......................................................................................... Oil Leaks ............................................................................................................................................... Park Brake Does Not Operate Properly ................................................................................................

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9035-10-1 9035-10-1 9035-10-1 9035-10-1 9035-10-1 9035-10-2 9035-10-2 9035-10-4 9035-10-4 9035-10-4 9035-10-4 9035-10-4 9035-10-4 9035-10-4 9035-10-5 9035-30-1 9035-30-2 9035-30-4 9035-30-5

9035-1

9035-2

Drive Axle/Unit

Principles of Operation

Group 10

Principles of Operation Drive Axle ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (A955) DESCRIPTION

Brakes

This series of lift trucks is equipped with a transaxle which consists of a drive motor, an in-line gear set drive unit, and a park brake on each drive wheel. This series of lift trucks is also equipped with a wet brake system which is located within the transaxle.

• Dual, hydraulically operated, wet disk service brakes are designed into the drive unit. • These brakes are inside the drive unit, and therefore are impervious to water and operate with no degradation of performance in these conditions. • The master cylinder and integrated reservoir have fluid level sensor connected to a warning light on the display panel. • Spring applied, electrically released park brake is mounted at the end of each motor. The parking brake is automatically set by the control system so that the brake is always applied whenever the truck is not moving, and no traction has been requested. A manual release mechanism has been designed into the park brake.

PRINCIPLES OF OPERATION The lift truck uses two drive units. One drive unit is mounted on each side of the lift truck frame beneath the cowl. The drive unit is an in-line gear set that incorporates a wet disk service brake assembly within the drive unit. The traction motor and park brake is mounted on one side of the drive unit, and the drive wheel and tire assemblies are mounted to the other side of the drive unit. The drive unit is secured to the lift truck frame using a series of five capscrews. The drive unit housing provides the mounts needed to attach the mast to the lift truck. Power from the traction motor is transmitted to the drive unit through an internal spline in the input gear. See Figure 9035-10-1, Page 9035-10-1.

Drive Units • Dual, in-line drive units are individually mounted in the frame with complete and separate traction motor and braking systems. This system allows for independent traction control for each wheel. • The drive unit assemblies mount to the frame with five capscrews per side. • The drive unit housings also support the mast through machined and bushed trunnion mounts. The hang-on mast mounting system, with its mounting hardware accessible from above, provides a convenient way to install/remove the mast. An easily accessible grease fitting is provided to lubricate the mast mounting and bushing. • Wet disk brakes are designed as an integral part of the drive unit.

1. DRIVE UNIT 2. MAST MOUNTING CAPS 3. TRACTION MOTORS

Figure 9035-10-1. Transaxle Mounting

Confidential/Proprietary - Do Not Copy or Duplicate

9035-10-1

Principles of Operation

Drive Axle/Unit

Drive Axle ERC22-35VG (ERC40-70VG) (A968)ERC16-20VA ERC030-040VA (A969) DESCRIPTION This lift truck is equipped with a conventional drive axle and uses dry service brakes. The drive axle is fastened to the frame of the lift truck with four bolts, washers, and nuts. See Figure 9035-10-2, Page 9035-10-2. The outer ends of the axle housings are the spindles for the wheel bearings. The cups for the tapered roller bearings are pressed into the wheel hubs. The nut on the end holds and adjusts the preload on the wheel bearings. The axle shafts are fastened to the hubs by capscrews. Studs and nuts fasten the wheel to the hub and brake drum. The back plate and brake assemblies are fastened to the axle assembly or assemblies. The center section contains the speed reducer and differential assembly. See Figure 9035-10-3, Page 9035-10-3. The speed reducer has a gear that engages the splines on the shaft of the traction motor. A second speed reducer gear is fastened to the pinion shaft for the differential.

1. 2. 3. 4.

9035-10-2

Confidential/Proprietary - Do Not Copy or Duplicate

DRIVE AXLE ASSEMBLY AXLE MOUNTING BOLT WASHER NUT

Figure 9035-10-2. Drive Axle Mounting

Drive Axle/Unit

1. 2. 3. 4. 5. 6. 7. 8. 9.

Principles of Operation

CAPSCREW AXLE SHAFT BEARING LOCK NUT BEARING LOCK WASHER WHEEL BEARING WASHER OUTER BEARING CONE OUTER BEARING CUP HUB OUTER SEAL

10. 11. 12. 13. 14. 15. 16. 17.

INNER BEARING CUP INNER BEARING CONE INNER SEAL LOCK BOLT BRAKE ASSEMBLY WASHER LH HANGER CENTER SECTION ASSEMBLY

Figure 9035-10-3. Drive Axle Assembly

Confidential/Proprietary - Do Not Copy or Duplicate

9035-10-3

Principles of Operation

Drive Axle/Unit

DRY BRAKE SYSTEM

Master Cylinder

General

The master cylinder is designed for a single-circuit system. The master cylinder has a piston that operates in the bore of the master cylinder.

The dry brake system includes the following parts: park brake, service brakes, master cylinder, and automatic park brake or manual. The manual park brake assembly contains a release handle, pedal, position sensor and cable. The service brake assembly contains the brake pedal, master cylinder, brake assembly (attached to wheel), and park brake cables. The automatic park brake assembly contains the brake (attached to the traction motor), cable, and handle.

The reservoir is equipped with an indicator for low fluid level. A float in the reservoir moves up and down with the fluid level. When the fluid level is low, a magnet on the float activates a switch in the bottom of the reservoir. This switch signals the Vehicle System Manager (VSM) which illuminates an icon on the Display Panel (DP).

Parking Brake The parking brake system uses the service brake shoes. Additional linkage activates the parking brake system. When the pedal is moved to apply the parking brake, the cables and linkage expand the brake shoes against the drums. The design of the parking brake linkage adjusts each cable so that the tension is the same when the pedal is moved to apply the parking brake. The park brake sensor is located on the left side of the park brake pedal.

Automatic Park Brake

1. PARK BRAKE RELEASE HANDLE 2. PARK BRAKE PEDAL 3. PARK BRAKE POSITION SENSOR (LEFT-HAND SIDE) 4. BRAKE PEDAL 5. MASTER CYLINDER 6. BRAKE ASSEMBLY 7. PARK BRAKE CABLES 8. AUTOMATIC PARK BRAKE ASSEMBLY 9. AUTOMATIC PARK BRAKE CABLE 10. AUTOMATIC PARK BRAKE RELEASE HANDLE 11. TRACTION MOTOR

Figure 9035-10-4. Brake System

9035-10-4

The automatic park brake is optional and replaces the standard parking brake. This brake is attached to the traction motor. The automatic park brake activates at zero speed. If the driver leaves the seat; a switch notifies the operating software and the lift truck will slow to a stop. When the lift truck is stopped for a period longer than two seconds, the park brake will apply automatically. When the accelerator is applied, the brake will release. The manual override is a handle attached to the cable and for use when the lift truck has no power. The brake is in the applied position when the handle rests against the mechanical stop. The brake is manually released by pulling the handle upright.

FOOT DIRECTIONAL CONTROL PEDAL Description The Foot Directional Control pedal controls the speed of the traction motor and direction of the drive unit. There are two foot-actuated momentary-push-on switches on the left and right sides of the pedal. Pressing the left side of the pedal actuates the forward direction pedal switch. Pressing on the right side of the pedal actuates the reverse direction pedal switch. Releasing the pedal releases both pedal direction switches.

Confidential/Proprietary - Do Not Copy or Duplicate

Drive Axle/Unit

Principles of Operation There is a small directional switch under each pad of the Foot Directional Control pedal. Each switch controls one direction. If both sides of the Foot Directional Control pedal are pushed at the same time, the transmission shifts to neutral until one or both switches is released. Then the transmission shifts back to the last direction selected or the new direction selected. The state of the transmission control circuit is displayed by icons on the Display Panel (DP) indicating neutral or the direction of travel. Before the lift truck will move the following conditions must be met: • Park brake pedal released. • Operator must be present in seat. • Traction motor signal requested. When the Foot Directional Control pedal is in the forward position, the Vehicle System Manager (VSM)

Confidential/Proprietary - Do Not Copy or Duplicate

Principles of Operation transmission control circuit will send signal to the transmission proportional valve to engage the forward clutch pack. When the Foot Directional Control pedal is in the reverse position, the Vehicle System Manager (VSM) transmission control circuit will send a signal to the transmission proportional valve to engage the reverse clutch pack. When any one of the following conditions occur the transmission shifts to neutral regardless of pedal position. • Park brake engaged. • Operator not present in seat. • Both directions (forward and reverse) are pressed at the same time. • When transmission control pressure is lost, and the transmission is effectively in neutral due to loss of the traction motor signal. • Some diagnostic trouble codes occur.

9035-10-5

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

9035-10-6

Drive Axle/Unit

Observed Symptoms

Group 30

Observed Symptoms One Drive Wheel Will Not Move POSSIBLE CAUSE A. ELECTRICAL SYSTEM FAULT B. DAMAGE TO TRACTION MOTOR. C. DAMAGE TO GEAR REDUCTION SYSTEM IN DRIVE UNIT. CAUSE A - ELECTRICAL SYSTEM FAULT PROCEDURE OR ACTION: 1. Troubleshoot electrical system. Are any faults found during troubleshooting electrical system? YES: Correct faults. Depending on your lift truck, see Electrical System 2200 YRM 1369, or Electrical System 2200 YRM 1337. NO: Go to Cause B. CAUSE B - DAMAGE TO TRACTION MOTOR. PROCEDURE OR ACTION: 1. Inspect for damaged traction motor.

Is traction motor apparently damaged? YES: Repair or replace traction motor. Depending on your lift truck, see Transaxle 1300 YRM 1330, Transaxle 1300 YRM 1370, or Drive Axle, Speed Reducer, and Differential 1300 YRM 1366. NO: Go to Cause C. CAUSE C - DAMAGE TO GEAR REDUCTION SYSTEM IN DRIVE UNIT. PROCEDURE OR ACTION: 1. Inspect for damaged drive unit. See Free Wheel Test.

Does drive unit pass test? YES: Resume operation. NO: Replace drive unit. Depending on your lift truck, see Transaxle 1300 YRM 1330, Transaxle 1300 YRM 1370, or Drive Axle, Speed Reducer, and Differential 1300 YRM 1366. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

Confidential/Proprietary - Do Not Copy or Duplicate

9035-30-1

Observed Symptoms

Drive Axle/Unit

Noise During Operation That Is Not Normal POSSIBLE CAUSE A. MISSING OR LOOSE LUG NUTS B. LOOSE DRIVE AXLE MOUNTING CAPSCREWS C. LOW OIL LEVEL D. BEARING DAMAGE E. NOISE CONTINUES AFTER CORRECT OIL LEVEL F. RING AND PINION BACKLASH IS NOT PROPER G. NOISE CONTINUES CAUSE A - MISSING OR LOOSE LUG NUTS PROCEDURE OR ACTION: 1. Check for missing or loose lug nuts. Are any lug nuts missing or loose? YES: Tighten loose or missing lug nuts. Depending on your lift truck, see Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. NO: Go to Cause B. CAUSE B - LOOSE DRIVE AXLE MOUNTING CAPSCREWS PROCEDURE OR ACTION: 1. Check for loose drive axle mounting capscrews.

Are any drive axle mounting capscrews loose? YES: Tighten drive axle mounting capscrew. Depending on your lift truck, see Transaxle 1300 YRM 1330, Transaxle 1300 YRM 1370, or Drive Axle, Speed Reducer, and Differential 1300 YRM 1366. NO: Go to Cause C CAUSE C - LOW OIL LEVEL PROCEDURE OR ACTION: 1. Check level of oil.

Is oil level low? YES: Add oil to correct level. See Operating Manual. NO: Go to Cause E. CAUSE D - BEARING DAMAGE PROCEDURE OR ACTION: 1. Check for damage on bearings.

Are bearings damaged? YES: Repair or replace traction motor. Depending on your lift truck, see Transaxle 1300 YRM 1330, Transaxle 1300 YRM 1370, or Drive Axle, Speed Reducer, and Differential 1300 YRM 1366. NO: Go to Cause F.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9035-30-2

Confidential/Proprietary - Do Not Copy or Duplicate

Drive Axle/Unit

Observed Symptoms

Noise During Operation That Is Not Normal (Cont) CAUSE E - NOISE CONTINUES AFTER CORRECT OIL LEVEL PROCEDURE OR ACTION: 1. Check for wear and damage in the gear reduction system.

Does gear reduction have wear and damage? YES: Repair the drive axle, speed reducer and differential assembly. See Drive Axle, Speed Reducer, and Differential 1300 YRM 1366. NO: Go to Cause D. CAUSE F - RING AND PINION BACKLASH IS NOT PROPER PROCEDURE OR ACTION: 1. Check the ring and pinion backlash. Is ring and pinion backlash within specifications? YES: Go to Cause G. NO: Adjust ring and pinion backlash. See Drive Axle, Speed Reducer, and Differential 1300 YRM 1366. CAUSE G - NOISE CONTINUES PROCEDURE OR ACTION: 1. Check to make sure that the ring and pinion is a matched gear set.

Are the ring and pinion a matched? YES: Resume operation. NO: repair or replace ring and pinion. See Drive Axle, Speed Reducer, and Differential 1300 YRM 1366. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

Confidential/Proprietary - Do Not Copy or Duplicate

9035-30-3

Observed Symptoms

Drive Axle/Unit

Oil Leaks POSSIBLE CAUSE A. B. C. D.

OIL LEAK BETWEEN DRIVE UNIT HOUSING AND COVER DAMAGED O-RINGS OR OIL SEALS DRAIN, LEVEL, OR FILL PLUG LOOSE OIL BEING EJECTED THROUGH BREATHER DUE TO OVERFILLING

CAUSE A - OIL LEAK BETWEEN DRIVE UNIT HOUSING AND COVER PROCEDURE OR ACTION: NOTE: This procedure is to be performed during the initial two year warranty period for lift trucks ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (A955). 1. Tighten housing bolts as directed in Transaxle 1300 YRM 1330, or Transaxle 1300 YRM 1370.

Did the leak stop? YES: Continue lift truck operation. NO: Replace the drive unit. See Transaxle 1300 YRM 1330, or Transaxle 1300 YRM 1370. After the two year warranty period has expired on the above lift trucks go to Cause B. CAUSE B - DAMAGED O-RINGS OR OIL SEALS PROCEDURE OR ACTION: NOTE: For lift trucks ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (A955) the following procedure is to be performed only after the two year warranty period has expired. 1. Inspect O-rings and oil seals.

Are O-rings or oil seals damaged? YES: Repair or replace damaged O-rings or oil seals. Depending on your lift truck, see Transaxle 1300 YRM 1330, Transaxle 1300 YRM 1370, or Drive Axle, Speed Reducer, and Differential 1300 YRM 1366. NO: Go to Cause C CAUSE C - DRAIN, LEVEL, OR FILL PLUG LOOSE PROCEDURE OR ACTION: 1. Inspect for loose drain, level, or fill plug.

Is drain. level, or fill plug loose? YES: Tighten plug if necessary. Tighten to 22 N•m (16. lbf ft) Depending on your lift truck, see Transaxle 1300 YRM 1330, Transaxle 1300 YRM 1370, or Drive Axle, Speed Reducer, and Differential 1300 YRM 1366. NO: Go to Cause D. CAUSE D - OIL BEING EJECTED THROUGH BREATHER DUE TO OVERFILLING PROCEDURE OR ACTION: 1. Inspect breather for ejection of excess oil.

Is excess oil being ejected from breather? YES: Remove oil drain plug and allow excess to drain until level is at bottom of oil fill plug. NO: Resume operation. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9035-30-4

Confidential/Proprietary - Do Not Copy or Duplicate

Drive Axle/Unit

Observed Symptoms

Park Brake Does Not Operate Properly POSSIBLE CAUSE A. PARK BRAKE ACCUMULATOR IS FAULTY. CAUSE A - PARK BRAKE ACCUMULATOR IS FAULTY. PROCEDURE OR ACTION: 1. Bring truck to a complete stop. 2. Run tilt over relief for 15 seconds (this will fully charge the accumulator). 3. Press the accelerator pedal to move the lift truck 0.3 m (1 ft) with no hydraulic functions actuated including steering. 4. Come to a compete stop then repeat Step 3.

Does hydraulic pump run at a fast rate for a brief period? YES: Replace accumulator. See Transaxle 1300 YRM 1370 NO: Problem not Verified. Resume Operation. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

Confidential/Proprietary - Do Not Copy or Duplicate

9035-30-5

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

9035-30-6

SECTION 9050

HYDRAULIC SYSTEMS TABLE OF CONTENTS Group 10 - Principles of Operation Manual Hydraulic Main Control Valve.................................................................................................... Description .......................................................................................................................................... Manual Hydraulic Control System ....................................................................................................... General Description (Open Center Valve)........................................................................................... CONSTRUCTION ............................................................................................................................. VALVE TYPE..................................................................................................................................... Features and Operation ...................................................................................................................... INLET ASSEMBLY ............................................................................................................................ Construction and Purpose .............................................................................................................. Porting............................................................................................................................................. Priority Steer ................................................................................................................................... Relief Cartridge............................................................................................................................... LIFT SECTION.................................................................................................................................. Construction.................................................................................................................................... Purpose .......................................................................................................................................... Load Check..................................................................................................................................... Operator Presence Solenoid........................................................................................................... Position Sensor Assembly .............................................................................................................. Mast Lowering Cartridge................................................................................................................. TILT SECTION .................................................................................................................................. Construction.................................................................................................................................... Purpose .......................................................................................................................................... AUXILIARY AND DUAL AUXILIARY SECTION ................................................................................ Construction.................................................................................................................................... Purpose .......................................................................................................................................... OUTLET COVER SECTION ........................................................................................................... Construction and Purpose ............................................................................................................ General Description (Closed Center Valve) ...................................................................................... CONSTRUCTION ........................................................................................................................... VALVE TYPE................................................................................................................................... Features and Operation .................................................................................................................... INLET ASSEMBLY .......................................................................................................................... Construction and Purpose ............................................................................................................ Porting........................................................................................................................................... Priority Steer ................................................................................................................................. Unloading Spool and Relief Cartridge .......................................................................................... LIFT SECTION................................................................................................................................ Purpose ........................................................................................................................................ Operation - Main Spool ................................................................................................................. Load Check................................................................................................................................... Operator Presence Solenoid......................................................................................................... Position Sensor ............................................................................................................................. Mast Lowering Cartridge............................................................................................................... TILT SECTION ................................................................................................................................ Construction and Purpose ............................................................................................................

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9050-10-1 9050-10-1 9050-10-1 9050-10-3 9050-10-3 9050-10-3 9050-10-4 9050-10-4 9050-10-4 9050-10-4 9050-10-4 9050-10-5 9050-10-5 9050-10-5 9050-10-5 9050-10-6 9050-10-6 9050-10-7 9050-10-7 9050-10-8 9050-10-8 9050-10-8 9050-10-9 9050-10-9 9050-10-9 9050-10-10 9050-10-10 9050-10-10 9050-10-10 9050-10-10 9050-10-11 9050-10-11 9050-10-11 9050-10-11 9050-10-12 9050-10-13 9050-10-14 9050-10-14 9050-10-14 9050-10-16 9050-10-17 9050-10-18 9050-10-18 9050-10-19 9050-10-19

9050-1

Section 9050

Hydraulic Systems

TABLE OF CONTENTS (Continued) Operation ...................................................................................................................................... Main Spool with Tilt-Lock .............................................................................................................. AUXILIARY AND DUAL AUXILIARY SECTIONS............................................................................ Construction and Purpose ............................................................................................................ Operation ...................................................................................................................................... E-Hydraulic Main Control Valve........................................................................................................... Electro-Hydraulic Control System ..................................................................................................... General Valve Description................................................................................................................. Construction.................................................................................................................................... Valve Type....................................................................................................................................... Features and Operation .................................................................................................................... Inlet Section .................................................................................................................................... Construction and Purpose ............................................................................................................ Porting........................................................................................................................................... Priority Steer ................................................................................................................................. Unloading Spool and Relief Cartridge .......................................................................................... Pilot Cartridge ............................................................................................................................... Lift Section ...................................................................................................................................... Construction and Purpose ............................................................................................................ Operation - Main Spool ................................................................................................................. Load Check................................................................................................................................... Mast Lowering Cartridge............................................................................................................... Electro-Hydraulic (EH) Solenoid ................................................................................................... Tilt Section ...................................................................................................................................... Construction and Purpose ............................................................................................................ Operation ...................................................................................................................................... Main Spool .................................................................................................................................... Spacer Sections.............................................................................................................................. Construction and Purpose ............................................................................................................ Auxiliary and Dual Auxiliary Sections.............................................................................................. Construction and Purpose ............................................................................................................ Operation ...................................................................................................................................... Steering System .................................................................................................................................. Description ........................................................................................................................................ Accumulator, Piston ........................................................................................................................ Priority Steer (E-Hydraulic Control Valve) ....................................................................................... Priority Steer (Manual Hydraulics Open Center Control Valve) ...................................................... Priority Steer (Manual Hydraulics Closed Center Control Valve) .................................................... Steering Control Unit (SCU) Operation ............................................................................................. Group 33 - Observed Symptoms-Gear Pump Abnormal Hydraulic Noise and/or Vibration .......................................................................................... Abnormal Smell/Discoloration/Foaming of Oil....................................................................................... Cycle Times Too Fast - Fast Actuation (E-Valve) .................................................................................. Jump/Delay In Lift or Lower Activation After Moving MLM (E-Valve)..................................................... Jump/Delay In Auxiliary Function Actuation After Moving MLM (E-Valve) .......................................... Jump/Delay In Tilt Forward or Back Actuation (E-Valve) ..................................................................... Forks Drop Slightly Before Lifting (E-Valve) ........................................................................................ Forks Lower Without Command (E-Valve) .......................................................................................... Forks Raise or Actuate Without Command (E-Valve) ......................................................................... Intermittent Activation (E-Valve) While Commanding Function ........................................................... Forks Tilt Forward Without Command (E-Valve) ................................................................................. Lift/Lower Function Maximum Speed Too Slow (E-Valve) ...................................................................

9050-2

9050-10-19 9050-10-20 9050-10-20 9050-10-20 9050-10-21 9050-10-22 9050-10-22 9050-10-23 9050-10-23 9050-10-23 9050-10-24 9050-10-24 9050-10-24 9050-10-24 9050-10-24 9050-10-25 9050-10-26 9050-10-26 9050-10-26 9050-10-26 9050-10-28 9050-10-28 9050-10-29 9050-10-29 9050-10-29 9050-10-29 9050-10-30 9050-10-30 9050-10-30 9050-10-31 9050-10-31 9050-10-31 9050-10-32 9050-10-32 9050-10-33 9050-10-33 9050-10-34 9050-10-35 9050-10-36 9050-33-1 9050-33-5 9050-33-6 9050-33-8 9050-33-10 9050-33-12 9050-33-13 9050-33-14 9050-33-15 9050-33-16 9050-33-17 9050-33-20

Confidential/Proprietary - Do Not Copy or Duplicate

Section 9050

Hydraulic Systems

TABLE OF CONTENTS (Continued) Lift Function Will Not Move With MLM Movement (E-Valve) ............................................................... Lift/Lower Continues To Move For Awhile After MLM Is Released (E-Valve) ...................................... Lift/Lower/Auxiliary Function Suddenly Jumps In Middle of Stroke (E-Valve) ..................................... Lower Function Will Not Move With MLM Movement (E-Valve) .......................................................... Poor Metering on Lift or Lower Functions (E-Valve) ............................................................................ Auxiliary Function Continues to Move for Awhile After MLM Is Released (E-Valve) ........................... Auxiliary Function Maximum Speed Too Slow (E-Valve)..................................................................... Auxiliary Function or Tilt Back Moves Without Command (E-Valve) ................................................... Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move With MLM Movement (E-Valve).............................................................................................................................................. Tilt Forward or Tilt Back Function Continues to Move for Awhile When MLM Is Released (E-Valve).............................................................................................................................................. Tilt Forward or Tilt Back Will Not Move With MLM Movement (E-Valve) ............................................. Too Much MLM Movement (Deadband) to Start Function Moving (E-Valve) ...................................... Wrong Actuation Operates or Actuation is Backward (E-Valve) .......................................................... Actuation Exhibits Slight Movement in Opposite Direction Before Moving (Manual Valve) ................. Auxiliary Function is Slow or Does Not Function (Manual Valve)........................................................ Cycle Times Too Fast - Fast Actuation (Manual Valve) ....................................................................... Function Continues to Activate After Returning to Neutral.................................................................. Lift Function Is Slow or Does Not Function (Manual Valve) ................................................................ Tilt Back Function Will Not Operate (Manual Valve)............................................................................ Tilt Forward or Tilt Back Will Not Function When Activated (Manual Valve) ....................................... No Steering (All Other Hydraulic Functions OK) ................................................................................. Steering Is Slow or Difficult ................................................................................................................. Steering Operation Is Not Smooth ...................................................................................................... Steering Wheel End Lock Position Cannot Be Felt by Operator ......................................................... Steering Wheel Turns By Itself or Does Not Return To Neutral........................................................... Steering Wheel Turns the Tires in the Wrong Direction ...................................................................... Actuations Do Not Act Simultaneously................................................................................................ Oil Leaking/Component Life Too Short................................................................................................ Abnormal Steer Axle Noise ................................................................................................................. Abnormal Steering Wheel Vibration .................................................................................................... Back Lash/Kick Back in Steering Wheel.............................................................................................. Group 43 - Tests and Adjustments-Gear Pump Hydraulic Warm-up Procedure .............................................................................................................. Primary Relief Valve Test and Adjustment ............................................................................................ Secondary Relief Valve Test and Adjustment........................................................................................ Hydraulic Pump Flow Test ..................................................................................................................... Main Control Valve LS Leakage Test (E-Valve) ................................................................................... Main Control Valve Unloader Margin Test ........................................................................................... E-Hydraulic Valve Leakage Test.......................................................................................................... Steering Relief Pressure Test and Adjustment.................................................................................... Steering Control Unit LS Pressure Test............................................................................................... Lift Cylinder Leakage Test ................................................................................................................... Tilt Cylinder Leakage Test ................................................................................................................... Steering Cylinder Leakage Test ..........................................................................................................

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9050-33-23 9050-33-27 9050-33-28 9050-33-29 9050-33-30 9050-33-33 9050-33-34 9050-33-37 9050-33-38 9050-33-42 9050-33-43 9050-33-45 9050-33-46 9050-33-47 9050-33-48 9050-33-51 9050-33-52 9050-33-53 9050-33-56 9050-33-57 9050-33-58 9050-33-60 9050-33-62 9050-33-64 9050-33-65 9050-33-67 9050-33-68 9050-33-69 9050-33-72 9050-33-74 9050-33-75 9050-43-1 9050-43-1 9050-43-4 9050-43-9 9050-43-11 9050-43-12 9050-43-14 9050-43-18 9050-43-21 9050-43-23 9050-43-25 9050-43-28

9050-3

9050-4

Hydraulic Systems

Principles of Operation

Group 10

Principles of Operation Manual Hydraulic Main Control Valve DESCRIPTION The manual main control valve controls the lift, tilt, and auxiliary functions. The main control valve is installed to the right of the operator, below the floor plate. The sections are held together with four through bolts and nuts. Each function of the main control valve is made as a separate section having a spool and valve body. Each valve body casting is the same. The control spools are different for each function. Other sections are added to the main control valve to control optional auxiliary functions. Each spool has a spring that returns the spool to the neutral position when the control lever is released. Each valve section has a check valve in the valve body. The check valve and spring is held in the valve body by the next section. This section will cover the principles of operation for two different types of manual hydraulic The open center type valve and control valves. For the control the closed center type valve. valve used on ERP15-20VT (ERP030-040VT)

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(G807), ERP16-20VF (ERP030-040VF) (A955), and ERC16-20VA (ERC030-ERC40VA) (A969), see General Description (Open Center Valve). For the control valve used on ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976), see General Description (Closed Center Valve).

MANUAL HYDRAULIC CONTROL SYSTEM The manual hydraulic control system controls all hydraulic functions, to include, lift/lower, tilt, and auxiliary functions. The system consists of the following components: • • • • • • •

Manual Hydraulic Control Valve Vehicle Master Controller Hydraulic Pump Motor Controller Dash Display Pump Motor and Fixed Displacement Gear Pump Operator’s Seat and Armrest PC Based Service Software (ETACC)

See Figure 9050-10-1, Page 9050-10-2 for component location.

9050-10-1

Principles of Operation

Hydraulic Systems

Figure 9050-10-1. Operator Station Components Legend for Figure 9050-10-1 1. 2. 3. 4. 5. 6. 7. 8.

HORN BUTTON ACCELERATOR PEDAL DISPLAY PANEL KEY SWITCH AND KEYLESS SWITCH LIGHT SWITCHES LIFT/LOWER CONTROL LEVER TILT CONTROL LEVER CONTROL LEVER FOR AUXILIARY HYDRAULIC FUNCTIONS (3RD LEVER) 9. CONTROL LEVER FOR AUXILIARY HYDRAULIC FUNCTIONS (4TH LEVER)

10. 11. 12. 13.

The manual hydraulic main control valve incorporates an emergency (manual) lowering valve. This valve allows the operator or service technician to lower the lift truck’s mast assembly if the electrical power to the lift truck is disrupted.

from the manual control levers. The master controller converts the operator’s input into controlled oil flow by simultaneously commanding the hydraulic pump motor controller to deliver a specific motor speed, and by commanding the manual hydraulic valve to deliver specific valve metering. Pump speed is variable up to the maximum speed preset in the master controller for the required hydraulic function.

The vehicle master controller, manual control levers, and hydraulic pump motor controller communicate with each other via the CANbus communication system. The master controller controls the hydraulic pump motor and the control valve based upon the inputs received

9050-10-2

EMERGENCY DISCONNECT SWITCH DIRECTION CONTROL SWITCH BRAKE PEDAL AUTOMATIC PARKING BRAKE MANUAL OVERRIDE HANDLE (OPTIONAL) 14. STEERING WHEEL 15. STEERING COLUMN TILT MEMORY LEVER 16. FOOT DIRECTIONAL CONTROL (FDC) PEDAL

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Hydraulic Systems

Principles of Operation

GENERAL DESCRIPTION (OPEN CENTER VALVE) CONSTRUCTION The valve assemblies for this application contain an inlet section, a lift section, a tilt section, an auxiliary section, and an outlet section. Some valve assemblies may include a dual (2nd) auxiliary section. All valves are assembled using tie rods and hex nuts. O-ring seals are placed between the various sections to prevent external fluid leakage between the sections.

VALVE TYPE The valve assemblies are open-center type valve used in conjunction with a fixed displacement pump. A fixed displacement pump will provide a fixed amount of fluid

with each revolution of the pump shaft. For example, if a 1 cubic inch per revolution pump is rotated at 1000 revolutions per minute, the pump output will be 1000 cubic inches per minute (1 cubic inch/rev x 1000 rev/min = 1000 cubic inches/min = 4.329 gal/min). In open center type valves, flow is passed through an open center core from the inlet port to the outlet port of the valve when all the spools are in the neutral (non-shifted) position. When a spool is shifted, flow is directed to the selected work port of the section and/or sections shifted. In open center systems fluid will follow the path of least resistance, meaning flow will be directed to the lowest load requirement when two or more valve spools are shifted. If flow is required by two or more sections at the same time, the operator generally must adjust the travel of each spool to get the desired flow rate from both work sections. See Figure 9050-10-2, Page 9050-10-3.

1. LIFT 2. TILT 3. AUXILIARY #1

Figure 9050-10-2. Basic Open Center Circuit

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9050-10-3

Principles of Operation

Hydraulic Systems

FEATURES AND OPERATION INLET ASSEMBLY Construction and Purpose Inlet assemblies provide the majority of the port connections used to connect various lines of the hydraulic circuit to the valve. All inlet assemblies include a priority spool for the steering circuit and a main relief valve to protect the pump from over pressurization. The housing is grey iron, and the major internal components are made of various types of steel.

Porting The inlet housing provides ports for the pump in (P), tank (T), steer supply (S), steer return (ST), steer load sense (SL), and pump pressure (PG).

Priority Steer Pump flow is directed across the priority spool before supplying flow for any downstream demands. Therefore, the steering circuit has priority over any downstream flow demands. Priority steering is accomplished

1. OPEN CENTER CORE 2. RELIEF CARTRIDGE

by using a normally open spring biased spool. Pump flow is directed across the priority spool to the steer port (S). If the steering control unit is not in use, there is no load sense signal communicated to the SL port from the steering control unit. The inlet pressure (PG) will increase just enough to overcome the priority spool’s spring force. Since the inlet pressure is communicated to the blind end of the priority spool, via the drilled passages within the spool, the spool will shift towards the spring end and flow to the steering unit will decrease and pump flow will be directed across the priority spool into a downstream (open center) core. If there is a flow demand from the steering unit, the load sense signal coming from the steering control unit is communicated to the spring end of the spool via the SL port. This increase in pressure will cause the spool to shift towards the blind end and flow to the steer (S) port will increase to meet the demands of the steering control unit. The downstream core coming from the priority spool is directed to the open center core of the valve assembly. If none of the work section spools are shifted, total pump flow is directed through the valve assembly via the open center core, across the work section spools to the outlet (T) port. See Figure 9050-10-3, Page 9050-10-4.

3. PRIORITY STEER SPOOL 4. SPRING

Figure 9050-10-3. Cross-Sectional View of Inlet Assembly

9050-10-4

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Principles of Operation

Relief Cartridge The primary function of a system relief valve is to prevent excessive system pressure. This valve assembly uses a direct acting relief cartridge and it is sized to pass total pump flow. The relief cartridge is in parallel with the pump inlet port. This design limits pressure to a predetermined level equal to the force generated by the relief spring. Inlet pressure is communicated through the relief body to the nose area of the poppet. When the force caused by pressure acting on the nose end of the poppet exceeds the force generated by the spring, the poppet will move towards the relief spring. Pump flow is then directed through the holes in the relief cartridge body and the poppet to the outlet side of the relief cartridge body. The outlet side of the cartridge is tied to the tank port (T) of the inlet assembly. If the pressure acting on the nose of the poppet decreases, the spring force will cause the poppet to move towards the nose end closing the outlet path. When actively relieving pressure, the inlet pressure (PG) will be slightly greater than the force generated by the relief spring.

spool position sensor, a load check valve assembly and a manual emergency lowering cartridge.

Purpose The purpose of the lift section is to allow for extending and retracting of the vehicle’s lift cylinder. The lift section uses a 3-way spool for raising and lowering the mast and incorporates an Operator Presence Solenoid (OPS) to help improve operator safety. SeeFigure 9050-10-4, Page 9050-10-5.

The lift section major components include: the housing, a main spool, an operator presence solenoid (OPS), a

When the spool is in neutral, flow passes through the open-center (OC) core and then to the next work section. If all the work section spools are in neutral, the flow will be directed to the tank (T) port in the inlet section. When the lift spool is shifted out of the housing, the open-center passage (OC) closes off, and flow is directed through power core at the inlet to the load check assembly into the high pressure bridge core. From the high pressure bridge core the flow is directed across metering notches of the spool, and out work port A to the lift cylinder and raises the mast. Shifting the spool into the housing from neutral connects work-port A to the tank core of the housing, thus allowing lowering of the mass. When lowering the mast, the open center core is open and directs flow to downstream functions. This allows other downstream functions to be used when lowering the mast.

1. 2. 3. 4. 5.

6. 7. 8. 9. 10.

LIFT SECTION Construction

MAST LOWER CARTRIDGE LOAD CHECK OPERATOR PRESENCE SOLENOID SPOOL POSITIONER POSITION SENSOR

TANK CORE OPEN CENTER CORE POWER CORE MAIN SPOOL TANK CORE

Figure 9050-10-4. Cross-Section of Lift Section

Confidential/Proprietary - Do Not Copy or Duplicate

9050-10-5

Principles of Operation

Hydraulic Systems

Load Check

Operator Presence Solenoid

The load-check assembly prevents back flow from the work ports under heavy load conditions. If the load check assembly was absent, under a heavy load condition the load would lower or drift when the spool is actuated, until the pressure builds to a sufficient level to move the load. Some drifting may occasionally occur since the load check assembly is not a zero leak device. See Figure 9050-10-5, Page 9050-10-6.

The Operator Presence Solenoid (OPS) has a spring loaded plunger which extends into an extension attached to the spool when de-energized. The plunger keeps the spool from moving when no electrical power is supplied to the solenoid’s coil. When power is supplied to the coil, a force is generated which pulls the plunger upward and out of the spool extension. Once the plunger disengages, the spool can be moved out of its neutral position. See Figure 9050-10-6, Page 9050-10-6.

1. POPPET 2. POWER CORE 3. BRIDGE CORE

Figure 9050-10-5. Cross Section of Load Check Assembly

1. OPERATOR PRESENCE SOLENOID 2. SPOOL EXTENSION

Figure 9050-10-6. Cross-Section of Operator Presence Solenoid

9050-10-6

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Hydraulic Systems

Principles of Operation

Position Sensor Assembly The position sensor monitors the travel of the valve spool and produces a variable output signal relative to how far the spool is from its neutral position. The vehicle’s electronics supplies the sensor with a 5 volt dc signal. When the spool is in its’ neutral position, the sensor output will be approximately 2.5 volts dc. As the spool

1. SPRING

is shifted from neutral, the sensor’s output voltage will increase or decrease depending upon the direction of spool travel. The output signal from the sensor is used by the vehicle’s electronic control system to vary the hydraulic pump flow. The intent is to meet predetermined function speed requirements. See Figure 9050-10-7, Page 9050-10-7.

2. POSITION SENSOR

Figure 9050-10-7. Cross-Section of Position Sensor Mast Lowering Cartridge The lift section housing incorporates a manual operated needle valve cartridge which allows the “A” work port to be directly connected to the tank core in the housing. When viewed from the lever end, turning the handle on the cartridge clockwise will shut the valve and

1. WORK PORT AREA

turning it counter clockwise will open the valve. The cartridge is intended to be used only in emergency situations to lower the mast. See Figure 9050-10-8, Page 9050-10-7.

2. TANK CORE AREA

Figure 9050-10-8. Cross-Section of Manual Lower Valve Cartridge

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9050-10-7

Principles of Operation

Hydraulic Systems

TILT SECTION Construction The tilt section major components include: the housing, a main spool, a tilt lock spool, an operator presence solenoid, a spool position sensor and a load check valve assembly.

spool which controls output flow when tilting the mast forward. The main function of the “tilt-lock” is that if the pump is not providing flow, the tilt cylinders will not extend. The tilt section uses a 4-way spool for tilting the mast forward and backward and incorporates an Operator Presence Solenoid (OPS) to help improve operator safety. See Figure 9050-10-9, Page 9050-10-8.

Purpose The purpose of the tilt section is to extend and retract the tilt cylinders, with an integrated “tilt-lock” shuttle

1. 2. 3. 4.

LOAD CHECK POWER CORE OPERATOR PRESENCE SYSTEM SPOOL POSITIONER

5. 6. 7. 8.

POSITION SENSOR TILT LOCK SHUTTLE SPOOL OPEN CENTER CORE MAIN SPOOL

Figure 9050-10-9. Cross-Section of Tilt Section When the spool is in neutral, flow passes through the open-center (OC) core and then down stream to the next work section. If all the work section spools are in neutral, flow will be directed to the tank (T) port in the inlet section. • Tilt Backward When the tilt spool is shifted out of the housing, the open-center (OC) core is closed off and flow is directed via the power core through the load check assembly, into the high pressure bridge core. From the high pressure bridge core the flow is directed out work port B to the rod end of the tilt cylinders. The flow from the base end of the tilt cylinders returns to the opposite work port (A), across metering notches in the main spool, and to the tank passage, thus tilting the mast backward. • Tilt Forward During tilt forward operation, the internal “tilt-lock” shuttle spool helps to control unintended increases in forward tilt speed. When the tilt spool is shifted into the housing, the open-center (OC) core

9050-10-8

is closed off and flow is directed via the power core through the load check valve to the high pressure bridge core. The pressure is sensed at the base of the tilt-lock shuttle spool, sliding the shuttle spool open against the spring. From the high pressure bridge core the flow is directed out work port A to the base end of the tilt cylinders. Flow from the rod end of the tilt cylinders returns to the opposite work port (B), directed inside the main spool, and metered out through holes in the main spool to the tank core. If the pump is not providing flow, there is no pressure at the base end of the tilt-lock shuttle spool, and the shuttle spool will not move. Under this condition, if the main spool is shifted, the tilt-lock shuttle spool blocks off the internal passage of the spool, preventing flow from work port B to the tank core, therefore the mast will not tilt forward. Since these are not zero-leak devices, some cylinder drift may occur.

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Hydraulic Systems

Principles of Operation

AUXILIARY AND DUAL AUXILIARY SECTION

When the spool is in neutral, flow passes through the open-center (OC) passage and downstream to the tank port of the valve.

Construction Auxiliary and/or a dual auxiliary section major components include: the housing, a main spool, a spool position sensor, and a load check valve assembly. Some auxiliary sections may include a spool lock solenoid device which is the same as an operator presence solenoid assembly.

Purpose

When the spool is actuated in or out, the open-center (OC) flow path is blocked off and forces the flow through power core across the load check valve into the high pressure bridge core. From the high pressure bridge core, the oil is directed out the selected work port (3A or 3B for three-function valve, 3A, 3B, 4A, or 4B for fourfunction valve) to the auxiliary attachment. Oil returns from the auxiliary attachment to the opposite work port in that section and is directed to the tank passage.

The auxiliary section is used to control various attachments that can be installed on the vehicle. See Figure 9050-10-10, Page 9050-10-9.

1. 2. 3. 4.

LOAD CHECK BRIDGE CORE WORK PORT OPTION PLUG SPOOL POSITIONER

5. 6. 7. 8.

POSITION SENSOR OPEN CENTER CORE POWER CORE MAIN SPOOL

Figure 9050-10-10. Cross-Section Dual Auxiliary Section

Confidential/Proprietary - Do Not Copy or Duplicate

9050-10-9

Principles of Operation

Hydraulic Systems

OUTLET COVER SECTION Construction and Purpose

plugged. The dual exhaust cores routed through the previous work-sections are joined together in the outlet. See Figure 9050-10-11, Page 9050-10-10.

The outlet cover connects the open-center to the exhaust core, and has an optional Tank port, which is

1. TANK CORE

2. OPTIONAL TANK PORT

Figure 9050-10-11. Cross Section of Outlet Cover

GENERAL DESCRIPTION (CLOSED CENTER VALVE) CONSTRUCTION Valve assemblies for this application are manually shifted. All valve assemblies include an inlet section, a lift section, a tilt section, and an auxiliary section. Some valve assemblies may include a second dual auxiliary section. All valves are assembled using tie rods and hex nuts. O-ring seals are placed between sections to prevent external fluid leakage.

VALVE TYPE Valves supplied are closed center load sense type. The valves are used with a fixed displacement pump. A fixed displacement pump will provide a fixed (known) amount of fluid with each revolution of the pump shaft. For example, if a 1 cubic inch per revolution pump is rotated at 1000 revolutions per minute, the pump output

9050-10-10

will be 1000 cubic inches per minute (1 cubic inch/rev x 1000 rev/min = 1000 cubic inches/min = 4.329 gal/min). These load sense type valves (VAL) direct flow to a closed center passageway called a power core. Flow is blocked from going out the work ports when the main spools, located within the sections are in the neutral position. Shifting a spool directs flow to the selected work port. In these valves, internal passageways in conjunction with shuttle valves, direct the highest loads pressure signal (load sense pressure) back to an unloading spool located in the inlet. Using an unloading spool allows the use of a fixed displacement pump, but incorporates the advantages of a load sensing circuit (system pressure slightly above the load requirement and flow to match the loads’ demand). If flow is simultaneously required by two or more work sections, the operator must adjust the travel of each spool to get the desired flow rate from each work section. See Figure 9050-10-12, Page 9050-10-11.

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

1. INLET 2. LIFT

Principles of Operation

3. TILT 4. AUXILIARY #1

Figure 9050-10-12. Load Sense Control Valve With Unloader and Priority Steering

FEATURES AND OPERATION

Porting

INLET ASSEMBLY

Inlet assemblies provide the majority of the porting connections to connect various lines of the hydraulic circuit. All inlet assemblies for this type of valve include a priority steering spool to control flow to the steer unit, a main relief valve to protect the pump from over pressurization, and an unloading spool to unload (dump to tank) any excess pump flow.

Port sizes vary based upon flow requirements and features within each inlet assembly. All inlets provide connections for: pump (P), tank (T), steer supply (S), steer return (ST), load sense signal coming from the steering control unit (SL), pump pressure (PG), load sense gage port (LSG) coming from the work section’s shuttle circuit, and reduced pressure gage port (BG). If a hydraulic brake option is required, ports are provide for the brake supply (PB) and the brake return (PBT). Be aware that the PB port is exposed to full system pressure.

Confidential/Proprietary - Do Not Copy or Duplicate

9050-10-11

Construction and Purpose

Principles of Operation

Priority Steer Pump flow is directed across a priority spool before supplying flow to any downstream functions. The steering circuit flow demand has priority over any downstream flow requirements. Priority steering is accomplished by using a normally open spring biased spool. Pump flow is directed across the priority spool to the steer port (S). If the steering control unit is not in use, there is no load sense signal communicated to the SL port from the steering control unit. The inlet pressure (P) will increase to overcome the priority spring force. The inlet pressure is communicated to the blind end of the priority spool via the drilled passages within the spool, the spool will shift

1. STEER UNIT OUTLET 2. PUMP INLET 3. UNLOADER SPOOL OUTLET

Hydraulic Systems towards the spring end and flow will be directed across the spool to a downstream core leading to the unloading spool. If there is a flow demand at the steer (S) port, the load sense signal coming from the steering control unit is communicated to the spring end of the spool via the SL port. This increase in pressure will cause the spool to shift towards the blind end and flow to the steer (S) port will increase to meet the demands of the steering control unit. See Figure 9050-10-13, Page 9050-10-12. If no work section spools are shifted, total pump flow is directed across an unloading spool to the outlet (T) port.

4. PRIORITY SPOOL 5. STEER LS PORT

Figure 9050-10-13. Cross-Section of Priority Steering Layout

9050-10-12

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Principles of Operation

Unloading Spool and Relief Cartridge The primary function of a relief cartridge is to prevent excessive system pressure. The relief cartridge works in conjunction with an unloading spool. The unloading spool directs excess flow (not required by any selected functions) back to tank (T). The advantage of this system is that a fixed (positive displacement) pump can be utilized. When there is no load from the steering control unit or the work sections, the pump will unload at a pressure which is only slightly higher than that required to overcome the forces generated by the priority spring and the unloading spring plus any pressure losses. See Figure 9050-10-14, Page 9050-10-13. The flow from the downstream side of the priority spool is directed to the unloading spool and to the downstream work sections. Pressure at the P port side of the unloading spool is communicated to the blind end of the unloading spool via the internal pathway drilled within the spool. Pressure (PG) will rise until it overcomes the force generated by the unloading spring and the unloading spool will shift towards the spring end. Flow will then be directed across the unloading spool and into a core that connects to the tank (T) port of the inlet.

1. 2. 3. 4.

STEER UNIT OUTLET PUMP INLET TANK CORE AREA UNLOADING SPOOL

If a steering load demand is present in the priority spring chamber (LS area), the inlet pressure will rise. The priority spool will shift towards its blind end to meet the demand. If required, flow to the steer (S) port will increase and flow available to the core feeding the unloading spool will decrease. If no work section spools are shifted, the unloading spool will continue to unload any flow not required by the steering control unit to the tank (T) port. When a downstream work function spool is shifted, internal passages (load sense shuttle circuit) of the valve assembly will communicate the pressure generated by the load at the work section port to the spring end of the unloading spool. Pump pressure will rise to meet the demand coming from the work section and the unloading spool will shift towards its blind end and restrict the amount of flow to the tank (T) port. If the pressure in the spring chamber of the unloading spool is high enough to overcome the force generated by the relief spring on the relief poppet, the poppet will open and limit the system pressure. The relief’s spring chamber is vented to the tank (T) port via internal passages within the inlet housing. It should be noted that the load sense/unloading spool design does not limit the pressure in the steer control unit. The steer control unit incorporates its own relief to control maximum pressure.

5. 6. 7. 8.

LOAD SENSE RELIEF CARTRIDGE LOAD SENSE ORIFICE PRIORITY SPOOL LS FROM STEER UNIT

Figure 9050-10-14. Cross-Section of Unloading Spool Layout

Confidential/Proprietary - Do Not Copy or Duplicate

9050-10-13

Principles of Operation

Hydraulic Systems

LIFT SECTION Purpose The purpose of the lift section housing is to allow for extending and retracting of vehicle’s lift cylinder (mast).

Operation - Main Spool

are in neutral (no flow requirement), pump flow comes into the inlet, travels across the priority spool and into the power core which directs flow to the various work sections. Since the power core is blocked (no spools shifted) at the last work section of the valve stack (thus called closed center type), flow is directed across the unloading spool, located in the inlet section to the tank (T) port. See Figure 9050-10-15, Page 9050-10-14.

The lift section uses a 3-way spool for raising and lowering the mast. When all the spools of the valve assembly

1. 2. 3. 4. 5.

POSITION SENSOR OPERATOR PRESENCE SOLENOID BRIDGE CORE WORK PORT MANUAL LOWERING VALVE

6. 7. 8. 9.

LIFT SPOOL TO LS SHUTTLE POWER CORE LOAD CHECK SPOOL

Figure 9050-10-15. Cross-Section of Manual Lift Section

9050-10-14

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Principles of Operation

When the lift spool is shifted to raise the mast (spool moved outward of the housing), flow travels from the inlet via the power core, across the load check spool, across the lift spool, and out work port A. Passageways within the lift section communicate the loads’ pressure back to the spring chamber of the unloading spool and the unloading spool shifts to meet the flow demand of the work section, any excess pump flow is unloaded to the tank (T) port. If more than one work section spool is shifted (downstream of lift function), a load sense shuttle circuit allows only the highest load pressure to be communicated to the unloading spool. This allows the pump pressure to raise enough to meet the highest load demand. The shuttle valve assembly is physically located within each work section on the mating face between the sections. See Figure 9050-10-16, Page 9050-10-15. 1. LS SIGNAL FROM DOWNSTREAM WORK SECTION 2. O-RING 3. SHUTTLE BALL 4. SEAT 5. FROM WORK CURRENT SECTION LS PICKUP 6. TO INLET UNLOADING SPOOL

Figure 9050-10-16. Cross-Section of Shuttle Valve Assembly

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9050-10-15

Principles of Operation

Hydraulic Systems

Load Check When there is a flow demand at the work section (main spool is shifted), flow traveling through the power core will communicate the pressure within the power core to the blind end of the load check spool via holes drilled into the spool. Once the pressure is high enough to overcome the force caused by the spring at the other end of the spool, the spool will shift towards the spring end and flow will pass across the load check spool. Pressure within the downstream core (feeding the main spool) is communicated to the spring end of the spool via drilled holes within the load check spool. If the pressure on the downstream side of the load check spool increases too much, the load check spool will shift towards the blind end and flow across the check will be

1. POWER CORE 2. LOAD CHECK SPOOL

restricted. If pressure within the power core decreases, pressure at the blind end of the spool will decrease and the spring will try to close the check spool, thus flow across the spool will be restricted. It should be noted that the load check spool is not a zero leak device. It will not completely stop flow if a line were to break or if a leak develops between the work port and the cylinder. It will decrease the flow output to the work port, but it will not do anything to restrict the flow coming from the cylinder. The main purpose of the load check is to reduce the amount of cylinder drift when shifting the main spool from the raise to lower position. See Figure 9050-10-17, Page 9050-10-16.

3. DOWNSTREAM CORE 4. LOAD CHECK SPRING

Figure 9050-10-17. Cross-Section of Load Check Assembly

9050-10-16

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Hydraulic Systems

Principles of Operation

Operator Presence Solenoid The Operator Presence Solenoid (OPS) has a spring loaded plunger which extends into an extension attached to the main spool. The plunger keeps the spool from moving when no electrical power is supplied to the solenoid’s coil. When power is supplied to the coil, a force is generated which pulls the plunger upward and out of the spool extension. Once the plunger disengages, the spool can be moved out of its neutral position. See Figure 9050-10-18, Page 9050-10-17

1. OPERATOR PRESENCE SOLENOID 2. SPOOL EXTENSION

Figure 9050-10-18. Cross-Section of Operator Presence Solenoid

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9050-10-17

Principles of Operation

Position Sensor The position sensor monitors the position of the valve spool and produces a variable output signal relative to how far the spool has traveled from its neutral position. The vehicle’s electronics supplies the sensor with a 5 volt DC signal. When the spool is in its neutral position, the sensor output will be approximately 2.5 volts DC.

1. POSITION SENSOR

Hydraulic Systems As the spool is shifted from neutral, the sensor’s output voltage will increase or decrease depending upon the direction of spool travel. The output signal from the sensor is used by the vehicle’s electronic control system to vary the hydraulic pump flow. The intent is to meet predetermined function speed requirements. See Figure 9050-10-19, Page 9050-10-18.

2. SPRING

Figure 9050-10-19. Cross-Section of Position Sensor Assembly Mast Lowering Cartridge The lift section housing incorporates a manual operated needle valve cartridge which allows the “A” work port to be directly connected to the tank core. When viewed from the hex end, turning the handle on the cartridge clockwise will shut the valve and turning it counter clockwise will open the valve. The cartridge is intended to be use only in an emergency situation to lower the mast. See Figure 9050-10-20, Page 9050-10-18.

Figure 9050-10-20. Cross-Section of Manual Lowering Cartridge

9050-10-18

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Hydraulic Systems

Principles of Operation

TILT SECTION

Operation

Construction and Purpose

The pressure reducing/load check assembly consists of a spool and two springs. Flow enters the tilt section via the power core and is directed across the pressure reducing/load check spool. The pressure reducing/load check spool is held in the normally open position by the springs. Pressure downstream of the spool is communicated to both ends of the spool via the holes drilled into the pressure reducing/load check spool. Once the pressure on the blind end of the spool is high enough, it will override the force generated by the springs and the spool will shift towards the spring end, thus limiting the pressure on the downstream side of the spool to balance the force of the springs plus the pressure on the downstream side of the pressure reducing/load check spool feeding the main spool. The lighter spring is used to limit the load check pressure setting and the heavier spring is used to limit the reduced pressure setting. A relief cartridge (same as the load sense relief in the inlet assembly) is utilized to limit the maximum pressure on the downstream side of the pressure reducing spool. Since the flow in the power core is available to any sections downstream of the tilt section, pressure to sections downstream of the lift function will be limited to the setting of the relief cartridge located in the pressure reducing/load check assembly of the lift section. See Figure 9050-10-21, Page 9050-10-19.

The tilt section includes a pressure reducing valve assembly, a relief cartridge, a main spool assembly, an operator presence solenoid (OPS), a position sensor assembly, and a load sense shuttle assembly. The operator presence solenoid, the position sensor and the load sense shuttle assembly are the same as in the lift section and operate the same. The tilt section’s purpose is to allow for extending and retracting of vehicle’s tilt cylinders. The major difference in this section versus a lift section is that the load check assembly has an additional feature of a pressure reducing spool assembly and the addition of an internal “tilt-lock” shuttle spool located inside a 4-way main spool. The purpose of the pressure reducing assembly is to restrict the maximum pressure available to the tilt section and any downstream sections. The purpose of the load check feature is to prevent the forks from tilting forward before they are commanded to tilt back. The main spool’s purpose is to direct flow to the section’s work ports when the spool is shifted out of neutral. The purpose of the “tilt-lock” shuttle spool is to limit unanticipated forward tilting (runaway condition) of the mast when trying to tilt back. The tilt-lock shuttle spool also prevents forward tilt of the mast when the hydraulic pump is not running.

1. 2. 3. 4. 5. 6.

POSITION SENSOR OPERATOR PRESENCE SENSOR TILT SPOOL BRIDGE CORE FEED CORE TANK CORE

7. 8. 9. 10. 11.

MAIN SPOOL PRESSURE REDUCING LOAD CHECK SPOOL POWER CORE SPRING RELIEF CARTRIDGE

Figure 9050-10-21. Cross-Section of Manual Tilt Section

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9050-10-19

Principles of Operation

Main Spool with Tilt-Lock The section’s main spool is shifted with manual input from the operator. The main spool is a 4 way type, meaning that flow is available to both the A and B work ports versus only the A port (3-way spool) in a lift section. Shifting the main spool out of the housing will pressurize work port B (tilt back) and shifting the main spool into the housing will pressurize work port A (forward tilt). The main spool assembly contains an internal “tilt-lock” spool which is active only in the tilt forward direction. • Tilt Back Actuating the main spool to the tilt back position (B port pressurized) sends a load-sense signal to the unloading spool located in the inlet cover. The unloading spool in the inlet closes and flow is directed to the power core. Flow from the power core is directed across the pressure reducing/load check spool assembly and travels to the main spool via a feed core. Flow travels across the main spool into the bridge core and is directed out of work port B. This “meter-in” flow is out the B workport to the rod end of the cylinder and “meter-out” flow is from the base end of the cylinder to the A port. Return flow from the tilt cylinder(s) is routed through work port A across the main spool into the tank core of the housing. Flow in the tank core is directed through the valve sections back to the tank (T) port located in the inlet section. • Tilt Forward During tilt forward operation, the internal “tilt-lock” shuttle spool helps to control any unintended increase in forward tilt speed. When the tilt spool is shifted into the housing (A work port pressurized), the unloading spool in the inlet closes and flow becomes available to the work sections. Flow travels from the power core across the pressure reducing/load check spool into the main spool feed core. Flow travels across the main spool into the bridge core. Flow passes across the main spool and out the A work port. This flows into the base end of the cylinder is known as “meter-in” flow. Return flow from the tilt cylinder(s) is directed into the B work port. Return flow is known as “meter-out” flow. Pressure in

9050-10-20

Hydraulic Systems the bridge core and the A work port is communicated through cross holes in the main spool to the blind end of the “tilt-lock” spool. The tilt spool shifts toward the spring end and flow in work port B is throttled across the tilt-lock spool into the tank core. If pressure seen at the blind end of the tilt-lock spool decreases enough, the spring will force the tilt-lock spool to shift towards the blind end and flow from work port B crossing the tilt-lock spool into the tank core will be restricted. This allows the tilt-lock spool to act like a counterbalance valve to keep the forks from running away from the meter-in supply. If the load causes the tilt to move forward too fast, the tilt-lock spool will lose the pilot signal from the meter-in supply on the opposing work port, therefore preventing movement or ultimately slowing the flow rate so the meter-in flow can maintain the proper pilot signal to the tilt-lock spool. If the pump is not providing flow, there is no pressure at the blind end of the tilt-lock spool, and the spool will not open to allow flow to the tank core. Therefore the tilt cylinder(s) should not move. Since the tilt-lock spool and the main spool are not zero-leak devices, some cylinder(s) drift may occur.

AUXILIARY AND DUAL AUXILIARY SECTIONS Construction and Purpose Auxiliary and dual auxiliary sections housings are constructed of grey iron and contain internal components made from various steels. The purpose of auxiliary sections is to provide flow to any auxiliary functions (attachments). When more than one auxiliary section is used, the upstream section is labeled as a dual auxiliary section. All valve assemblies contain an end (single) auxiliary section. Both types of auxiliary sections contain a 4-way main spool, a position sensor and a load sense shuttle valve. These components are the same as used on the lift and tilt sections and operate the same. Some auxiliary sections include an optional clamp lock feature. See Figure 9050-10-22, Page 9050-10-21.

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Hydraulic Systems

Principles of Operation

1. POSITION SENSOR 2. TANK CORE 3. BRIDGE CORE

4. TANK CORE 5. FEED CORE 6. MAIN SPOOL

Figure 9050-10-22. Cross-Section of Auxiliary Section Operation Both the dual and end auxiliary sections operate the same. Input flow to all auxiliary sections are downstream of the feed core of the tilt section, therefore the maximum load pressure is limited to the setting of the relief cartridge used in conjunction with the pressure reducing/load check assembly located in the tilt section. Auxiliary sections do not contain a load check assembly. Main spools are 4-way type, shifting the spool out of the housing will pressurize work port B and shifting the spool into the housing will pressurize work port A. To regulate the output flow of a work port, the operator must position the spool until the desired flow rate is obtained. Shifting the spool out of neutral communicates a load sense signal via the internal shuttle circuit to the unloading spool in the inlet. The unloading spool will shift and direct flow to downstream functions when a load demand is present.

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The optional clamp lock feature uses a solenoid and a plunger assembly to prevent spool movement. This feature is controlled by the vehicle’s electronic controls. If there is no electric signal supplied to the coil, the plunger is forced, via an internal spring within the solenoid assembly, into a groove on the spool extension to prevent movement of the spool. The clamp lock solenoid assembly is the same part number as the operator presence solenoid used on other sections. The position sensor assembly is the same as used on other sections. End auxiliary sections contain an SAE plug (BG port) on the outside surface which connects to the power core. Pressure at this port would represent the pressure setting of the pressure reducing valve assembly located in the tilt section.

9050-10-21

Principles of Operation

Hydraulic Systems

E-Hydraulic Main Control Valve ELECTRO-HYDRAULIC CONTROL SYSTEM The electro-hydraulic control system controls all hydraulic functions, to include, lift/lower, tilt, and auxiliary functions. The system consists of the following components: • Electro-Hydraulic Control Valve • Mini-Levers

1. 2. 3. 4. 5. 6. 7. 8.

HORN BUTTON ACCELERATOR PEDAL DISPLAY PANEL KEY SWITCH AND KEYLESS SWITCH LIGHT SWITCHES LIFT/LOWER CONTROL LEVER TILT CONTROL LEVER CONTROL LEVER FOR AUXILIARY HYDRAULIC FUNCTIONS (3RD LEVER)

• • • • • •

Vehicle Master Controller Hydraulic Pump Motor Controller Dash Display Pump Motor and Fixed Displacement Gear Pump Operator’s Seat and Armrest PC Based Service Software

See Figure 9050-10-23, Page 9050-10-22 for component location.

9. CONTROL LEVER FOR AUXILIARY HYDRAULIC FUNCTIONS (4TH LEVER) 10. EMERGENCY DISCONNECT SWITCH 11. DIRECTION CONTROL SWITCH 12. BRAKE PEDAL 13. AUTOMATIC PARKING BRAKE MANUAL OVERRIDE HANDLE (OPTIONAL) 14. STEERING WHEEL 15. STEERING COLUMN TILT MEMORY LEVER 16. YALE FOOT DIRECTIONAL CONTROL (FDC) PEDAL

Figure 9050-10-23. Operator Station Components The electro-hydraulic main control valve controls the lift, tilt, and auxiliary functions. The electro-hydraulic control valve is installed to the right of the operator, below the floor plate. The electro-hydraulic main control valve incorporates an emergency (manual) lowering valve. This valve allows the operator or service technician to lower the lift truck’s mast assembly if the electrical signal to the electro-hydraulic main control valve is disrupted.

The vehicle master controller, mini-levers, and hydraulic pump motor controller communicate with each other via the CANbus communication system. The master controller controls the hydraulic pump motor and the electro-hydraulic control valve based upon the inputs received from the mini levers. The master controller converts the operator’s input into controlled oil flow by simultaneously commanding the hydraulic pump motor

9050-10-22

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems controller to deliver a specific motor speed, and by commanding the electro-hydraulic control valve to deliver specific valve metering. Pump speed is variable up to the maximum speed preset in the master controller for the required hydraulic function.

Principles of Operation

Valves supplied are closed center load sense type. The valves can be used with a fixed displacement pump. A fixed displacement pump will provide a fixed (known) amount of fluid with each revolution of the pump shaft. For example, if a 1 cubic inch per revolution pump is rotated at 1000 revolutions per minute, the pump output

will be 1000 cubic inches per minute (1 cubic inch/rev x 1000 rev/min = 1000 cubic inches/min = 4.329 gal/min). These load sense type valves (VAL) direct flow to a closed center passageway called a power core. Flow is blocked from going out the work ports when the main spools, located within the sections, are in the neutral position. Shifting a function’s spool is accomplished by applying an electrical signal to a solenoid located on either end of the section. Pilot pressure is supplied by the main pump, but at a reduced pressure. The pilot supply pressure is reduced through the use of a pressure reducing pilot cartridge located in the inlet. Shifting a spool directs flow to the selected work port. In these valves, internal passageways in conjunction with shuttle valves, direct the highest load’s pressure signal (load sense pressure) back to an unloading spool located in the inlet. Using an unloading spool allows the use of a fixed displacement pump, but incorporates the advantages of a load sensing circuit (system pressure slightly above the load requirement and flow to match the load’s demand). If flow is simultaneously required by two or more work sections, the operator must adjust the travel of each spool to get the desired flow rate from each work section. See Figure 9050-10-24, Page 9050-10-23.

1. LIFT 2. TILT

3. SPACER 4. AUXILIARY 1

GENERAL VALVE DESCRIPTION Construction Valve assemblies are electro-hydraulically shifted. All valve assemblies include an inlet section, a lift section, a tilt section, and an auxiliary section. Some valve assemblies may include a second dual auxiliary section and/or a spacer section. All valves are assembled using tie rods and hex nuts. O-ring seals are placed between sections to prevent external fluid leakage.

Valve Type

Figure 9050-10-24. Load Sense Control Valve With Unloader and Priority Steering

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9050-10-23

Principles of Operation

Hydraulic Systems

FEATURES AND OPERATION

Priority Steer

Inlet Section

Pump flow is directed across a priority spool before supplying flow to any downstream functions. The steering circuit flow demand has priority over any downstream flow requirements. Priority steering is accomplished by using a normally open spring biased spool. Pump flow is directed across the priority spool to the steer port (S). If the steering control unit is not in use, there is no load sense signal communicated to the SL port from the steering control unit. The inlet pressure (P) will increase to overcome the priority spring force. The inlet pressure is communicated to the blind end of the priority spool via the drilled passages within the spool, the spool will shift towards the spring end and flow will be directed across the spool to a downstream core leading to the unloading spool. If there is a flow demand at the steer (S) port, the load sense signal coming from the steering control unit is communicated to the spring end of the spool via the SL port. This increase in pressure will cause the spool to shift towards the blind end and flow to the steer (S) port will increase to meet the demands of the steering control unit. See Figure 9050-10-25, Page 9050-10-24.

Construction and Purpose Inlet section provides the majority of the porting connections to connect various lines of the hydraulic circuit. All inlet sections for this type of valve include a priority steering spool to control flow to the steer unit, a main relief valve to protect the pump from over pressurization, an unloading spool to unload (dump to tank) any excess pump flow and a pressure reducing pilot cartridge.

Porting Port sizes vary based upon flow requirements and features within each inlet section. All inlets provide connections for: pump (P), tank (T), steer supply (S), steer return (ST), load sense signal coming from the steering control unit (SL), pump pressure (PG), load sense gage port (LSG) coming from the work section’s shuttle circuit, reduced pressure gage port (BG) and pilot pressure (PP). If a hydraulic brake option is required, ports are provide for the brake supply (PB) and the brake return (PBT). Be aware that the PB port is exposed to full system pressure.

1. TO STEER UNIT 2. FROM PUMP 3. TO UNLOADER SPOOL

If no work section spools are shifted, total pump flow is directed across an unloading spool to the outlet (T) port.

4. PRIORITY SPOOL 5. STEER LS PORT

Figure 9050-10-25. Cross Section of Priority Steering Layout

9050-10-24

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Hydraulic Systems

Principles of Operation

Unloading Spool and Relief Cartridge The primary function of a relief cartridge is to prevent excessive system pressure. The relief cartridge works in conjunction with an unloading spool. The unloading spool directs excess flow (not required by any selected functions) back to tank (T). The advantage of this system is that a fixed (positive displacement) pump can be utilized. When there is no load from the steering control unit or the work sections, the pump will unload at a pressure which is only slightly higher than that required to overcome the forces generated by the priority spring and the unloading spring plus any pressure losses. See Figure 9050-10-26, Page 9050-10-25. The flow from the downstream side of the priority spool is directed to the unloading spool and to the downstream work sections. Pressure at the (P) port side of the unloading spool is communicated to the blind end of the unloading spool via the internal pathway drilled within the spool. Pressure (PG) will rise until it overcomes the force generated by the unloading spring and the unloading spool will shift towards the spring end. Flow will then be directed across the unloading spool and into a core that connects to the tank (T) port of the inlet.

1. 2. 3. 4.

TO STEER UNIT FROM PUMP TANK CORE AREA UNLOADING SPOOL

5. 6. 7. 8.

LOAD SENSE RELIEF CARTRIDGE LOAD SENSE ORIFICE PRIORITY SPOOL FROM STEER UNIT

Figure 9050-10-26. Cross Section of Unloading Spool Layout

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9050-10-25

Principles of Operation

Hydraulic Systems

Pilot Cartridge The pilot cartridge receives flow from the pump and maintains a constant reduced output pressure to feed the electro-hydraulic (EH) solenoids of the work sections. The supply pressure for the electro-hydraulic solenoids must be reduced because the solenoids will not withstand full system pressure. Flow enters the pilot cartridge at the IN passage and the OUT pressure is sensed at the blind end of the reducing spool through holes drilled into the spool. The pressure at

1. OUT

2. TANK

the blind end of the spool will build to match the force generated by the spring. The spool will shift to the left or right to maintain a pressure equal to the force generated by the spring. The reducing spool is constantly modulating, and maintains the pilot pressure at the OUT passage based upon the spring force. Any leakage from the OUT side into the spring chamber is vented back to the tank side of the valve assembly. See Figure 9050-10-27, Page 9050-10-26.

3. IN

Figure 9050-10-27. Cross Section of Pilot Cartridge

Lift Section Construction and Purpose The lift section’s purpose is to allow for extending and retracting of vehicle’s lift cylinder (mast).

Operation - Main Spool

The lift section uses a 3-way spool for raising and lowering the mast. When all the spools of the valve assembly

Figure 9050-10-28. Cross-Section of EH Lift Section

9050-10-26

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Hydraulic Systems

Principles of Operation

Legend for Figure 9050-10-28 1. 2. 3. 4. 5.

EH SOLENOID BRIDGE CORE MAST LOWERING CARTRIDGE EH SOLENOID MAIN SPOOL

6. 7. 8. 9.

POWER CORE FEED CORE LOAD CHECK TANK CORE

1. 2. 3. 4. 5. 6.

LS SIGNAL FROM WORK SECTION O-RING SHUTTLE BALL SEAT FROM WORK CURRENT SECTION LS PICKUP TO INLET UNLOADING SPOOL

When the lift spool is shifted to raise the mast (solenoid on the A port side energized), flow travels from the inlet via the power core, across the load check spool, across the lift spool, and out workport A. Passageways within the lift section communicate the loads’ pressure back to the spring chamber of the unloading spool and the unloading spool shifts to meet the flow demand of the work section, any excess pump flow is unloaded to the tank (T) port. If more than one work section spool is shifted (downstream of lift function), a load sense shuttle circuit allows only the highest load pressure to be communicated to the unloading spool. This allows the pump pressure to raise enough to meet the highest load demand. The shuttle valve assembly is physically located within each work section on the mating face between the sections. See Figure 9050-10-29, Page 9050-10-27.

Figure 9050-10-29. Cross-Section View of Shuttle Valve Assembly

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9050-10-27

Principles of Operation

Load Check When there is a flow demand at the work section (main spool shifted), flow traveling through the power core will communicate the pressure within the power core to the blind end of the load check spool via holes drilled into the spool. Once the pressure is high enough to overcome the force caused by the spring at the other end of the spool, the spool will shift towards the spring end and flow will pass across the load check spool. Pressure within the downstream core (feeding the main spool) is communicated to the spring end of the spool via drilled holes within the load check spool. If the pressure on the downstream side of the load check spool increases too much, the load check spool will shift towards the blind

1. LOAD CHECK SPRING 2. POWER CORE

Hydraulic Systems end and flow across the check will be restricted. If pressure within the power core decreases, pressure at the blind end of the spool will decrease and the spring will try to close the check spool, thus flow across the spool will be restricted. It should be noted that the load check spool is not a zero leak device. It will not completely stop flow if a line were to break or if a leak develops between the workport and the cylinder. It will decrease the flow output to the workport, but it will not do anything to restrict the flow coming from the cylinder. The main purpose of the load check is to reduce the amount of cylinder drift when shifting the main spool from the raise to lower position. See Figure 9050-10-30, Page 9050-10-28.

3. LOAD CHECK SPOOL 4. DOWNSTREAM CORE

Figure 9050-10-30. Cross-Section View Load Check Assembly Mast Lowering Cartridge The lift section housing incorporates a manually operated needle valve cartridge which allows the “A” workport to be directly connected to the tank core. When viewed from the hex end, turning the handle on the cartridge clockwise will shut the valve and turning it counter clockwise will open the valve. The cartridge is intended to be used only in an emergency situation to lower the mast. See Figure 9050-10-31, Page 9050-10-28.

Figure 9050-10-31. Cross-Section View of Manual Lowering Cartridge

9050-10-28

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Hydraulic Systems

Principles of Operation

Electro-Hydraulic (EH) Solenoid

Tilt Section

Reduced pressure flow coming from the pilot cartridge located in the inlet, is delivered to the inlet side of each electro-hydraulic (EH) solenoid via internal holes drilled into the work sections. When an electrical current is applied to the coil, a force is generated by the coil which moves the pin within the solenoid and in turn moves the spool in the solenoid assembly. As the spool moves away from the spring end of the assembly, flow is passed from the inlet side to the output side of the spool. When the force generated by the pressure acting on the spool area becomes equal to the force generated by the current acting on the pin of the solenoid, the spool will close and flow across the inlet to the outlet will stop. If the current applied to the solenoid coil is varied, the regulated output pressure will vary to maintain a force balance between the output pressure and the input current. In short, the output pressure is a function of input current.

Construction and Purpose

The output pressure from the solenoid assembly is applied to the end of the main spool of the section being operated. Once the output pressure from the solenoid becomes great enough to overcome the force generated by the return spring and spool drag, the main spool will begin to shift. An increase in current at the solenoid will increase the regulated output pressure acting on the main spool and the spool will shift further. Due to metering notches located on the main spool, the flow across the main spool will increase with an increase in current applied to the solenoid. Therefore, the output flow of a work section is a function of input current to the solenoid. Thus the label of "proportional" is given to the section, since output varies as a function of input. See Figure 9050-10-32, Page 9050-10-29.

1. INLET 2. TANK 3. REGULATED OUTPUT PRESSURE

Figure 9050-10-32. Cross-Sectional View of Electro-Hydraulic (EH) Solenoid

Confidential/Proprietary - Do Not Copy or Duplicate

The tilt section includes a pressure reducing valve assembly, a relief cartridge, a main spool assembly, a load sense shuttle assembly, two electro-hydraulic solenoids and an anti-cavitation check. The tilt section’s purpose is to allow for extending and retracting of vehicle’s tilt cylinders. The major difference in this section versus a lift section is that the load check assembly has an additional feature of a pressure reducing spool assembly. The purpose of the pressure reducing assembly is to restrict the maximum pressure available to the tilt section and any downstream sections. The purpose of the load check feature is to prevent the forks from tilting forward before they are commanded to tilt back. The main spool’s purpose is to direct flow to the section’s workports when the spool is shifted out of neutral.

Operation NOTE: 1-2 Ton valves do not include the relief cartridge, but they do contain the pressure reducing/load check spool. However the valve can be retrofitted with a relief cartridge kit when one may be required because of pressure limitations of auxiliary equipment. The pressure reducing/load check assembly consists of a spool and two springs. Flow enters the tilt section via the power core and is directed across the pressure reducing/load check spool. The pressure reducing/load check spool is held in the normally open position by the springs. Pressure downstream of the spool is communicated to both ends of the spool via the holes drilled into the pressure reducing/load check spool. Once the pressure on the blind end of the spool is high enough, it will override the force generated by the springs and the spool will shift towards the spring end, thus limiting the pressure on the downstream side of the spool to balance the force of the springs plus the pressure on the downstream side of the pressure reducing/load check spool feeding the main spool. The lighter spring is used to produce the load check pressure and the heavier spring is used to regulate the reduced pressure setting. A relief cartridge (same as the load sense relief in the inlet assembly) is utilized to limit the maximum pressure on the downstream side of the pressure reducing spool. Since the flow into the offset power core is available to any sections downstream of the tilt section, pressure to sections downstream of the lift function will be limited to the setting of the relief cartridge located in the pressure reducing/load check assembly of the lift section. The anti-cavitation check, located next to the A work port become active when the pressure within the

9050-10-29

Principles of Operation

Hydraulic Systems

work port is lower than the pressure in the tank core. This allows oil to pass from the tank core into the work

port to keep air out of the lines and the tilt cylinder. See Figure 9050-10-33, Page 9050-10-30.

1. 2. 3. 4. 5.

6. 7. 8. 9.

BRIDGE CORE ANTI CAVITY CHECK EH SOLENOID MAIN SPOOL POWER CORE

FEED CORE PRESSURE REDUCING LOAD CHECK TANK CORE EH SOLENOID

Figure 9050-10-33. Cross-Section of EH Tilt Section Main Spool The main spool is a 4-way type, meaning that flow is available to both the A and B work ports versus only the A port (3-way spool) in a lift section. Energizing the solenoid on the A work port side of the section shifts the spool to power workport A. Energizing the solenoid on the B work port side of the section shifts the spool to power work port B. • Tilt Back Actuating the main spool to the tilt back position (B port pressurized) sends a load-sense signal to the unloading spool located in the inlet cover. The unloading spool in the inlet closes and flow is directed to the power core. Flow from the power core is directed across the pressure reducing/load check spool assembly and travels to the main spool via a feed core. Flow travels across the main spool into the bridge core and is directed out of work port B. Return flow from the tilt cylinder(s) is routed through work port A across the main spool into the tank core of the housing. Flow in the tank core is directed through

9050-10-30

the valve sections back to the tank (T) port located in the inlet section. • Tilt Forward When the tilt spool is shifted to pressurize work port A, the unloading spool in the inlet closes and flow becomes available to the work sections. Flow travels from the power core across the pressure reducing/load check spool into the main spool feed core. Flow travels across the main spool into the bridge core. Flow passes across the main spool and out the A work port. Return flow from the tilt cylinder(s) is directed into the B work port.

Spacer Sections Construction and Purpose Spacer sections are used in certain valve stacks to increase the length of the valve stack to overcome mechanical structure interference on certain vehicle models. They contain drilled passageways to allow oil to pass to the next work section. The only components they contain are common plugs and section seals.

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Principles of Operation

Auxiliary and Dual Auxiliary Sections Construction and Purpose Auxiliary and dual auxiliary sections housings are constructed of grey iron and contain internal components made from various steels. The purpose of auxiliary sections is to provide flow to any auxiliary functions (attachments). When more than one auxiliary section is used, the upstream section is labeled as a dual auxiliary section. All valve assemblies contain an end (single) auxiliary section. Both types of auxiliary sections contain a 4-way main spool, two electro-hydraulic solenoids to shift the main spool, and a load sense shuttle valve. These components are the same as used on the lift and tilt sections and operate the same. See Figure 9050-1034, Page 9050-10-31.

Operation

maximum load pressure is limited to the setting of the relief cartridge used in conjunction with the pressure reducing/load check assembly located in the tilt section. Auxiliary sections do not contain a load check assembly. Main spools are 4-way type, energizing solenoid A will power the A work port. Energizing solenoid B will provide power the B work port. To regulate the output flow of a work port, the operator must position the spool until the desired flow rate is obtained. Shifting the spool out of neutral communicates a load sense signal via the internal shuttle circuit to the unloading spool in the inlet. The unloading spool will shift and direct flow to downstream functions when a load demand is present. End auxiliary sections contain an SAE plug (BG port) on the outside surface which connects to the power core. Pressure at this port would represent the pressure setting of the pressure reducing valve assembly located in the tilt section.

Both the dual and end auxiliary sections operate the same. Input flow to all auxiliary sections are downstream of the feed core of the tilt section, therefore the

1. BRIDGE CORE 2. EH SOLENOID 3. TANK CORE

4. FEED CORE 5. MAIN SPOOL 6. EH SOLENOID

Figure 9050-10-34. Cross-Section of EH Auxiliary Section

Confidential/Proprietary - Do Not Copy or Duplicate

9050-10-31

Principles of Operation

Hydraulic Systems

Steering System DESCRIPTION The steering column assembly uses a steering control unit with hose connections on the bottom of the unit to connect hydraulic hoses to the main control valve and the steering cylinder. The steering housing has mounts for the steering column and the steering control unit. The steering wheel is installed on the steering column. See Figure 9050-10-35, Page 9050-10-32. The housing is adjustable and is held in position by a latch. The position of the housing can be tilted up or down for operator comfort. If the lift truck is equipped with the telescopic option; the steering wheel may also be moved toward or away from the operator. The steering system is a hydraulic system that does not have a mechanical connection between the steering wheel and the steering axle. The control of the steering is through a hydraulic circuit. See Priority Steer (E-Hydraulic Control Valve), Priority Steer (Manual Hydraulics Open Center Control Valve), or Priority Steer (Manual Hydraulics Closed Center Control Valve) as applicable for your lift truck. If the hydraulic pump for the steering system does not operate, steering is still possible. A check valve permits the steering control unit to control the steering cylinder. The lift truck is difficult to steer when the steering pump is not operating, but the steering control unit can operate the steering cylinder and make steering possible.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

STEERING WHEEL STEERING COLUMN STEERING CONTROL UNIT TILT MEMORY LEVER STEERING DIRECTION SENSOR TILT BASE STEERING COLUMN TILT CYLINDER MOUNTING BASE HYDRAULIC HOSES TELESCOPIC COLUMN ADJUSTING LEVER TELESCOPIC COLUMN LOCKING HANDLE

Figure 9050-10-35. Steering Housing Assembly

9050-10-32

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Principles of Operation

Accumulator, Piston The steering accumulator consists of a cylinder assembly, piston assembly, and two end-caps assemblies. The cylinder assembly houses a piston assembly, and incorporates provisions for securing the end-caps. An accumulator contains a free-floating piston with liquid on one side of the piston and pre-charged nitrogen on the other side. An increase of liquid volume decreases the gas volume and increases gas pressure, which provides a work potential when the liquid is allowed to discharge. The steering supply incorporates a back flow check valve. This valve is the straight adapter in the main control valve. The accumulator in the steering control unit supply circuit is designed to cushion any impulses that are generated within the hydraulic steering system.

Priority Steer (E-Hydraulic Control Valve) Pump flow is directed across a priority spool before supplying flow to any downstream functions. The steering

1. TO STEER UNIT 2. FROM PUMP 3. TO UNLOADER SPOOL

circuit flow demand has priority over any downstream flow requirements. Priority steering is accomplished by using a normally open spring biased spool. Pump flow is directed across the priority spool to the steer port (S). If the steering control unit is not in use, there is no load sense signal communicated to the SL port from the steering control unit. The inlet pressure (P) will increase to overcome the priority spring force. The inlet pressure is communicated to the blind end of the priority spool via the drilled passages within the spool, the spool will shift towards the spring end and flow will be directed across the spool to a downstream core leading to the unloading spool. If there is a flow demand at the steer (S) port, the load sense signal coming from the steering control unit is communicated to the spring end of the spool via the SL port. This increase in pressure will cause the spool to shift towards the blind end and flow to the steer (S) port will increase to meet the demands of the steering control unit. See Figure 9050-10-36, Page 9050-10-33. If no work section spools are shifted, total pump flow is directed across an unloading spool to the outlet (T) port.

4. PRIORITY SPOOL 5. STEER LS PORT

Figure 9050-10-36. Cross Section of Priority Steering Layout

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9050-10-33

Principles of Operation

Hydraulic Systems

Priority Steer (Manual Hydraulics Open Center Control Valve) Pump flow is directed across the priority spool before supplying flow for any downstream demands. Therefore, the steering circuit has priority over any downstream flow demands. Priority steering is accomplished by using a normally open spring biased spool. Pump flow is directed across the priority spool to the steer port (S). If the steering control unit is not in use, there is no load sense signal communicated to the SL port from the steering control unit. The inlet pressure (PG) will increase just enough to overcome the priority spool’s spring force. Since the inlet pressure is communicated to the blind end of the priority spool, via the drilled passages within the spool, the spool will shift towards the

1. OPEN CENTER CORE 2. RELIEF CARTRIDGE

spring end and flow to the steering unit will decrease and pump flow will be directed across the priority spool into a downstream (open center) core. If there is a flow demand from the steering unit, the load sense signal coming from the steering control unit is communicated to the spring end of the spool via the SL port. This increase in pressure will cause the spool to shift towards the blind end and flow to the steer (S) port will increase to meet the demands of the steering control unit. The downstream core coming from the priority spool is directed to the open center core of the valve assembly. If none of the work section spools are shifted, total pump flow is directed through the valve assembly via the open center core, across the work section spools to the outlet (T) port. See Figure 9050-10-37, Page 9050-10-34.

3. PRIORITY STEER SPOOL 4. SPRING

Figure 9050-10-37. Cross-Sectional View of Inlet Assembly

9050-10-34

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Principles of Operation

Priority Steer (Manual Hydraulics Closed Center Control Valve) Pump flow is directed across a priority spool before supplying flow to any downstream functions. The steering circuit flow demand has priority over any downstream flow requirements. Priority steering is accomplished by using a normally open spring biased spool. Pump flow is directed across the priority spool to the steer port (S). If the steering control unit is not in use, there is no load sense signal communicated to the SL port from the steering control unit. The inlet pressure (P) will increase to overcome the priority spring force. The inlet pressure is communicated to the blind end of the priority spool via

1. STEER UNIT OUTLET 2. PUMP INLET 3. UNLOADER SPOOL OUTLET

the drilled passages within the spool, the spool will shift towards the spring end and flow will be directed across the spool to a downstream core leading to the unloading spool. If there is a flow demand at the steer (S) port, the load sense signal coming from the steering control unit is communicated to the spring end of the spool via the SL port. This increase in pressure will cause the spool to shift towards the blind end and flow to the steer (S) port will increase to meet the demands of the steering control unit. See Figure 9050-10-38, Page 9050-10-35. If no work section spools are shifted, total pump flow is directed across an unloading spool to the outlet (T) port.

4. PRIORITY SPOOL 5. STEER LS PORT

Figure 9050-10-38. Cross-Section of Priority Steering Layout

Confidential/Proprietary - Do Not Copy or Duplicate

9050-10-35

Principles of Operation

STEERING CONTROL UNIT (SCU) OPERATION The steering control unit is a rotary valve operated by the steering wheel. See Figure 9050-10-39, Page 9050-10-37. During the steering operation, the steering control unit controls the direction and amount of oil flow to the steering cylinder. The steering cylinder in the axle actuates the steering linkage to move the steer tires. Hydraulic oil returns from the steering cylinder to the steering control unit and then to the hydraulic tank. Turning the steering wheel actuates three main parts of the steering control unit: the spool for the control section, the sleeve for the control section, and the rotor in the metering section. When the steering wheel is not moving, the spool and sleeve are held in the NEUTRAL (center) position by springs. During this time, oil flows freely through the steering control unit but none flows to the steering cylinder. As the steering wheel is turned, the spool begins to rotate. The springs try to move the sleeve to keep the NEUTRAL position between the spool and sleeve. However, the necessary force to turn the rotor is greater than the pressure of the springs. The springs begin to bend, letting the spool move a small amount within the sleeve. The spool stops moving when it touches the center pin. In this position, the holes in the sleeve and the spool are aligned. Oil coming into the control unit flows to the metering section.

Hydraulic Systems sleeve and the rotor in the metering section. The oil then flows to one side of the steering cylinder. Oil from the other side of the cylinder returns through the control section of the steering control unit. When the steering wheel stops moving, the metering action in the metering section also stops. The NEUTRAL position springs return the sleeve to the NEUTRAL position, stopping oil flow to or from the cylinder. The pressure stays in the steering cylinder to keep the steer tires in position. Oil from the pump flows through the steering control unit to the tank or other parts of the system. To return the steer wheels to the straight position, the steering wheel must be rotated in the opposite direction. The steering control unit will operate as described, but all parts will rotate in the opposite direction. The makeup valve (see Figure 9050-10-39, Page 905010-37) controls steering synchronization between the steering wheel and the steered wheels to ensure that the steering wheel is always in the same position relative to the steered wheels when the steered wheels are in the straight ahead direction. Calibration procedures allow the operator to establish a spinner knob comfort position when the steered wheels are in the straight ahead position. The system will maintain this relationship between the steering wheel and steered wheels through the use of the makeup valve. The steering control unit and the steered wheels have sensors mounted on them to determine relative angles.

More rotation of the steering wheel causes the spool to rotate the pin. This action causes the rotation of the

9050-10-36

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

1. 2. 3. 4.

Principles of Operation

STEERING CONTROL UNIT LOAD SENSE RETURN TO CONTROL VALVE MAKE-UP VALVE

5. SUPPLY PRESSURE 6. LEFT 7. RIGHT

Figure 9050-10-39. Steering Control Unit

Confidential/Proprietary - Do Not Copy or Duplicate

9050-10-37

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

9050-10-38

Hydraulic Systems

Observed Symptoms-Gear Pump

Group 33

Observed Symptoms-Gear Pump Abnormal Hydraulic Noise and/or Vibration POSSIBLE CAUSE A. LOW OIL LEVEL IN TANK. B. AIR TRAPPED IN CIRCUIT. C. SUCTION SIDE OF HYDRAULIC PUMP IS RESTRICTED. D. HYDRAULIC PUMP LEAK AT THE INLET SUCTION HOSES. E. HYDRAULIC PUMP IS WORN. F. VIBRATION WITH TILT FUNCTION ONLY. G. UNSTABLE MAIN RELIEF VALVE. H. UNSTABLE SECONDARY RELIEF VALVE. I. HYDRAULIC SYSTEM OVERHEATING. J. UNSTABLE UNLOADER SPOOL. K. UNSTABLE PRIORITY VALVE IN CONTROL VALVE INLET. CAUSE A - LOW OIL LEVEL IN TANK. PROCEDURE OR ACTION: NOTE: Cavitation of a hydraulic pump will cause noise and it is caused by air in the hydraulic oil. The hydraulic pump suction oil must be free of air and unrestricted to pump. Check hydraulic oil level in tank.

Is oil at correct level? YES: Go to Cause B. NO: Add oil to correct level. See Operating Manual. CAUSE B - AIR TRAPPED IN CIRCUIT. PROCEDURE OR ACTION: Remove air from circuit by cycling functions at one-second intervals, for E-Valve hoist and lower only. All other functions, cycle fully for 5 - 10 times. If symptom is still present, go to Cause C. CAUSE C - SUCTION SIDE OF HYDRAULIC PUMP IS RESTRICTED. PROCEDURE OR ACTION: 1. Check for restricted inlet screen.

Is inlet screen restricted? YES: Clean or replace inlet screen. NO: Go to Step 2. 2. Check for collapsed suction hose. Is suction hose collapsed? YES: Replace suction hose. NO: Go to Cause D.

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Confidential/Proprietary - Do Not Copy or Duplicate

9050-33-1

Observed Symptoms-Gear Pump

Hydraulic Systems

Abnormal Hydraulic Noise and/or Vibration (Cont) CAUSE D - HYDRAULIC PUMP LEAK AT THE INLET SUCTION HOSES. PROCEDURE OR ACTION: 1. Look at Steering System component location drawing to identify suction hose. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363. • Inspect suction hoses between tank and pump. Check for loose hose clamps and oil seepage.

Is oil leaking from suction side of hydraulic pump? YES: Check and tighten suction hose clamps. NO: Go to Cause E. 2. Inspect hydraulic oil. Check for foaming or aeration of oil. Is oil foaming or aerated? YES: Repair suction side air leak and test oil for contamination. See Maintenance, Oil Sampling Procedure. Depending on your lift truck, see Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. NO: Go to Cause E. CAUSE E - HYDRAULIC PUMP IS WORN. PROCEDURE OR ACTION: Check hydraulic pump flow. See Tests and Adjustments-Gear Pump, Hydraulic Pump Flow Test, Page 9050-43-9 in this section. Is hydraulic pump flow out of specifications? YES: Replace hydraulic pump. Depending on your lift truck, see Hydraulic System 1900 YRM 1367 or Hydraulic System 1900 YRM 1333. NO: Go to Cause F. CAUSE F - VIBRATION WITH TILT FUNCTION ONLY. PROCEDURE OR ACTION: 1. Inspect tilt spool and orifices for contamination or damage. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is tilt spool or orifices contaminated or plugged? YES: Clean or replace valve section. NO: Go to Cause G.

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9050-33-2

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Abnormal Hydraulic Noise and/or Vibration (Cont) CAUSE G - UNSTABLE MAIN RELIEF VALVE. PROCEDURE OR ACTION: 1. Install pressure gauge in hydraulic control valve. See Tests and Adjustments-Gear Pump, Primary Relief Valve Test and Adjustment, Page 9050-43-1. 2. Operate the hoist function while observing pressure gauge.

Does pressure fluctuate during hoist function. YES: Go to Cause H. NO: Go to Step 3. 3. Hold hoist function over relief. Does relief pressure meet test specifications? YES: Go to Cause H. NO: Replace relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE H - UNSTABLE SECONDARY RELIEF VALVE. PROCEDURE OR ACTION: 1. Install pressure gauge in hydraulic control valve. See Tests and Adjustments-Gear Pump, Secondary Relief Valve Test and Adjustment, Page 9050-43-4. 2. Operate a auxiliary function while observing pressure gauge.

Does pressure fluctuate during auxiliary function. YES: Go to Cause I. NO: Go to Step 3. 3. Hold auxiliary function over relief. Does relief pressure meet test specifications? YES: Go to Cause I. NO: Replace relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE I - HYDRAULIC SYSTEM OVERHEATING. PROCEDURE OR ACTION: Check temperature sensor for operation.

Is temperature sensor working properly? YES: Go to Cause J. NO: Replace temperature sensor. Depending on your lift truck, see Hydraulic System 1900 YRM 1367 or Hydraulic System 1900 YRM 1333.

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9050-33-3

Observed Symptoms-Gear Pump

Hydraulic Systems

Abnormal Hydraulic Noise and/or Vibration (Cont) CAUSE J - UNSTABLE UNLOADER SPOOL. PROCEDURE OR ACTION: Inspect unloader valve for damage or contamination. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is unloader valve free of contamination and in good condition? YES: Go to Cause K. NO: Clean or replace unloader valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE K - UNSTABLE PRIORITY VALVE IN CONTROL VALVE INLET. PROCEDURE OR ACTION: Perform Operational Checkout, Priority Flow Divider Valve Check, Page 9010-05-6. Does priority flow divider valve pass the check? YES: Priority flow divider valve is OK. NO: • Cannot turn steering wheel, wheel locks up. See Observed Symptoms-Gear Pump, No Steering (All Other Hydraulic Functions OK), Page 9050-33-58. • Steering wheel turns but fails Priority Valve Flow Divider Valve Check. Remove and clean flow divider spool. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

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9050-33-4

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Abnormal Smell/Discoloration/Foaming of Oil POSSIBLE CAUSE A. HYDRAULIC SYSTEM HAS BEEN OVERHEATED. B. HYDRAULIC FLUID CONTAMINATED OR WRONG TYPE. C. AIR LEAK ON SUCTION SIDE OF HYDRAULIC PUMP. CAUSE A - HYDRAULIC SYSTEM HAS BEEN OVERHEATED. PROCEDURE OR ACTION: Inspect for the following: • Level and condition of hydraulic oil in tank • Valve stuck causing system to run at relief

Are any of the above symptoms present? YES: Drain and refill hydraulic tank. Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. Repair or replace stuck valve. NO: Go to Cause B. CAUSE B - HYDRAULIC FLUID CONTAMINATED OR WRONG TYPE. PROCEDURE OR ACTION: Check hydraulic oil for contamination and correct type.

Is hydraulic oil contaminated or incorrect type used? YES: Drain and refill hydraulic tank. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. NO: Go to Cause C. CAUSE C - AIR LEAK ON SUCTION SIDE OF HYDRAULIC PUMP. PROCEDURE OR ACTION: Inspect condition of hydraulic oil.

Is the hydraulic oil foaming or aerated? YES: Repair leak on suction side of hydraulic pump. For [A968], ERC22-35VG (ERC045-070VG); [A976] ERP2235VL (ERP040-070VL); see Hydraulic System 1900 YRM 1367, For [G807], ERP16-20TH (ERP030- 040TH), [A955] ERP16-20VF; see Hydraulic System 1900 YRM 1333. NO: Check service record of lift truck to see if it requires periodic maintenance.

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9050-33-5

Observed Symptoms-Gear Pump

Hydraulic Systems

Cycle Times Too Fast - Fast Actuation (E-Valve) POSSIBLE CAUSE A. MAX FUNCTION SPEED SETTING TOO HIGH. B. RAMP SETTING TOO HIGH FOR FUNCTION. C. ORIFICES MISSING OR INSTALLED WRONG IN CYLINDER PORTS (ON AFTERMARKET CYLINDERS). D. FAULTY MLCV FOR LOWERING FUNCTION ONLY. E. UNLOADER VALVE PRODUCING TOO MUCH MARGIN PRESSURE. CAUSE A - MAX FUNCTION SPEED SETTING TOO HIGH. PROCEDURE OR ACTION: Adjust function speed setting on Display Panel. If problem is still present, go to Cause B. CAUSE B - RAMP SETTING TOO HIGH FOR FUNCTION. PROCEDURE OR ACTION:

Do cycle times meet specifications? YES: Go to Cause D. NO: Inspect and repair orifices in cylinder ports. See aftermarket Service Manuals. CAUSE D - FAULTY MLCV FOR LOWERING FUNCTION ONLY. PROCEDURE OR ACTION: Check the lowering cycle times.

Are the lowering cycle times too fast? YES: Repair or replace Mast Lowering Control Valve (MLCV). Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. NO: Go to Cause E.

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9050-33-6

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Cycle Times Too Fast - Fast Actuation (E-Valve) (Cont) CAUSE E - UNLOADER VALVE PRODUCING TOO MUCH MARGIN PRESSURE. PROCEDURE OR ACTION: Test unloader valve. See Tests and Adjustments-Gear Pump, Main Control Valve Unloader Margin Test, Page 905043-12.

Is margin pressure too high? YES: Replace unloader valve spool spring. Depending on your left truck, see Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. NO: Perform operational check.

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9050-33-7

Observed Symptoms-Gear Pump

Hydraulic Systems

Jump/Delay In Lift or Lower Activation After Moving MLM (E-Valve) POSSIBLE CAUSE A. RAMP RATE NOT SET TO DESIRED LEVEL. B. COIL NOT ATTACHED TO SOLENOID CORRECTLY. C. AIR TRAPPED IN CIRCUIT. D. OUTPUT THRESHOLD IS SET TOO HIGH. E. MAST/ATTACHMENT IS BINDING. F. STICKING UNLOADER SPOOL. G. MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE. CAUSE A - RAMP RATE NOT SET TO DESIRED LEVEL. PROCEDURE OR ACTION:

WARNING Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until problem has been repaired. 1. Adjust function ramp setting on Display Panel. See User Interface, Service Technician 2200 YRM 1336. If problem is still present, go to Cause B. CAUSE B - COIL NOT ATTACHED TO SOLENOID CORRECTLY. PROCEDURE OR ACTION: Inspect coil installation. Depending on your left truck, see Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. Is coil installed correctly to solenoid? YES: Go to Cause C. NO: Replace coil or solenoid. Coil cannot be repaired. CAUSE C - AIR TRAPPED IN CIRCUIT. PROCEDURE OR ACTION: 1. Remove air from circuit by cycling function at one second intervals, for E-Valve hoist and lower only. All other functions, cycle fully for 5 - 10 times. If symptom is still present, go to Cause D. CAUSE D - OUTPUT THRESHOLD IS SET TOO HIGH. PROCEDURE OR ACTION: Check current at Electro-Hydraulic Valve.

Is setting at valve correct? YES: Go to Cause E. NO: Decrease setting to specification or until operation is acceptable to operator.

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9050-33-8

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Jump/Delay In Lift or Lower Activation After Moving MLM (E-Valve) (Cont) CAUSE E - MAST/ATTACHMENT IS BINDING. PROCEDURE OR ACTION: Check for mast or attachment binding.

Is mast or attachment binding? YES: Repair mast or attachment. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. NO: Go to Cause F. CAUSE F - STICKING UNLOADER SPOOL. PROCEDURE OR ACTION: Inspect unloader valve for damage or contamination. Depending on your left truck, see Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is unloader free of contamination and in good condition? YES: Go to Cause G. NO: Clean or replace unloader valve. CAUSE G - MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE. PROCEDURE OR ACTION: Check LS pressure. See Tests and Adjustments-Gear Pump, Main Control Valve LS Leakage Test (E-Valve), Page 9050-43-11.

Does LS pressure meet test specifications? YES: See Observed Symptoms-Gear Pump, Lift Function Will Not Move With MLM Movement (E-Valve), Page 905033-23. NO: Clean or replace main relief valve. Depending on your left truck, see Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

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9050-33-9

Observed Symptoms-Gear Pump

Hydraulic Systems

Jump/Delay In Auxiliary Function Actuation After Moving MLM (E-Valve) POSSIBLE CAUSE A. RAMP RATE NOT SET TO DESIRED LEVEL. B. AIR TRAPPED IN CIRCUIT. C. OUTPUT THRESHOLD IS SET TOO HIGH. D. MAST/ATTACHMENT IS BINDING. E. PILOT PRESSURE NOT BEING PRODUCED FAST ENOUGH. F. STICKING VALVE SPOOL. G. STICKING UNLOADER SPOOL. H. VALVE SPOOL END SPRINGS TOO SOFT. CAUSE A - RAMP RATE NOT SET TO DESIRED LEVEL. PROCEDURE OR ACTION:

WARNING Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until problem has been repaired. 1. Adjust function ramp setting on Display Panel. See User Interface, Service Technician 2200 YRM 1336. If problem is still present, go to Cause B. CAUSE B - AIR TRAPPED IN CIRCUIT. PROCEDURE OR ACTION: Remove air from circuit by cycling function full stroke of hydraulic hoist cylinder at one second intervals. If symptom is still present, go to Cause C. CAUSE C - OUTPUT THRESHOLD IS SET TOO HIGH. PROCEDURE OR ACTION: Check current at valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is setting at valve correct? YES: Go to Cause D. NO: Decrease setting to specification or until operation is acceptable to operator. CAUSE D - MAST/ATTACHMENT IS BINDING. PROCEDURE OR ACTION: Check for mast or attachment binding.

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9050-33-10

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Jump/Delay In Auxiliary Function Actuation After Moving MLM (E-Valve) (Cont) CAUSE E - PILOT PRESSURE NOT BEING PRODUCED FAST ENOUGH. PROCEDURE OR ACTION: 1. Inspect filter. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is filter clean and in good condition? YES: Go to Cause F. NO: Clean or replace filter. CAUSE F - STICKING VALVE SPOOL. PROCEDURE OR ACTION: Inspect spool. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. Is spool clean and in good condition? YES: Go to Cause G. NO: Clean or replace spool. CAUSE G - STICKING UNLOADER SPOOL. PROCEDURE OR ACTION: Inspect unloader valve for damage or contamination. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is unloader free of contamination and in good condition? YES: Go to Cause H. NO: Clean or replace unloader valve. CAUSE H - VALVE SPOOL END SPRINGS TOO SOFT. PROCEDURE OR ACTION: Replace springs. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. If problem is still present, see Observed Symptoms-Gear Pump, Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move With MLM Movement (E-Valve), Page 9050-33-38.

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9050-33-11

Observed Symptoms-Gear Pump

Hydraulic Systems

Jump/Delay In Tilt Forward or Back Actuation (E-Valve) POSSIBLE CAUSE A. RAMP RATE NOT SET TO DESIRED LEVEL. B. AIR TRAPPED IN CIRCUIT. C. OUTPUT THRESHOLD IS SET TOO HIGH. CAUSE A - RAMP RATE NOT SET TO DESIRED LEVEL. PROCEDURE OR ACTION:

Is setting at valve correct? YES: Resume operation. NO: Decrease setting to specification or until operation is acceptable to operator.

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9050-33-12

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Forks Drop Slightly Before Lifting (E-Valve) POSSIBLE CAUSE A. EXCESSIVE LEAKAGE IN LOAD CHECK VALVE. CAUSE A - EXCESSIVE LEAKAGE IN LOAD CHECK VALVE. PROCEDURE OR ACTION:

WARNING Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until problem has been repaired. Check for contamination or damage to load check valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is load check valve in good condition? YES: Clean lift low leak valve. NO: Replace lift low leak valve.

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9050-33-13

Observed Symptoms-Gear Pump

Hydraulic Systems

Forks Lower Without Command (E-Valve) POSSIBLE CAUSE A. MLM CONTROL MALFUNCTION. B. EMERGENCY LOWER VALVE IS PARTIALLY OPEN. C. EXCESSIVE LIFT CYLINDER LEAKAGE. CAUSE A - MLM CONTROL MALFUNCTION. PROCEDURE OR ACTION: 1. Ensure power is OFF. Operate lift/lower lever in both directions. Does lever exhibit any binding/stickiness or not return to center position? YES: Remove and replace lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Note: Inspect cassette rotary mechanism for dirt contamination. NO: Go to Step 2. 2. Turn Power ON. 3. Go to the Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. 4. Move lever(s) to full stroke position and allow to snap back to the center position. Does Display value = 0%? YES: Go to Cause B. NO: Go to Step 5. 5. Power OFF. Replace lift/lower lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) 6. Retest. Turn power ON. 7. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. 8. Move lever(s) to full stroke position and allow to snap back to the center position.

Does Display value = 0%? YES: Go to Cause B. NO: Replace MLM PCB Cassette. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) 9. Retest. Turn power ON. 10. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. 11. Move lever(s) to full stroke position and allow to snap back to the center position. Display value = 0%? YES: Repair Complete. Resume operation. NO: Go to Cause B. CAUSE B - EMERGENCY LOWER VALVE IS PARTIALLY OPEN. PROCEDURE OR ACTION: NOTE: Emergency lower valve has tee handle located on control valve. See Operating Manual for location and correct use. Check and close valve. If problem is still present, go to Cause C. CAUSE C - EXCESSIVE LIFT CYLINDER LEAKAGE. PROCEDURE OR ACTION: Do lift cylinder leakage test. See Tests and Adjustments-Gear Pump, Lift Cylinder Leakage Test, Page 9050-43-23.

Is there leakage in the lift cylinder? YES: Repair or replace lift cylinder. NO: Resume operation.

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9050-33-14

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Forks Raise or Actuate Without Command (E-Valve) POSSIBLE CAUSE A. MLM CONTROL MALFUNCTION. B. AIR TRAPPED IN CIRCUIT. CAUSE A - MLM CONTROL MALFUNCTION. PROCEDURE OR ACTION: 1. Ensure power is OFF. Operate lift/lower lever in both directions. Does lever exhibit any binding/stickiness or not return to center position? YES: Remove and replace lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Note: Inspect cassette rotary mechanism for dirt contamination. NO: Go to Step 2. 2. Turn Power ON. 3. Go to the Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. 4. Move lever(s) to full stroke position and allow to snap back to the center position. Does Display value = 0%? YES: Go to Cause B. NO: Go to Step 5. 5. Power OFF. Replace lift/lower lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) 6. Retest. Turn power ON. 7. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. 8. Move lever(s) to full stroke position and allow to snap back to the center position.

Does Display value = 0%? YES: Go to Cause B. NO: Replace MLM PCB Cassette. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) 9. Retest. Turn power ON. 10. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. 11. Move lever(s) to full stroke position and allow to snap back to the center position. Does Display value = 0%? YES: Repair Complete. Resume Operation. NO: Go to Cause B. CAUSE B - AIR TRAPPED IN CIRCUIT. PROCEDURE OR ACTION: Remove air from circuit by cycling function at one-second intervals, for E-Valve hoist and lower only. All other functions, cycle fully for 5 - 10 times.

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9050-33-15

Observed Symptoms-Gear Pump

Hydraulic Systems

Intermittent Activation (E-Valve) While Commanding Function POSSIBLE CAUSE A. LOOSE WIRES OR CONNECTORS ON VALVE HARNESS. B. MAST/ATTACHMENT IS BINDING. C. CONTAMINATION IN HYDRAULIC CONTROL VALVE. CAUSE A - LOOSE WIRES OR CONNECTORS ON VALVE HARNESS. PROCEDURE OR ACTION: 1. Check the Display Panel for DTC.

Is a DTC displayed? YES: Go to DTC diagnostic procedure. NO: Go to Step 2. 2. Check wire connection. See Wire Harness Repair 2200 YRM 1128. If problem is still present, go to Cause B. CAUSE B - MAST/ATTACHMENT IS BINDING. PROCEDURE OR ACTION: Check for mast or attachment binding.

Is mast or attachment binding? YES: Repair mast or attachment. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. NO: Go to Cause C. CAUSE C - CONTAMINATION IN HYDRAULIC CONTROL VALVE. PROCEDURE OR ACTION: Inspect and clean control valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

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9050-33-16

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Forks Tilt Forward Without Command (E-Valve) POSSIBLE CAUSE A. MLM CONTROL MALFUNCTION. B. PPRV GETTING STRAY SIGNAL. C. EXCESSIVE TILT CYLINDER LEAKAGE. D. EXCESSIVE SPOOL LEAKAGE. E. PISTON STUCK. F. TILT CONTROL SPOOL DAMAGED OR LEAKING EXCESSIVELY. CAUSE A - MLM CONTROL MALFUNCTION. PROCEDURE OR ACTION: 1. Ensure power is OFF. Operate tilt lever in both directions. Does lever exhibit any binding/stickiness or not return to center position? YES: Remove and replace lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Note: Inspect cassette rotary mechanism for dirt contamination. NO: Go to Step 2. 2. Turn power ON. 3. Go to the Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. 4. Move lever(s) to full stroke position and allow to snap back to the center position. Does Display value = 0%? YES: Go to Cause B. 5. 6. 7. 8.

NO: Go to Step 5. Power OFF. Replace tilt lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Retest. Turn power ON. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the lever(s) to the full stroke position and hold. Observe value.

Does Display value = 0% at the center position and 92 to 100% at the full stroke position? YES: Go to Cause B. NO: Replace MLM PCB Cassette. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) 9. Retest. Turn power ON. 10. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. 11. Move lever(s) to full stroke position and allow to snap back to the center position. Does Display value = 0%? YES: Repair Complete. Resume operation. NO: Go to Cause B.

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9050-33-17

Observed Symptoms-Gear Pump

Hydraulic Systems

Forks Tilt Forward Without Command (E-Valve) (Cont) CAUSE B - PPRV GETTING STRAY SIGNAL. PROCEDURE OR ACTION: 1. Check for proper harness installation. See Wire Harness Repair 2200 YRM 1128.

Is valve harness installed wrong? YES: Install valve harness properly. NO: Go to Step 2. 2. Check for shorts in valve harness. See Wire Harness Repair 2200 YRM 1128. Does valve harness have shorts? YES: Repair or replace valve harness. NO: Go to Cause C. CAUSE C - EXCESSIVE TILT CYLINDER LEAKAGE. PROCEDURE OR ACTION: Do tilt cylinder leakage test. See Tests and Adjustments-Gear Pump, Tilt Cylinder Leakage Test, Page 9050-43-25. Is there leakage in the tilt cylinder? YES: Repair or replace tilt cylinder. NO: Go to Cause D. CAUSE D - EXCESSIVE SPOOL LEAKAGE. PROCEDURE OR ACTION: Check spool for: • Damage • Free movement • Debris or contamination

Is spool and mating bore in good condition? YES: Go to Cause E. NO: Replace damaged parts. CAUSE E - PISTON STUCK. PROCEDURE OR ACTION: Inspect tilt control piston. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Does piston move freely in bore? YES: Go to Cause F. NO: Clean piston or replace valve section.

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9050-33-18

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Forks Tilt Forward Without Command (E-Valve) (Cont) CAUSE F - TILT CONTROL SPOOL DAMAGED OR LEAKING EXCESSIVELY. PROCEDURE OR ACTION: Inspect valve section. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is spool in good condition? YES: See Observed Symptoms-Gear Pump, Forks Raise or Actuate Without Command (E-Valve), Page 9050-33-15. NO: Clean or replace spool.

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9050-33-19

Observed Symptoms-Gear Pump

Hydraulic Systems

Lift/Lower Function Maximum Speed Too Slow (E-Valve) POSSIBLE CAUSE A. MAX FUNCTION SPEED SETTING TOO LOW. B. RAMP SETTING TOO LOW FOR FUNCTION. C. OUTPUT THRESHOLD IS SET TOO LOW. D. MAST/ATTACHMENT IS BINDING. E. MLM CONTROL MALFUNCTION. F. MAIN RELIEF VALVE DAMAGED OR STUCK OPEN (LIFT FUNCTION ONLY). G. EXCESSIVE PUMP LEAKAGE (LIFT FUNCTION ONLY). H. UNLOADER NOT PRODUCING ENOUGH MARGIN PRESSURE (LIFT FUNCTION ONLY). I. MAIN CONTROL VALVE LS (LOAD SENSE) LEAKAGE (LIFT FUNCTION ONLY). J. FAULTY MAST LOWERING CONTROL VALVE. CAUSE A - MAX FUNCTION SPEED SETTING TOO LOW. PROCEDURE OR ACTION: Adjust function speed setting on Display Panel. If problem is still present, go to Cause B. CAUSE B - RAMP SETTING TOO LOW FOR FUNCTION. PROCEDURE OR ACTION:

Is setting at valve correct? YES: Go to Cause D. NO: Increase setting to specification or until operation is acceptable to operator. CAUSE D - MAST/ATTACHMENT IS BINDING. PROCEDURE OR ACTION: Check for mast or attachment binding.

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9050-33-20

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Lift/Lower Function Maximum Speed Too Slow (E-Valve) (Cont) CAUSE E - MLM CONTROL MALFUNCTION. PROCEDURE OR ACTION: 1. Turn power ON. 2. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. 3. Move lever to full stroke position – both directions.

4. 5. 6. 7.

Is Display value >=92%? YES: Go to Cause F. NO: Go to Step 4. Power OFF. Replace lift/lower Lever(s). See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337. Retest. Turn power ON. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever to full stroke position – both directions. Is Display value >=92%? YES: Go to Cause F. NO: Replace MLM PCB Cassette. See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.

CAUSE F - MAIN RELIEF VALVE DAMAGED OR STUCK OPEN (LIFT FUNCTION ONLY). PROCEDURE OR ACTION: 1. Install pressure gauge in hydraulic control valve. See Tests and Adjustments-Gear Pump, Primary Relief Valve Test and Adjustment, Page 9050-43-1. 2. Hold lift function over relief.

Does relief pressure meet test specifications? YES: Go to Cause G. NO: Replace relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE G - EXCESSIVE PUMP LEAKAGE (LIFT FUNCTION ONLY). PROCEDURE OR ACTION: Test hydraulic pump for excessive leakage. See Tests and Adjustments-Gear Pump, Hydraulic Pump Flow Test, Page 9050-43-9.

Does hydraulic pump have excessive leakage? YES: Repair or replace pump. See Hydraulic System 1900 YRM 1333. NO: Go to Cause H. CAUSE H - UNLOADER NOT PRODUCING ENOUGH MARGIN PRESSURE (LIFT FUNCTION ONLY). PROCEDURE OR ACTION: Test unloader spool spring. See Tests and Adjustments-Gear Pump, Main Control Valve Unloader Margin Test, Page 9050-43-12.

Does unloader valve pressure meet test specifications? YES: Go to Cause I. NO: Replace spring.

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9050-33-21

Observed Symptoms-Gear Pump

Hydraulic Systems

Lift/Lower Function Maximum Speed Too Slow (E-Valve) (Cont) CAUSE I - MAIN CONTROL VALVE LS (LOAD SENSE) LEAKAGE (LIFT FUNCTION ONLY). PROCEDURE OR ACTION: Check LS pressure. See Tests and Adjustments-Gear Pump, Main Control Valve LS Leakage Test (E-Valve), Page 9050-43-11.

Does LS pressure meet test specifications? YES: See Observed Symptoms-Gear Pump, Lift Function Will Not Move With MLM Movement (E-Valve), Page 905033-23. NO: Clean or replace main relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE J - FAULTY MAST LOWERING CONTROL VALVE. PROCEDURE OR ACTION: Inspect mast lowering control valve for blockage.

Is mast lowering control valve blocking flow? YES: Repair or replace mast lowering control valve. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. NO: Resume operation.

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9050-33-22

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Lift Function Will Not Move With MLM Movement (E-Valve) POSSIBLE CAUSE A. PUMP NOT GENERATING ENOUGH FLOW. B. LOAD IS GREATER THAN TRUCK CAPACITY. C. MLM CONTROL MALFUNCTION. D. EMERGENCY LOWER VALVE IS PARTIALLY OPEN. E. LIFT SPEED IS SET AT 0%. F. MAIN RELIEF VALVE IS SET TOO LOW. G. MAIN RELIEF VALVE DAMAGED OR STUCK OPEN. H. SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN. I. MAST LOWERING CONTROL VALVE BLOCKING FLOW. J. UNLOADER SPOOL IS STUCK OPEN. K. MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE. CAUSE A - PUMP NOT GENERATING ENOUGH FLOW. PROCEDURE OR ACTION: Do hydraulic pump flow check. See Hydraulic Pump Flow Check.

Does pump pass check? YES: Pump is OK. Go to Cause B. NO: Do Tests and Adjustments-Gear Pump, Hydraulic Pump Flow Test, Page 9050-43-9 before replacing pump. CAUSE B - LOAD IS GREATER THAN TRUCK CAPACITY. NOTE: See Serial Number plate or Operating Manual for lift capacity. PROCEDURE OR ACTION: Check load weight and compare to truck capacity rating. Adjust as necessary. If problem is still present, go to Cause C.

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9050-33-23

Observed Symptoms-Gear Pump

Hydraulic Systems

Lift Function Will Not Move With MLM Movement (E-Valve) (Cont) CAUSE C - MLM CONTROL MALFUNCTION. PROCEDURE OR ACTION: 1. Power ON and operator in seat. Operate lift/lower lever.

5. 6. 7. 8.

9. 10. 11.

Is a hydraulic interlock message displayed? YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2. NO: Go to Cause D. Observe value Is Operator Presence sensor value greater than 1.8 volts? YES: Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values, then go to Step 3. NO: Go to Seat Sensor Out of Range Low (OORL). Operate lift/lower lever in both directions. Does lever exhibit any binding/stickiness or not return to center position? YES: Remove and replace lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Note: Inspect cassette rotary mechanism for dirt contamination. NO: Go to Step 4. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the lever(s) to the full stroke position and hold. Observe value. Does Display value = 0% at the center position and 92 to 100% at the full stroke position? YES: Go to Cause D. NO: Go to Step 5. Power OFF. Replace lever(s). (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Retest. Turn power ON. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the lever(s) to the full stroke position and hold. Observe value. Does Display value = 0% at the center position and 92 to 100% at the full stroke position? YES: Repair complete. Resume operation. NO: Replace MLM PCB Cassette. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Retest. Turn power ON. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the lever(s) to the full stroke position and hold. Observe value. Does Display value = 0%? at the center position and 92 to 100% at the full stroke position? YES: Repair complete. Resume Operation. NO: Go to Cause D.

CAUSE D - EMERGENCY LOWER VALVE IS PARTIALLY OPEN. PROCEDURE OR ACTION: NOTE: Emergency lower valve has tee handle located on control valve. See Operating Manual for location and correct use. Check and close valve. If problem is still present, go to Cause E.

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9050-33-24

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Lift Function Will Not Move With MLM Movement (E-Valve) (Cont) CAUSE E - LIFT SPEED IS SET AT 0%. PROCEDURE OR ACTION: Check current setting of lift hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.

Is Hydraulic Function set at 0%? YES: Reset hydraulic function to appropriate level. NO: Go to Cause F. CAUSE F - MAIN RELIEF VALVE IS SET TOO LOW. PROCEDURE OR ACTION: Test and adjust pressure. See Tests and Adjustments-Gear Pump, Primary Relief Valve Test and Adjustment, Page 9050-43-1. Is relief set at specifications? YES: Go to Cause G. NO: Adjust pressure to test specifications. CAUSE G - MAIN RELIEF VALVE DAMAGED OR STUCK OPEN. PROCEDURE OR ACTION: Remove and inspect relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is relief set at specifications? YES: Go to Cause I. NO: Adjust pressure to test specifications. CAUSE I - MAST LOWERING CONTROL VALVE BLOCKING FLOW. PROCEDURE OR ACTION: Inspect mast lowering control valve for blockage. Is mast lowering control valve blocking flow? YES: Repair or replace mast lowering control valve. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. NO: Go to Cause J.

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9050-33-25

Observed Symptoms-Gear Pump

Hydraulic Systems

Lift Function Will Not Move With MLM Movement (E-Valve) (Cont) CAUSE J - UNLOADER SPOOL IS STUCK OPEN. PROCEDURE OR ACTION: Inspect and repair unloader spool. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. If problem is still present, go to Cause K. CAUSE K - MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE. PROCEDURE OR ACTION: Check LS pressure. See Tests and Adjustments-Gear Pump, Main Control Valve LS Leakage Test (E-Valve), Page 9050-43-11.

Does LS pressure meet test specifications? YES: See Observed Symptoms-Gear Pump, Too Much MLM Movement (Deadband) to Start Function Moving (E-Valve), Page 9050-33-45. NO: Clean or replace main relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

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9050-33-26

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Lift/Lower Continues To Move For Awhile After MLM Is Released (E-Valve) POSSIBLE CAUSE A. RAMP SETTINGS TO HIGH/LOW FOR OPERATION. CAUSE A - RAMP SETTINGS TO HIGH/LOW FOR OPERATION. PROCEDURE OR ACTION:

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9050-33-27

Observed Symptoms-Gear Pump

Hydraulic Systems

Lift/Lower/Auxiliary Function Suddenly Jumps In Middle of Stroke (E-Valve) POSSIBLE CAUSE A. STICKING VALVE SPOOL (AUXILIARY FUNCTIONS ONLY). B. VALVE SPOOL END SPRINGS TOO SOFT (AUXILIARY FUNCTIONS ONLY). CAUSE A - STICKING VALVE SPOOL (AUXILIARY FUNCTIONS ONLY). PROCEDURE OR ACTION: Remove and inspect spool. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is the spool undamaged and moves freely in bore? YES: Cause B. NO: Clean or replace valve spool. CAUSE B - VALVE SPOOL END SPRINGS TOO SOFT (AUXILIARY FUNCTIONS ONLY). PROCEDURE OR ACTION: Replace springs. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

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9050-33-28

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Lower Function Will Not Move With MLM Movement (E-Valve) POSSIBLE CAUSE A. LOWER SPEED IS SET AT 0%. B. MLM CONTROL MALFUNCTION. CAUSE A - LOWER SPEED IS SET AT 0%. PROCEDURE OR ACTION: Check current setting of lower hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function. Is Hydraulic Function set at 0%? YES: Reset hydraulic function to appropriate level. NO: Go to Cause B. CAUSE B - MLM CONTROL MALFUNCTION. PROCEDURE OR ACTION: 1. Power ON and operator in seat. Operate lift/lower Lever.

5. 6. 7. 8.

Is a hydraulic interlock message displayed? YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2. NO: Go to Step 3. Observe Value. Is Operator Presence sensor value greater than 1.8 volts? YES: Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values, then go to Step 3. NO: Go to Seat Sensor Out of Range Low (OORL). Operate lift/lower lever in both directions. Does lever exhibit any binding/stickiness or not return to center position? YES: Remove and replace lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Note: Inspect cassette rotary mechanism for dirt contamination. NO: Go to Step 4. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the lever(s) to the full stroke position and hold. Observe value. Does Display value = 0% at the center position and 92 to 100% at the full stroke position? YES: Repair complete. Resume operation NO: Go to Step 5. Power OFF. Replace lever(s). (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Retest. Turn power ON. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the lever(s) to the full stroke position and hold. Observe value. Does display value = 0% at the center position and 92 to 100% at the full stroke position? YES: Repair complete. Resume operation. NO: Replace MLM PCB Cassette. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Retest.

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9050-33-29

Observed Symptoms-Gear Pump

Hydraulic Systems

Poor Metering on Lift or Lower Functions (E-Valve) POSSIBLE CAUSE A. AIR TRAPPED IN CIRCUIT. B. RAMP SETTING TOO HIGH FOR FUNCTION. C. OUTPUT THRESHOLD IS SET TOO HIGH. D. MAST/ATTACHMENT IS BINDING. E. MLM CONTROL MALFUNCTION. F. MAST LOWERING CONTROL VALVE IS STICKING. G. STICKING UNLOADER SPOOL (LIFT FUNCTION ONLY). H. MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE. CAUSE A - AIR TRAPPED IN CIRCUIT. PROCEDURE OR ACTION: Remove air from circuit by cycling function full stroke of hydraulic hoist cylinder at one second intervals. If symptom is still present, go to Cause B. CAUSE B - RAMP SETTING TOO HIGH FOR FUNCTION. PROCEDURE OR ACTION:

Is mast or attachment binding? YES: Repair or lubricate mast or attachment. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. NO: Go to Cause E.

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9050-33-30

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Poor Metering on Lift or Lower Functions (E-Valve) (Cont) CAUSE E - MLM CONTROL MALFUNCTION. PROCEDURE OR ACTION: 1. Ensure power is OFF. Operate lift/lower lever in both directions.

2. 3. 4.

5. 6. 7. 8.

Does lever exhibit any binding/stickiness or not return to center position? YES: Remove and replace lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Note: Inspect cassette rotary mechanism for dirt contamination. NO: Go to Step 2. Turn Power ON. Go to the Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever(s) to full stroke position and allow to snap back to the center position. Does Display value = 0%? YES: Go to Cause F. NO: Go to Step 5. Power OFF. Replace lift/lower lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Retest. Turn power ON. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the lever(s) to the full stroke position and hold. Observe value. Does Display value = 0% at the center position and 92 to 100% at the full stroke position? YES: Go to Cause F. NO: Replace MLM PCB Cassette. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Retest.

CAUSE F - MAST LOWERING CONTROL VALVE IS STICKING. PROCEDURE OR ACTION: Inspect mast lowering control valve for proper operation. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. Is mast lowering control valve sticking? YES: Repair or replace mast lowering control valve. NO: Go to Cause G.

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9050-33-31

Observed Symptoms-Gear Pump

Hydraulic Systems

Poor Metering on Lift or Lower Functions (E-Valve) (Cont) CAUSE G - STICKING UNLOADER SPOOL (LIFT FUNCTION ONLY). PROCEDURE OR ACTION: Inspect unloader valve for damage or contamination. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is unloader free of contamination and in good condition? YES: Go to Cause H. NO: Clean or replace unloader valve. CAUSE H - MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE. PROCEDURE OR ACTION: Check LS pressure. See Tests and Adjustments-Gear Pump, Main Control Valve LS Leakage Test (E-Valve), Page 9050-43-11.

Does LS pressure meet test specifications? YES: See Observed Symptoms-Gear Pump, Lift Function Will Not Move With MLM Movement (E-Valve), Page 905033-23. NO: Clean or replace main relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

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9050-33-32

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Auxiliary Function Continues to Move for Awhile After MLM Is Released (E-Valve) POSSIBLE CAUSE A. RAMP SETTINGS TO HIGH/LOW FOR OPERATION. B. STICKING VALVE SPOOL. CAUSE A - RAMP SETTINGS TO HIGH/LOW FOR OPERATION. PROCEDURE OR ACTION:

WARNING Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until problem has been repaired. 1. Depending on associated hydraulic function, adjust ramp settings for proper operation. See User Interface, Service Technician 2200 YRM 1336. If problem is still present, go to Cause B. CAUSE B - STICKING VALVE SPOOL. PROCEDURE OR ACTION: Remove and inspect spool. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is the spool undamaged and moves freely in bore? YES: Resume operation. NO: Clean or replace valve spool.

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9050-33-33

Observed Symptoms-Gear Pump

Hydraulic Systems

Auxiliary Function Maximum Speed Too Slow (E-Valve) POSSIBLE CAUSE A. MAX FUNCTION SPEED SETTING TOO LOW. B. RAMP SETTING TOO LOW FOR FUNCTION. C. OUTPUT THRESHOLD IS SET TOO LOW. D. MAST/ATTACHMENT IS BINDING. E. MLM CONTROL MALFUNCTION. F. ORIFICES INSTALLED IN CIRCUIT TOO SMALL (ON AFTERMARKET CYLINDERS). G. MAIN RELIEF VALVE DAMAGED OR STUCK OPEN. H. SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN. I. PROPORTIONAL PRESSURE REDUCING VALVE TOO LOW. J. STICKING SPOOL. K. UNLOADER NOT PRODUCING ENOUGH MARGIN PRESSURE. L. MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE. CAUSE A - MAX FUNCTION SPEED SETTING TOO LOW. PROCEDURE OR ACTION: Adjust function speed setting on Display Panel. If problem is still present, go to Cause B. CAUSE B - RAMP SETTING TOO LOW FOR FUNCTION. PROCEDURE OR ACTION:

Is setting at valve correct? YES: Go to Cause D. NO: Increase setting until operation is acceptable to operator. CAUSE D - MAST/ATTACHMENT IS BINDING. PROCEDURE OR ACTION: Check for mast or attachment binding.

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9050-33-34

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Auxiliary Function Maximum Speed Too Slow (E-Valve) (Cont) CAUSE E - MLM CONTROL MALFUNCTION. PROCEDURE OR ACTION: 1. Turn power ON. 2. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. 3. Move Lever to full stroke position – both directions.

4. 5. 6. 7.

Is Display value >=92%? YES: Go to Cause F. NO: Go to Step 4. Power OFF. Replace Auxiliary Lever(s). (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Retest. Turn power ON. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever to full stroke position – both directions. Is Display value >=92%? YES: Go to Cause F. NO: Replace MLM PCB Cassette. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.)

CAUSE F - ORIFICES INSTALLED IN CIRCUIT TOO SMALL (ON AFTERMARKET CYLINDERS). PROCEDURE OR ACTION: Check cycle times. See aftermarket specifications.

Do cycle times meet specifications? YES: Go to Cause G. NO: Inspect and replace orifices in cylinder ports. See aftermarket service manuals. CAUSE G - MAIN RELIEF VALVE DAMAGED OR STUCK OPEN. PROCEDURE OR ACTION: 1. Install pressure gauge in hydraulic control valve. See Tests and Adjustments-Gear Pump, Primary Relief Valve Test and Adjustment, Page 9050-43-1. 2. Hold lift function over relief.

Does relief pressure meet test specifications? YES: Go to Cause H. NO: Replace relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE H - SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN. PROCEDURE OR ACTION: Test and adjust pressure. See Tests and Adjustments-Gear Pump, Secondary Relief Valve Test and Adjustment, Page 9050-43-4.

Is relief set at specifications? YES: Go to Cause I. NO: Adjust pressure to test specifications.

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9050-33-35

Observed Symptoms-Gear Pump

Hydraulic Systems

Auxiliary Function Maximum Speed Too Slow (E-Valve) (Cont) CAUSE I - PROPORTIONAL PRESSURE REDUCING VALVE TOO LOW. PROCEDURE OR ACTION: 1. Test Proportional Pressure Reducing Valve (PPRV) pressure. See PPRV Pilot Pressure Test.

Is PPRV pressure at specifications? YES: Go to Cause J. NO: Clean screen on PPRV. If problem is still present, replace PPRV. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE J - STICKING SPOOL. PROCEDURE OR ACTION: Inspect spool. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. Is spool clean and in good condition? YES: Go to Cause K. NO: Clean or replace spool. CAUSE K - UNLOADER NOT PRODUCING ENOUGH MARGIN PRESSURE. PROCEDURE OR ACTION: Test unloader spool spring. See Tests and Adjustments-Gear Pump, Main Control Valve Unloader Margin Test, Page 9050-43-12.

Does unloader valve pressure meet test specifications? YES: Go to Cause L. NO: Replace spring. CAUSE L - MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE. PROCEDURE OR ACTION: Check LS pressure. See Tests and Adjustments-Gear Pump, Main Control Valve LS Leakage Test (E-Valve), Page 9050-43-11.

Does LS pressure meet test specifications? YES: Check for DTCs. See General Maintenance and Diagnostic Data, Diagnostic Trouble Codes, Page 9030-03-6. NO: Clean or replace main relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

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9050-33-36

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Auxiliary Function or Tilt Back Moves Without Command (E-Valve) POSSIBLE CAUSE A. MLM CONTROL MALFUNCTION. B. EXCESSIVE SPOOL LEAKAGE. CAUSE A - MLM CONTROL MALFUNCTION. PROCEDURE OR ACTION: 1. Ensure power is OFF. Operate lever in both directions. Does lever exhibit any binding/stickiness or not return to center position? YES: Remove and replace lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Note: Inspect cassette rotary mechanism for dirt contamination. NO: Go to Step 2. 2. Turn power ON. 3. Go to the Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. 4. Move lever(s) to full stroke position and allow to snap back to the center position. Does Display value = 0%? YES: Go to Cause B. 5. 6. 7. 8.

NO: Go to Step 5. Power OFF. Replace lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Retest. Turn power ON. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever(s) to full stroke position and allow to snap back to the center position.

Does Display value = 0%? YES: Go to Cause B. NO: Replace MLM PCB Cassette. See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337. 9. Retest. Turn power ON. 10. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. 11. Move lever(s) to full stroke position and allow to snap back to the center position. Does Display value = 0%? YES: Repair Complete. Resume operation. NO: Go to Cause B. CAUSE B - EXCESSIVE SPOOL LEAKAGE. PROCEDURE OR ACTION: Check spool for items below. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. • Damage • Free movement • Debris or contamination

Is spool and mating bore in good condition? YES: See Observed Symptoms-Gear Pump, Auxiliary Function Continues to Move for Awhile After MLM Is Released (E-Valve), Page 9050-33-33. NO: Replace damaged parts.

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9050-33-37

Observed Symptoms-Gear Pump

Hydraulic Systems

Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move With MLM Movement (E-Valve) POSSIBLE CAUSE A. PUMP NOT GENERATING ENOUGH FLOW. B. LOAD IS GREATER THAN TRUCK CAPACITY. C. MLM CONTROL MALFUNCTION. D. HYDRAULIC FUNCTION SPEED IS SET AT 0%. E. SECONDARY RELIEF VALVE IS SET TOO LOW. F. MAST/ATTACHMENT IS BINDING. G. STUCK SPOOL IN CONTROL VALVE. H. PROPORTIONAL PRESSURE REDUCING VALVE TOO LOW. I. SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN. J. MAIN RELIEF VALVE DAMAGED OR STUCK OPEN. K. UNLOADER VALVE STUCK OPEN. L. MAIN RELIEF LS (LOAD SENSE) STUCK OPEN. M. MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE. CAUSE A - PUMP NOT GENERATING ENOUGH FLOW. PROCEDURE OR ACTION: Do hydraulic pump flow check. See Hydraulic Pump Flow Check.

Does pump pass check? YES: Pump is OK. Go to Cause B. NO: Perform Tests and Adjustments-Gear Pump, Hydraulic Pump Flow Test, Page 9050-43-9 before replacing pump. CAUSE B - LOAD IS GREATER THAN TRUCK CAPACITY. NOTE: See Serial Number plate or Operating Manual for lift capacity. PROCEDURE OR ACTION: Check load weight and compare to truck capacity rating. Adjust as necessary. If problem is still present, go to Cause C. CAUSE C - MLM CONTROL MALFUNCTION. PROCEDURE OR ACTION: 1. Power ON and operator in seat. Operate lever/s.

Is a hydraulic interlock message displayed? YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2. NO: Go to Cause D. 2. Observe value. Is Operator Presence sensor value greater than 1.8 volts? YES: Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values, then go to Step 3. NO: Go to Seat Sensor Out of Range Low (OORL). 3. Operate lever/s in both directions. Does lever exhibit any binding/stickiness or not return to center position? YES: Remove and replace lever. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Note: Inspect cassette rotary mechanism for dirt contamination. NO: Go to Next Step.

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9050-33-38

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move With MLM Movement (E-Valve) (Cont) 4. Move lever(s) to full stroke position and allow to snap back to the center position. Observe Value. Move the lever(s) to the full stroke position and hold. Observe Value.

5. 6. 7. 8.

9. 10. 11.

Does Display value = 0% at the center position and 92 to 100% at the full stroke position? YES: Go to Cause D. NO: Go to Step 5. Power OFF. Replace lever(s). (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Retest. Turn power ON. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the lever(s) to the full stroke position and hold. Observe value. Does Display value = 0% at the center position and 92 to 100% at the full stroke position? YES: Repair complete. Resume operation. NO: Replace MLM PCB Cassette. (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.) Retest. Turn power ON. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the lever(s) to the full stroke position and hold. Observe value. Does Display value = 0%? at the center position and 92 to 100% at the full stroke position? YES: Repair complete. Resume operation. NO: Go to Cause D.

CAUSE D - HYDRAULIC FUNCTION SPEED IS SET AT 0%. PROCEDURE OR ACTION: Check current setting of tilt hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.

Is Hydraulic Function set at 0%? YES: Reset hydraulic function to appropriate level. NO: Go to Cause E. CAUSE E - SECONDARY RELIEF VALVE IS SET TOO LOW. PROCEDURE OR ACTION: Test and adjust pressure. See Tests and Adjustments-Gear Pump, Secondary Relief Valve Test and Adjustment, Page 9050-43-4. Is relief set at specifications? YES: Go to Cause F. NO: Adjust pressure to test specifications.

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9050-33-39

Observed Symptoms-Gear Pump

Hydraulic Systems

Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move With MLM Movement (E-Valve) (Cont) CAUSE F - MAST/ATTACHMENT IS BINDING. PROCEDURE OR ACTION: Check for mast or attachment binding.

Is mast or attachment binding? YES: Lubricate or repair mast or attachment. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. NO: Go to Cause G. CAUSE G - STUCK SPOOL IN CONTROL VALVE. PROCEDURE OR ACTION: Remove and inspect spool. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. Does the spool move freely in bore and in good condition? YES: Go to Cause H. NO: Repair or replace valve spool or section. CAUSE H - PROPORTIONAL PRESSURE REDUCING VALVE TOO LOW. PROCEDURE OR ACTION: Test Proportional Pressure Reducing Valve (PPRV) pressure. See PPRV Pilot Pressure Test.

Is PPRV pressure at specifications? YES: Go to Cause I. NO: Clean screen on PPRV. If problem is still present, replace PPRV. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE I - SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN. PROCEDURE OR ACTION: NOTE: This only affects hoist circuit when a auxiliary function is activated. Test and adjust pressure. See Tests and Adjustments-Gear Pump, Secondary Relief Valve Test and Adjustment, Page 9050-43-4.

Is relief set at specifications? YES: Go to Cause J. NO: Adjust pressure to test specifications.

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9050-33-40

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move With MLM Movement (E-Valve) (Cont) CAUSE J - MAIN RELIEF VALVE DAMAGED OR STUCK OPEN. PROCEDURE OR ACTION: Remove and inspect relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is relief valve damaged or stuck open? YES: Install new relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. NO: Go to Cause K. CAUSE K - UNLOADER VALVE STUCK OPEN. PROCEDURE OR ACTION: Remove and inspect unloader spool. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. Does unloader spool move freely in bore and in good condition? YES: Go to Cause L. NO: Repair or replace unloader spool. CAUSE L - MAIN RELIEF LS (LOAD SENSE) STUCK OPEN. PROCEDURE OR ACTION: Remove and inspect main relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is the LS relief clean and spring OK? YES: Go to Cause M. NO: Check for contamination. Clean or replace relief valve. CAUSE M - MAIN CONTROL VALVE LS (LOAD SENSE) RELIEF LEAKAGE. PROCEDURE OR ACTION: Check LS pressure. See Tests and Adjustments-Gear Pump, Main Control Valve LS Leakage Test (E-Valve), Page 9050-43-11. Does LS pressure meet test specifications? YES: See Observed Symptoms-Gear Pump, Too Much MLM Movement (Deadband) to Start Function Moving (E-Valve), Page 9050-33-45. NO: Clean or replace main relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

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9050-33-41

Observed Symptoms-Gear Pump

Hydraulic Systems

Tilt Forward or Tilt Back Function Continues to Move for Awhile When MLM Is Released (E-Valve) POSSIBLE CAUSE A. RAMP SETTINGS TO HIGH/LOW FOR OPERATION. B. STICKING VALVE SPOOL. C. STICKING TILT CONTROL PISTON IN TILT SPOOL. CAUSE A - RAMP SETTINGS TO HIGH/LOW FOR OPERATION. PROCEDURE OR ACTION:

Is the spool undamaged and moves freely in bore? YES: Go to Cause C. NO: Clean or replace valve spool. CAUSE C - STICKING TILT CONTROL PISTON IN TILT SPOOL. PROCEDURE OR ACTION: Inspect piston. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Does piston move freely in bore? YES: Resume operation. NO: Clean piston or replace valve section.

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9050-33-42

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Tilt Forward or Tilt Back Will Not Move With MLM Movement (E-Valve) POSSIBLE CAUSE A. B. C. D.

MLM CONTROL MALFUNCTION. TILT SPEED IS SET AT 0%. PROPORTIONAL PRESSURE REDUCING VALVE TOO LOW. STUCK SPOOL IN CONTROL VALVE.

CAUSE A - MLM CONTROL MALFUNCTION. PROCEDURE OR ACTION: 1. Power ON and Operator in Seat. Operate Lever/s. Is a hydraulic interlock message displayed? YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2. NO: Go to Cause B. 2. Observe value

5. 6. 7. 8.

9. 10. 11.

Is Operator Presence sensor value greater than 1.8 volts? YES: Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values, then go to Step 3. NO: Go to Seat Sensor Out of Range Low (OORL). Operate lever/s in both directions. Does lever exhibit any binding/stickiness or not return to center position? YES: Remove and replace lever. See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337. Note: Inspect cassette rotary mechanism for dirt contamination. NO: Go to Step 4. Move lever(s) to full stroke position and allow to snap back to the center position. Observe Value. Move the lever(s) to the full stroke position and hold. Observe value. Does Display value = 0% at the center position and 92 to 100% at the full stroke position? YES: Go to Cause B. NO: Go to Step 5. Power OFF. Replace lever(s). (See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337..) Retest. Turn power ON. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the lever(s) to the full stroke position and hold. Observe value. Does Display value = 0% at the center position and 92 to 100% at the full stroke position? YES: Repair complete. Resume operation. NO: Replace MLM PCB Cassette. See Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337. Retest. Turn power ON. Go to Display Menu/Diagnostics/Hydraulics Inputs/Lever Input values. Move lever(s) to full stroke position and allow to snap back to the center position. Observe value. Move the lever(s) to the full stroke position and hold. Observe value. Does Display value = 0%? at the center position and 92 to 100% at the full stroke position? YES: Repair complete. Resume operation. NO: Go to Cause B.

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9050-33-43

Observed Symptoms-Gear Pump

Hydraulic Systems

Tilt Forward or Tilt Back Will Not Move With MLM Movement (E-Valve) (Cont) CAUSE B - TILT SPEED IS SET AT 0%. PROCEDURE OR ACTION: Check current setting of tilt hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.

Is Hydraulic Function set at 0%? YES: Reset hydraulic function to appropriate level. NO: Go to Cause C. CAUSE C - PROPORTIONAL PRESSURE REDUCING VALVE TOO LOW. PROCEDURE OR ACTION: Test Proportional Pressure Reducing Valve (PPRV) pilot pressure. See PPRV Pilot Pressure Test. Is PPRV pressure at specifications? YES: Go to Cause D. NO: Clean screen on PPRV. If problem is still present, replace PPRV. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE D - STUCK SPOOL IN CONTROL VALVE. PROCEDURE OR ACTION: Remove, disassemble, and inspect spool. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Does the spool move freely in bore and in good condition? YES: See Observed Symptoms-Gear Pump, Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move With MLM Movement (E-Valve), Page 9050-33-38. NO: Repair or replace valve spool or section.

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9050-33-44

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Too Much MLM Movement (Deadband) to Start Function Moving (E-Valve) POSSIBLE CAUSE A. OUTPUT THRESHOLD IS SET TOO HIGH. CAUSE A - OUTPUT THRESHOLD IS SET TOO HIGH. PROCEDURE OR ACTION: Check threshold at Display Panel. Is setting at valve correct? YES: • For hoist/lower functions, see Observed Symptoms-Gear Pump, Jump/Delay In Lift or Lower Activation After Moving MLM (E-Valve), Page 9050-33-8. • For auxiliary functions, see Observed Symptoms-Gear Pump, Jump/Delay In Auxiliary Function Actuation After Moving MLM (E-Valve), Page 9050-33-10. • For tilt forward function, see Observed Symptoms-Gear Pump, Jump/Delay In Tilt Forward or Back Actuation (E-Valve), Page 9050-33-12. NO: Decrease setting to specification or until operation is acceptable to operator.

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9050-33-45

Observed Symptoms-Gear Pump

Hydraulic Systems

Wrong Actuation Operates or Actuation is Backward (E-Valve) POSSIBLE CAUSE A. WIRING HARNESS INSTALLED WRONG. B. HYDRAULIC HOSES INSTALLED WRONG. C. WIRING HARNESS HAS FAILED. CAUSE A - WIRING HARNESS INSTALLED WRONG. PROCEDURE OR ACTION:

WARNING Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until problem has been repaired. Inspect wiring harness. Depending on your lift truck, see Electrical System 2200 YRM 1369 or Electrical System 2200 YRM 1337.

Is harness installed correctly? YES: Go to Cause B. NO: Adjust or repair harness. See Wire Harness Repair 2200 YRM 1128. CAUSE B - HYDRAULIC HOSES INSTALLED WRONG. PROCEDURE OR ACTION: Inspect hydraulic hose routing and correct as required. For proper hose routing, see Hydraulic Component Locator (1.0-5.5 Ton Shown). If problem is still present, go to Cause C. CAUSE C - WIRING HARNESS HAS FAILED. PROCEDURE OR ACTION: Inspect harness for shorts.

Does harness have a short? YES: Repair wiring harness. See Wire Harness Repair 2200 YRM 1128. NO: Resume operation.

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9050-33-46

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Actuation Exhibits Slight Movement in Opposite Direction Before Moving (Manual Valve) POSSIBLE CAUSE A. AIR WAS NOT REMOVED AFTER REPAIR TO THE HYDRAULIC SYSTEM. B. EXCESSIVE CONTROL VALVE SPOOL OR CYLINDER LEAKAGE. CAUSE A - AIR WAS NOT REMOVED AFTER REPAIR TO THE HYDRAULIC SYSTEM. PROCEDURE OR ACTION: Check service record of lift truck. Was hydraulic system repaired recently? YES: Check the repaired hose connections and remove air from system by cycling function full stroke of steering cylinder in each direction. NO: Go to Cause B. CAUSE B - EXCESSIVE CONTROL VALVE SPOOL OR CYLINDER LEAKAGE. PROCEDURE OR ACTION: Identify if problem is in lift cylinder or control valve. Do Tests and Adjustments-Gear Pump, Lift Cylinder Leakage Test, Page 9050-43-23.

Does lift cylinder pass leakage test. YES: Problem is in control valve. Clean and repair. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. NO: Repair or replace lift cylinder. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382.

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9050-33-47

Observed Symptoms-Gear Pump

Hydraulic Systems

Auxiliary Function is Slow or Does Not Function (Manual Valve) POSSIBLE CAUSE A. OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT. B. PUMP NOT GENERATING ENOUGH FLOW. C. LOAD IS GREATER THAN TRUCK CAPACITY. D. AUXILIARY FUNCTION SPEED IS SET AT 0%. E. SPOOL IS NOT FULLY ACTUATED. F. SECONDARY RELIEF VALVE IS SET TOO LOW. G. SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN. H. MAIN RELIEF VALVE SET TOO LOW, DAMAGED, OR STUCK OPEN. I. MAST/ATTACHMENT IS BINDING. J. EXCESSIVE INTERNAL SPOOL LEAKAGE. CAUSE A - OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT. PROCEDURE OR ACTION: 1. Power ON and operator in seat. Operate auxiliary lever. Is a hydraulic interlock message displayed? YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2. NO: Go to Cause B. 2. Observe value.

Is Operator Presence sensor value greater than 1.8 volts? YES: Go to Cause B. NO: Go to Seat Sensor Out of Range Low (OORL). CAUSE B - PUMP NOT GENERATING ENOUGH FLOW. PROCEDURE OR ACTION: Do hydraulic pump flow check. See Hydraulic Pump Flow Check.

Does pump pass check? YES: Pump is OK. Go to Cause C. NO: Do Tests and Adjustments-Gear Pump, Hydraulic Pump Flow Test, Page 9050-43-9 before replacing pump. CAUSE C - LOAD IS GREATER THAN TRUCK CAPACITY. NOTE: See Serial Number plate or Operating Manual for lift capacity. PROCEDURE OR ACTION: Check load weight and compare to truck capacity rating. Adjust as necessary. If problem is still present, go to Cause D. CAUSE D - AUXILIARY FUNCTION SPEED IS SET AT 0%. PROCEDURE OR ACTION: Depending on associated hydraulic function, adjust ramp settings for proper operation. See User Interface, Service Technician 2200 YRM 1336. If problem is still present, go to Cause E.

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9050-33-48

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Auxiliary Function is Slow or Does Not Function (Manual Valve) (Cont) CAUSE E - SPOOL IS NOT FULLY ACTUATED. PROCEDURE OR ACTION: Inspect linkage. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Does linkage prematurely contact dash? YES: Repair or replace linkage. NO: Go to Cause F. CAUSE F - SECONDARY RELIEF VALVE IS SET TOO LOW. PROCEDURE OR ACTION: Test and adjust pressure. See Tests and Adjustments-Gear Pump, Secondary Relief Valve Test and Adjustment, Page 9050-43-4. Is relief set at specifications? YES: Go to Cause G. NO: Adjust pressure to test specifications. CAUSE G - SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN. PROCEDURE OR ACTION: Remove and inspect relief valve. See Hydraulic System 1900 YRM 1333.

Is relief valve damaged or stuck open? YES: Install new relief valve. NO: Go to Cause H. CAUSE H - MAIN RELIEF VALVE SET TOO LOW, DAMAGED, OR STUCK OPEN. PROCEDURE OR ACTION: NOTE: This symptom only affects auxiliary functions when hoist function is activated. Test and adjust pressure. See Tests and Adjustments-Gear Pump, Primary Relief Valve Test and Adjustment, Page 9050-43-1.

Is relief set at specifications? YES: Go to Cause I. NO: Adjust pressure to test specifications and retest. If problem is still present, replace relief valve. See Hydraulic System 1900 YRM 1333. CAUSE I - MAST/ATTACHMENT IS BINDING. PROCEDURE OR ACTION: Check for mast or attachment binding.

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9050-33-49

Observed Symptoms-Gear Pump

Hydraulic Systems

Auxiliary Function is Slow or Does Not Function (Manual Valve) (Cont) CAUSE J - EXCESSIVE INTERNAL SPOOL LEAKAGE. PROCEDURE OR ACTION: Replace spool or complete control valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

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9050-33-50

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Cycle Times Too Fast - Fast Actuation (Manual Valve) POSSIBLE CAUSE A. ORIFICES MISSING OR INSTALLED IN WRONG CYLINDER PORTS (ON AFTERMARKET CYLINDERS). B. FAULTY MAST LOWERING CONTROL VALVE (MLCV) FOR LOWERING FUNCTION ONLY. CAUSE A - ORIFICES MISSING OR INSTALLED IN WRONG CYLINDER PORTS (ON AFTERMARKET CYLINDERS). PROCEDURE OR ACTION: Check cycle times. See aftermarket specifications.

Are cycle times to specifications? YES: Go to Cause B. NO: Inspect and repair orifices in cylinder ports. Go to aftermarket Service Manuals. CAUSE B - FAULTY MAST LOWERING CONTROL VALVE (MLCV) FOR LOWERING FUNCTION ONLY. PROCEDURE OR ACTION: Check the lowering cycle times.

Are the lowering cycle times too fast? YES: Repair or replace MLCV. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. NO: Repeat lowering cycle times to make sure they are not too fast.

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9050-33-51

Observed Symptoms-Gear Pump

Hydraulic Systems

Function Continues to Activate After Returning to Neutral POSSIBLE CAUSE A. B. C. D.

CONTROL LINKAGE BINDING (MANUAL VALVE). VALVE SPOOL STICKING IN BORE (MANUAL VALVE). MLM SWITCH PROBLEM (E-VALVE). SPOOL STUCK OPEN.

CAUSE A - CONTROL LINKAGE BINDING (MANUAL VALVE). PROCEDURE OR ACTION:

WARNING Unexpected movement of hydraulic function can cause injury or death. Do not operate the lift truck until problem has been repaired. Inspect control linkage for sticking or binding. Repair or lubricate as required. If problem is still present, go to Cause B. CAUSE B - VALVE SPOOL STICKING IN BORE (MANUAL VALVE). PROCEDURE OR ACTION: Inspect valve spool. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Does valve spool move freely in bore? YES: Replace spool end cap centering springs. If problem is still present, go to Cause C. NO: Clean or replace valve spool. CAUSE C - MLM SWITCH PROBLEM (E-VALVE). PROCEDURE OR ACTION: Check valve calibration.

Is control valve calibrated correctly? YES: Go to Cause D. NO: Calibrate control valve. CAUSE D - SPOOL STUCK OPEN. PROCEDURE OR ACTION: Inspect valve spool. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is valve spool damaged or stuck open? YES: Clean or replace valve spool. NO: Valve has excessive leakage. Replace valve spool.

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9050-33-52

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Lift Function Is Slow or Does Not Function (Manual Valve) POSSIBLE CAUSE A. OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT. B. PUMP NOT GENERATING ENOUGH FLOW. C. LOAD IS GREATER THAN TRUCK CAPACITY. D. EMERGENCY LOWER VALVE IS PARTIALLY OPEN. E. LIFT SPEED IS SET AT 0%. F. LIFT SPOOL IS NOT FULLY ACTUATED. G. MAIN RELIEF VALVE IS SET TOO LOW. H. MAIN RELIEF VALVE DAMAGED OR STUCK OPEN. I. SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN. J. MAST/ATTACHMENT IS BINDING. K. EXCESSIVE INTERNAL SPOOL LEAKAGE. L. MAST LOWERING CONTROL VALVE BLOCKING FLOW. CAUSE A - OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT. PROCEDURE OR ACTION: 1. Power ON and operator in seat. Operate lift/lower lever. Is a hydraulic interlock message displayed? YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2. NO: Go to Cause B. 2. Observe value.

Does pump pass check? YES: Pump is OK. Go to Cause C. NO: Do Tests and Adjustments-Gear Pump, Hydraulic Pump Flow Test, Page 9050-43-9 before replacing pump. CAUSE C - LOAD IS GREATER THAN TRUCK CAPACITY. NOTE: See Serial Number plate or Operating Manual for lift capacity. PROCEDURE OR ACTION: Check load weight and compare to truck capacity rating. Adjust as necessary. If problem is still present, go to Cause D. CAUSE D - EMERGENCY LOWER VALVE IS PARTIALLY OPEN. PROCEDURE OR ACTION: NOTE: Emergency lower valve has tee handle located on control valve. See Operating Manual for location and correct use. Check and close valve. If problem is still present, go to Cause E.

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9050-33-53

Observed Symptoms-Gear Pump

Hydraulic Systems

Lift Function Is Slow or Does Not Function (Manual Valve) (Cont) CAUSE E - LIFT SPEED IS SET AT 0%. PROCEDURE OR ACTION: Check current setting of lift hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.

Is Hydraulic Function set at 0%? YES: Reset hydraulic function to appropriate level. NO: Go to Cause F. CAUSE F - LIFT SPOOL IS NOT FULLY ACTUATED. PROCEDURE OR ACTION: Inspect linkage. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. Does linkage prematurely contact dash? YES: Repair or replace linkage. NO: Go to Cause G. CAUSE G - MAIN RELIEF VALVE IS SET TOO LOW. PROCEDURE OR ACTION: Test and adjust pressure. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is relief set at specifications? YES: Go to Cause H. NO: Adjust pressure to test specifications. CAUSE H - MAIN RELIEF VALVE DAMAGED OR STUCK OPEN. PROCEDURE OR ACTION: Remove and inspect relief valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is relief valve damaged or stuck open? YES: Install new relief valve. NO: Go to Cause I. CAUSE I - SECONDARY RELIEF VALVE DAMAGED OR STUCK OPEN. PROCEDURE OR ACTION: Test and adjust pressure. See Tests and Adjustments-Gear Pump, Secondary Relief Valve Test and Adjustment, Page 9050-43-4. Is relief set at specifications? YES: Go to Cause J. NO: Adjust pressure to test specifications.

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9050-33-54

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Lift Function Is Slow or Does Not Function (Manual Valve) (Cont) CAUSE J - MAST/ATTACHMENT IS BINDING. PROCEDURE OR ACTION: Check for mast or attachment binding.

Is mast or attachment binding? YES: Repair mast or attachment. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. NO: Go to Cause K. CAUSE K - EXCESSIVE INTERNAL SPOOL LEAKAGE. PROCEDURE OR ACTION: Replace spool or complete control valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE L - MAST LOWERING CONTROL VALVE BLOCKING FLOW. PROCEDURE OR ACTION: Inspect mast lowering control valve for blockage.

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9050-33-55

Observed Symptoms-Gear Pump

Hydraulic Systems

Tilt Back Function Will Not Operate (Manual Valve) POSSIBLE CAUSE A. OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT. B. TILT BACK SPEED IS SET AT 0%. C. CONTROL VALVE PISTON IS STUCK IN OPEN POSITION. CAUSE A - OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT. PROCEDURE OR ACTION: 1. Power ON and operator in seat. Operate tilt back lever. Is a hydraulic interlock message displayed? YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2. NO: Go to Cause B. 2. Observe value.

Is Operator Presence sensor value greater than 1.8 volts? YES: Go to Cause B. NO: Go to Seat Sensor Out of Range Low (OORL). CAUSE B - TILT BACK SPEED IS SET AT 0%. PROCEDURE OR ACTION: Check current setting of tilt hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.

Is Hydraulic Function set at 0%? YES: Reset hydraulic function to appropriate level. NO: Go to Cause C. CAUSE C - CONTROL VALVE PISTON IS STUCK IN OPEN POSITION. PROCEDURE OR ACTION: Inspect control valve piston and exhaust orifices. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Does the valve move freely and are exhaust orifices open? YES: Valve is OK. See Observed Symptoms-Gear Pump, Auxiliary Function is Slow or Does Not Function (Manual Valve), Page 9050-33-48. NO: Replace control valve piston.

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9050-33-56

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Tilt Forward or Tilt Back Will Not Function When Activated (Manual Valve) POSSIBLE CAUSE A. B. C. D.

OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT. TILT SPEED IS SET AT 0%. TILT CONTROL VALVE IS STUCK IN CLOSED POSITION. TILT CONTROL VALVE EXHAUST HOLES PLUGGED IN VALVE.

CAUSE A - OPERATOR PRESENCE SENSOR HAS HYDRAULIC FUNCTION LOCKED OUT. PROCEDURE OR ACTION: 1. Power ON and operator in seat. Operate tilt forward/back lever. Is a hydraulic interlock message displayed? YES: Go to Display Menu/Diagnostics/Seat (Operator Presence), then go to Step 2. NO: Go to Cause B. 2. Observe value.

Is Operator Presence sensor value greater than 1.8 volts? YES: Go to Cause B. NO: Go to Seat Sensor Out of Range Low (OORL). CAUSE B - TILT SPEED IS SET AT 0%. PROCEDURE OR ACTION: Check current setting of tilt hydraulic function. Go to Display Menu/Truck Set-Up/Hydraulic Function.

Is Hydraulic Function set at 0%? YES: Reset hydraulic function to appropriate level. NO: Go to Cause C. CAUSE C - TILT CONTROL VALVE IS STUCK IN CLOSED POSITION. PROCEDURE OR ACTION: Inspect tilt control valve and exhaust orifices. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Does the control valve piston move freely and are exhaust orifices open? YES: Go to Cause D. NO: Clean or replace tilt control valve spool. CAUSE D - TILT CONTROL VALVE EXHAUST HOLES PLUGGED IN VALVE. PROCEDURE OR ACTION: Inspect valve section. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. Are exhaust holes open? YES: Valve is OK. See Observed Symptoms-Gear Pump, Auxiliary Function is Slow or Does Not Function (Manual Valve), Page 9050-33-48. NO: Clean or replace valve.

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9050-33-57

Observed Symptoms-Gear Pump

Hydraulic Systems

No Steering (All Other Hydraulic Functions OK) POSSIBLE CAUSE A. HYDRAULIC HOSES ARE NOT CONNECTED OR DAMAGED. B. STEERING RELIEF VALVE IS SET TOO LOW. C. TRANSAXLE/DRIVE UNIT IS BINDING. D. PRIORITY FLOW DIVIDER VALVE IS CONTAMINATED. E. STEERING CYLINDER PISTON SEALS ARE WORN OR DAMAGED. F. SLEEVE AND SPOOL IN THE CONTROL UNIT WILL NOT MOVE. G. STEERING CONTROL UNIT IS DAMAGED. CAUSE A - HYDRAULIC HOSES ARE NOT CONNECTED OR DAMAGED. PROCEDURE OR ACTION: Look at Steering System component location drawing to identify steering hoses. Inspect hoses for wear, damage, and correct installation. Are steering hoses in good condition and installed correctly? YES: Go to Cause B. NO: Install new components as necessary. CAUSE B - STEERING RELIEF VALVE IS SET TOO LOW. PROCEDURE OR ACTION: Perform Operational Checkout, Steering Relief Valve Low Pressure Check, Page 9010-05-12.

Is steering relief pressure set too low? YES: Adjust steering relief pressure. See Tests and Adjustments-Gear Pump, Steering Relief Pressure Test and Adjustment, Page 9050-43-18. NO: Go to Cause C. CAUSE C - TRANSAXLE/DRIVE UNIT IS BINDING. PROCEDURE OR ACTION: Inspect transaxle/drive unit for binding.

Is transaxle/drive unit binding? YES: Replace transaxle/drive unit. Depending on your lift truck, see Transaxle 1300 YRM 1330 or Transaxle 1300 YRM 1370. NO: Go to Cause D. CAUSE D - PRIORITY FLOW DIVIDER VALVE IS CONTAMINATED. PROCEDURE OR ACTION: Perform Operational Checkout, Priority Flow Divider Valve Check, Page 9010-05-6. Does priority flow divider valve pass the check? YES: Priority flow divider valve is OK. Go to Cause E. NO: • Cannot turn steering wheel, wheel locks up. Go to Cause F. • Steering wheel turns but fails Priority Valve Flow Divider Valve Check. Remove and clean flow divider spool. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439.

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9050-33-58

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

No Steering (All Other Hydraulic Functions OK) (Cont) CAUSE E - STEERING CYLINDER PISTON SEALS ARE WORN OR DAMAGED. PROCEDURE OR ACTION: Do Tests and Adjustments-Gear Pump, Steering Cylinder Leakage Test, Page 9050-43-28.

Does steering cylinder pass leakage test? YES: Cylinder is OK. Go to Cause G. NO: Remove and repair steering cylinder. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering Axle 1600 YRM 1360. CAUSE F - SLEEVE AND SPOOL IN THE CONTROL UNIT WILL NOT MOVE. PROCEDURE OR ACTION: Turn steering wheel with engine running. Does steering wheel move? YES: Sleeve and spool are not seized. Go to Cause G. NO: Repair steering control unit. Replace components as required. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363. CAUSE G - STEERING CONTROL UNIT IS DAMAGED. PROCEDURE OR ACTION: Inspect SCU.

Is steering control unit damaged? YES: Install new SCU. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363. NO: Repair steering control unit. Replace components as required. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363.

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9050-33-59

Observed Symptoms-Gear Pump

Hydraulic Systems

Steering Is Slow or Difficult POSSIBLE CAUSE A. LOW PUMP FLOW. B. STEERING RELIEF PRESSURE IS SET TOO LOW. C. PRIORITY FLOW DIVIDER VALVE IS CONTAMINATED. D. HYDRAULIC LINES ARE RESTRICTED. E. SEAL IN THE STEERING CYLINDER LEAKS. F. TRANSAXLE/DRIVE UNIT COMPONENTS ARE DAMAGED AND/OR BINDING. G. SCU IS WORN, NOT ASSEMBLED CORRECTLY, OR DAMAGED. CAUSE A - LOW PUMP FLOW. PROCEDURE OR ACTION: Do Tests and Adjustments-Gear Pump, Hydraulic Pump Flow Test, Page 9050-43-9. Are other hydraulic functions OK? YES: Hydraulic pump output is OK. Go to Cause B. NO: Test hydraulic system relief pressure. See Tests and Adjustments-Gear Pump, Primary Relief Valve Test and Adjustment, Page 9050-43-1. CAUSE B - STEERING RELIEF PRESSURE IS SET TOO LOW. PROCEDURE OR ACTION: Perform Operational Checkout, Steering Relief Valve Low Pressure Check, Page 9010-05-12.

Is steering relief pressure set too low? YES: Adjust steering relief pressure. See Tests and Adjustments-Gear Pump, Steering Relief Pressure Test and Adjustment, Page 9050-43-18. NO: Go to Cause C. CAUSE C - PRIORITY FLOW DIVIDER VALVE IS CONTAMINATED. PROCEDURE OR ACTION: Perform Operational Check, seeOperational Checkout, Priority Flow Divider Valve Check, Page 9010-05-6.

Does priority flow divider valve pass check? YES: Priority flow divider valve is OK. Go to Cause D. NO: • Flow divider valve spool is stuck. Remove and clean flow divider spool. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. • LS signal pressure is leaking away. See Tests and Adjustments-Gear Pump, Steering Control Unit LS Pressure Test, Page 9050-43-21. CAUSE D - HYDRAULIC LINES ARE RESTRICTED. PROCEDURE OR ACTION: Look at Steering System component. Inspect hoses for wear, damage, and correct installation. Are steering hoses in good condition and correctly installed? YES: Go to Cause E. NO: Install new hoses as necessary.

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9050-33-60

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Steering Is Slow or Difficult (Cont) CAUSE E - SEAL IN THE STEERING CYLINDER LEAKS. PROCEDURE OR ACTION: Perform Tests and Adjustments-Gear Pump, Steering Cylinder Leakage Test, Page 9050-43-28.

Does steering cylinder pass leakage test? YES: Cylinder is OK. Go to Cause F. NO: Remove and repair steering cylinder. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363. CAUSE F - TRANSAXLE/DRIVE UNIT COMPONENTS ARE DAMAGED AND/OR BINDING. PROCEDURE OR ACTION: Turn steering wheel stop to stop in both directions while observing tires. Do tires shake or make noise while turning? YES: Inspect and repair damage transaxle/drive unit components. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363. NO: Go to Cause G. CAUSE G - SCU IS WORN, NOT ASSEMBLED CORRECTLY, OR DAMAGED. PROCEDURE OR ACTION: Inspect SCU. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is steering control unit damaged? YES: Install new SCU. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. NO: See Observed Symptoms-Gear Pump, Steering Operation Is Not Smooth, Page 9050-33-62.

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9050-33-61

Observed Symptoms-Gear Pump

Hydraulic Systems

Steering Operation Is Not Smooth POSSIBLE CAUSE A. AIR WAS NOT REMOVED AFTER REPAIR TO THE HYDRAULIC SYSTEM. B. STEERING RELIEF PRESSURE SET TOO LOW. C. HYDRAULIC STEER ACCUMULATOR IS NOT WORKING PROPERLY. D. BINDING IN STEERING COLUMN. E. LOW PUMP FLOW. F. FAILED CENTERING SPRINGS IN SCU. G. STEERING CONTROL UNIT IS ASSEMBLED INCORRECTLY, DAMAGED, OR CONTAMINATED. CAUSE A - AIR WAS NOT REMOVED AFTER REPAIR TO THE HYDRAULIC SYSTEM. PROCEDURE OR ACTION: Check service record of lift truck. Was hydraulic system repaired recently? YES: Check the repaired hose connections and remove air from system by cycling of steering cylinder full stroke in each direction. NO: Go to Cause B. CAUSE B - STEERING RELIEF PRESSURE SET TOO LOW. PROCEDURE OR ACTION: Perform Operational Check, seeOperational Checkout, Steering Relief Valve Low Pressure Check, Page 9010-05-12.

Is steering relief pressure set too low? YES: Adjust steering relief pressure. See Tests and Adjustments-Gear Pump, Steering Relief Pressure Test and Adjustment, Page 9050-43-18. NO: Go to Cause C. CAUSE C - HYDRAULIC STEER ACCUMULATOR IS NOT WORKING PROPERLY. PROCEDURE OR ACTION: Turn steering wheel slowly while operating a mast function over relief, then suddenly release the control lever.

Does steering wheel jerk abruptly? YES: Replace the steering accumulator. See Hydraulic System 1900 YRM 1367 NO: Go to Cause D. CAUSE D - BINDING IN STEERING COLUMN. PROCEDURE OR ACTION: Turn steering wheel stop to stop with engine running at slow idle. Is steering shaft binding in steering column? YES: Inspect and repair steering column. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363. NO: Go to Cause E.

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9050-33-62

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Steering Operation Is Not Smooth (Cont) CAUSE E - LOW PUMP FLOW. PROCEDURE OR ACTION: Do Tests and Adjustments-Gear Pump, Hydraulic Pump Flow Test, Page 9050-43-9.

Are other hydraulic functions OK? YES: Hydraulic pump output is OK. Go to Cause F. NO: Test hydraulic system relief pressure. See Tests and Adjustments-Gear Pump, Primary Relief Valve Test and Adjustment, Page 9050-43-1. CAUSE F - FAILED CENTERING SPRINGS IN SCU. PROCEDURE OR ACTION: Inspect SCU. Are the centering springs in good condition? YES: Springs are OK. Go to Cause G. NO: Replace centering springs. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE G - STEERING CONTROL UNIT IS ASSEMBLED INCORRECTLY, DAMAGED, OR CONTAMINATED. PROCEDURE OR ACTION: Inspect SCU.

Is SCU properly assembled and clean? YES: Install new steering control unit. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. NO: Clean steering valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

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9050-33-63

Observed Symptoms-Gear Pump

Hydraulic Systems

Steering Wheel End Lock Position Cannot Be Felt by Operator POSSIBLE CAUSE A. ANTI-KICKBACK VALVES ARE SAME PRESSURE SETTING AS RELIEF VALVE. B. CONTAMINATION CAUSING IMPROPER SHOCK VALVE OPERATION. CAUSE A - ANTI-KICKBACK VALVES ARE SAME PRESSURE SETTING AS RELIEF VALVE. PROCEDURE OR ACTION: Inspect SCU. Are the anti-kickback valves in good condition? YES: Anti-kickback valves OK. Go to Cause B. NO: Replace anti-kickback valves. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE B - CONTAMINATION CAUSING IMPROPER SHOCK VALVE OPERATION. PROCEDURE OR ACTION: Inspect assembly of SCU.

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9050-33-64

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Steering Wheel Turns By Itself or Does Not Return To Neutral POSSIBLE CAUSE A. STEERING RELIEF PRESSURE SET TOO LOW. B. BINDING IN STEERING COLUMN OR NO RESISTANCE. C. FAILED CENTERING SPRINGS IN SCU. D. DEFLECTION OF SPOOL AND SLEEVE CAUSED BY HIGH SYSTEM PRESSURE. E. STEERING CONTROL UNIT IS ASSEMBLED INCORRECTLY OR IS DAMAGED. CAUSE A - STEERING RELIEF PRESSURE SET TOO LOW. PROCEDURE OR ACTION: Perform Operational Checkout, Steering Relief Valve Low Pressure Check, Page 9010-05-12. Is steering relief pressure set too low? YES: Adjust steering relief pressure. See Tests and Adjustments-Gear Pump, Steering Relief Pressure Test and Adjustment, Page 9050-43-18. NO: Go to Cause B. CAUSE B - BINDING IN STEERING COLUMN OR NO RESISTANCE. PROCEDURE OR ACTION: Turn steering wheel stop to stop with engine running at slow idle.

Is linkage binding in steering column? YES: Inspect and repair steering column. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363. NO: Go to Cause C. CAUSE C - FAILED CENTERING SPRINGS IN SCU. PROCEDURE OR ACTION: Inspect SCU.

Are the centering springs in good condition? YES: Springs are OK. Go to Cause D. NO: Replace centering springs. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. CAUSE D - DEFLECTION OF SPOOL AND SLEEVE CAUSED BY HIGH SYSTEM PRESSURE. PROCEDURE OR ACTION: Perform Tests and Adjustments-Gear Pump, Steering Relief Pressure Test and Adjustment, Page 9050-43-18. Does steering relief pass check? YES: Go to Cause E. NO: Adjust relief pressure. See Tests and Adjustments-Gear Pump, Steering Relief Pressure Test and Adjustment, Page 9050-43-18.

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9050-33-65

Observed Symptoms-Gear Pump

Hydraulic Systems

Steering Wheel Turns By Itself or Does Not Return To Neutral (Cont) CAUSE E - STEERING CONTROL UNIT IS ASSEMBLED INCORRECTLY OR IS DAMAGED. PROCEDURE OR ACTION: Inspect SCU.

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9050-33-66

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Steering Wheel Turns the Tires in the Wrong Direction POSSIBLE CAUSE A. HYDRAULIC HOSES ARE NOT CONNECTED CORRECTLY AT THE STEERING CYLINDER OR AT THE SCU. CAUSE A - HYDRAULIC HOSES ARE NOT CONNECTED CORRECTLY AT THE STEERING CYLINDER OR AT THE SCU. PROCEDURE OR ACTION: Look at Steering System component to identify steering hoses. Are hoses correctly installed? YES: Problem is in SCU. Repair or replace SCU. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. NO: Correct steering hose routing at valve or steering cylinder.

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9050-33-67

Observed Symptoms-Gear Pump

Hydraulic Systems

Actuations Do Not Act Simultaneously POSSIBLE CAUSE A. LOW PUMP FLOW. B. SECONDARY RELIEF VALVE SET TOO LOW. CAUSE A - LOW PUMP FLOW. PROCEDURE OR ACTION: Check cycle times of lift function. Is lift function speed ok? YES: Go to Cause B. NO: Go to Observed Symptoms-Gear Pump, Abnormal Hydraulic Noise and/or Vibration, Page 9050-33-1. CAUSE B - SECONDARY RELIEF VALVE SET TOO LOW. PROCEDURE OR ACTION: Test and adjust secondary relief pressure. See Tests and Adjustments-Gear Pump, Secondary Relief Valve Test and Adjustment, Page 9050-43-4.

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9050-33-68

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Oil Leaking/Component Life Too Short POSSIBLE CAUSE A. HYDRAULIC OIL TANK IS OVERFILLED. B. LOOSE OR DAMAGED HARDWARE. C. DAMAGED O-RING/ROD SEAL. D. HYDRAULIC RELIEF PRESSURES SET TOO HIGH. E. HYDRAULIC FLUID CONTAMINATED OR WRONG TYPE. F. EXCESSIVE DEBRIS IN HYDRAULIC CIRCUIT. G. HYDRAULIC OIL TANK OPEN TO ATMOSPHERE. H. HYDRAULICS OPERATED ABOVE RECOMMENDED OPERATING RANGE. I. WARPED COMPONENT SECTION OF HYDRAULIC CONTROL VALVE. J. SEALS BETWEEN VALVE SECTIONS FAILED CAUSE A - HYDRAULIC OIL TANK IS OVERFILLED. PROCEDURE OR ACTION: Check to see if hydraulic oil tank is overfilled. Is hydraulic oil tank overfilled? YES: Drain hydraulic oil to proper level. NO: Go to Cause B. CAUSE B - LOOSE OR DAMAGED HARDWARE. PROCEDURE OR ACTION: Locate source of oil leak by checking the following items. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. • Check torque on fittings. • Check torque on tie rod at valve outlet housing. • Check torque on hardware between SCU and valve.

Did leak stop after checking hardware? YES: Problem solved. NO: Go to Cause C. CAUSE C - DAMAGED O-RING/ROD SEAL. PROCEDURE OR ACTION: Replace damaged O-ring or rod seal. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337.

Is problem fixed? YES: Problem solved. NO: Go to Cause D.

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9050-33-69

Observed Symptoms-Gear Pump

Hydraulic Systems

Oil Leaking/Component Life Too Short (Cont) CAUSE D - HYDRAULIC RELIEF PRESSURES SET TOO HIGH. PROCEDURE OR ACTION: Check main and secondary relief pressures. Go to Tests and Adjustments-Gear Pump, Primary Relief Valve Test and Adjustment, Page 9050-43-1.

Does relief pressure meet specifications? YES: Go to Cause E. NO: Adjust or replace relief valve. CAUSE E - HYDRAULIC FLUID CONTAMINATED OR WRONG TYPE. PROCEDURE OR ACTION: Check hydraulic oil for contamination and correct type. Is hydraulic oil contaminated or incorrect type used? YES: Drain and refill hydraulic tank. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. NO: Go to Cause F. CAUSE F - EXCESSIVE DEBRIS IN HYDRAULIC CIRCUIT. PROCEDURE OR ACTION: 1. Check for plugged and bypassing hydraulic oil filter.

Is hydraulic oil filter plugged and bypassing? YES: Clean or replace hydraulic oil filter. NO: Go to Step 2. 2. Check for contaminated oil. Is hydraulic oil contaminated? YES: Drain and refill hydraulic tank. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. NO: Go to Cause G. CAUSE G - HYDRAULIC OIL TANK OPEN TO ATMOSPHERE. PROCEDURE OR ACTION: Check hydraulic oil tank for missing breather or missing dipstick.

Is breather or dipstick missing from hydraulic oil tank? YES: Replace breather or dipstick. NO: Go to Cause H.

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9050-33-70

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Oil Leaking/Component Life Too Short (Cont) CAUSE H - HYDRAULICS OPERATED ABOVE RECOMMENDED OPERATING RANGE. PROCEDURE OR ACTION: Inspect hydraulic components and oil for signs of excessive heat.

Do components and oil show signs of overheating? YES: Replace damaged components and service hydraulic system. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. NO: Go to Cause I. CAUSE I - WARPED COMPONENT SECTION OF HYDRAULIC CONTROL VALVE. PROCEDURE OR ACTION: Check hydraulic control valve for warped component section. Does hydraulic control valve have warped component section? YES: Replace hydraulic control valve. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. NO: Go to Cause J. CAUSE J - SEALS BETWEEN VALVE SECTIONS FAILED PROCEDURE OR ACTION: Check hydraulic control valve for oil leakage between valve sections.

Is oil leaking between valve sections? YES: Replace seals between valve sections. Depending on your left truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439, or Electrical System 2200 YRM 1337. NO: Seals between valve sections OK.

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9050-33-71

Observed Symptoms-Gear Pump

Hydraulic Systems

Abnormal Steer Axle Noise POSSIBLE CAUSE A. WHEEL IS LOOSE. B. STEER WHEEL CONTACTING STEERING AXLE OR CHASSIS. C. TIE ROD AND/OR BUSHINGS ARE WORN. D. WHEEL OR SPINDLE BEARING LUBRICATION IS INADEQUATE. E. WHEEL OR SPINDLE BEARING FAILURE. F. STEERING AXLE BUSHINGS WORN. G. STEERING AXLE DAMAGED. CAUSE A - WHEEL IS LOOSE. PROCEDURE OR ACTION: Inspect wheels, lug nuts, and studs for damage. Are wheels, lug nuts, and studs damaged or loose? YES: If loose, tighten wheel lugs. Repair or replace damaged parts.Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. NO: Go to Cause B. CAUSE B - STEER WHEEL CONTACTING STEERING AXLE OR CHASSIS. PROCEDURE OR ACTION: Inspect steer wheels, steering axle, and chassis.

Are wheels contacting steering axle or chassis? YES: Repair or replace steer wheel or steering axle, or repair chassis. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363. NO: Go to Cause C. CAUSE C - TIE ROD AND/OR BUSHINGS ARE WORN. PROCEDURE OR ACTION: Inspect tie rod and bushing.

Are tie rods and bushing in good condition? YES: Go to Cause D. NO: Repair or adjust tie rods or bushings. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363. CAUSE D - WHEEL OR SPINDLE BEARING LUBRICATION IS INADEQUATE. NOTE: See Operating Manual for lubrication procedures. PROCEDURE OR ACTION: Lubricate wheel and spindle bearings.

Did the bearings lack lubrication? YES: Service lift truck per Operating Manual instructions. NO: Go to Cause E.

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9050-33-72

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Abnormal Steer Axle Noise (Cont) CAUSE E - WHEEL OR SPINDLE BEARING FAILURE. PROCEDURE OR ACTION: Inspect bearings and spindle.

Are the bearings and spindle in good condition? YES: If bearings are OK, go to Cause F. NO: Replace bearings and/or spindle. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363. CAUSE F - STEERING AXLE BUSHINGS WORN. PROCEDURE OR ACTION: 1. Inspect steering axle bushings for wear. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363.

Are the steering axle bushings in good condition? YES: Go to Cause G. NO: Replace bushings. CAUSE G - STEERING AXLE DAMAGED. PROCEDURE OR ACTION: Inspect steering axle for damage.

Is steering axle in good condition? YES: Resume operation while monitoring systems to locate source of noise. NO: Repair as required. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363.

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9050-33-73

Observed Symptoms-Gear Pump

Hydraulic Systems

Abnormal Steering Wheel Vibration POSSIBLE CAUSE A. B. C. D.

WORN TIRES. LOW OIL LEVEL IN TANK. AIR WAS NOT REMOVED AFTER REPAIR TO THE HYDRAULIC SYSTEM. STEERING AXLE COMPONENTS WORN.

CAUSE A - WORN TIRES. PROCEDURE OR ACTION: Inspect tires.

Are tires worn? YES: Replace tires. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. NO: Go to Cause B. CAUSE B - LOW OIL LEVEL IN TANK. PROCEDURE OR ACTION: NOTE: Cavitation of a hydraulic pump will cause noise and it is caused by air in the hydraulic oil. The hydraulic pump suction oil must be free of air and unrestricted to pump. Check hydraulic oil level in tank.

Is oil at correct level? YES: Go to Cause C. NO: Add oil to correct level. See Operating Manual. CAUSE C - AIR WAS NOT REMOVED AFTER REPAIR TO THE HYDRAULIC SYSTEM. PROCEDURE OR ACTION: Check service record of lift truck.

Was hydraulic system repaired recently? YES: Check the repaired hose connections. Remove air from system by cycling function full stroke of steering cylinder in each direction. NO: Go to Cause D. CAUSE D - STEERING AXLE COMPONENTS WORN. PROCEDURE OR ACTION: Operate truck to determine if vibration is hydraulic or mechanical. Is the vibration caused by hydraulics? YES: See Observed Symptoms-Gear Pump, Abnormal Hydraulic Noise and/or Vibration, Page 9050-33-1. NO: Repair or replace worn or damaged steer axle components. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363.

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9050-33-74

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Observed Symptoms-Gear Pump

Back Lash/Kick Back in Steering Wheel POSSIBLE CAUSE A. LOOSE STEERING AXLE COMPONENTS. B. SPLINES OR STEERING SHAFT UNIVERSAL JOINT IN STEERING COLUMN WORN OR BROKEN. C. STEERING RELIEF PRESSURE IS NOT SET CORRECTLY. D. FAILED CENTERING SPRINGS IN SCU. E. STEERING CONTROL UNIT IS ASSEMBLED INCORRECTLY OR IS DAMAGED. CAUSE A - LOOSE STEERING AXLE COMPONENTS. PROCEDURE OR ACTION: Turn steering wheel back and forth while observing steer axle wheels at slow idle. Do the tires respond directly to steering wheel movement? YES: Go to Cause B. NO: Inspect wheel studs and steering axle components for damage. Repair as required. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering Axle 1600 YRM 1360. CAUSE B - SPLINES OR STEERING SHAFT UNIVERSAL JOINT IN STEERING COLUMN WORN OR BROKEN. PROCEDURE OR ACTION: Turn steering wheel back and forth while observing steer axle wheels at slow idle.

Does the steer axle wheels movement match steering wheel movement in both directions? YES: Go to Cause C. NO: Inspect and repair steering column. Depending on your lift truck, see Steering System 1600 YRM 1331Steering System 1600 YRM 1363. CAUSE C - STEERING RELIEF PRESSURE IS NOT SET CORRECTLY. PROCEDURE OR ACTION: Do Operational Checkout, Steering Relief Valve High Pressure Check, Page 9010-05-12.

Is steering relief pressure set to specification? YES: Adjust steering relief pressure. See Tests and Adjustments-Gear Pump, Steering Relief Pressure Test and Adjustment, Page 9050-43-18. NO: Go to Cause D. CAUSE D - FAILED CENTERING SPRINGS IN SCU. PROCEDURE OR ACTION: Inspect SCU. Are the centering springs in good condition? YES: Springs are OK. Go to Cause E. NO: Replace centering springs. Depending on your lift truck, see Steering System 1600 YRM 1331Steering System 1600 YRM 1363.

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9050-33-75

Observed Symptoms-Gear Pump

Hydraulic Systems

Back Lash/Kick Back in Steering Wheel (Cont) CAUSE E - STEERING CONTROL UNIT IS ASSEMBLED INCORRECTLY OR IS DAMAGED. PROCEDURE OR ACTION: Inspect SCU.

Is SCU properly assembled and clean? YES: Replace the SCU. Depending on your lift truck, see Steering System 1600 YRM 1331Steering System 1600 YRM 1363. NO: Repair steering control unit. Depending on your lift truck, see Steering System 1600 YRM 1331Steering System 1600 YRM 1363.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9050-33-76

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Hydraulic Systems

Tests and Adjustments-Gear Pump

Group 43

Tests and Adjustments-Gear Pump Hydraulic Warm-up Procedure Use this procedure to get the hydraulic oil temperature to test specification. Install the test equipment on lift truck before starting this procedure to reduce handling of hot component or oil.

pressure before removing or installing test equipment.

Table 9050-43-1. Test Specifications

Do not permit dirt or other contaminants to enter the hydraulic system. Disconnected hoses, tubes, open valves, cylinder fittings, and ports should be protected with clean caps or plugs.

Oil Temperature

50 - 65°C (122 - 150 °F)

Table 9050-43-2. Service Tools Temperature Reader - Thermocouple

CAUTION

1. Install test equipment as called out in test. 2. Insert thermocouple in dipstick hole. 3. Turn key or keyless switch to the ON position.

WARNING Hot hydraulic oil can cause serious burns to skin. Do not touch hydraulic components or oil during test. Make sure hydraulic oil has cooled to safe temperature before installing or removing test equipment.

WARNING Hydraulic oil under pressure can be injected into skin. Lower forks to ground and relieve all circuit

4. Tilt the mast back and hold over relief for 20 seconds, then release lever. Cycle both tilt and lift cylinders to circulate oil and equalize temperature in system. 5. Read temperature and compare to temperature specifications of test to be performed. 6. Repeat Step 4 and Step 5 until oil temperature is at test specifications.

Primary Relief Valve Test and Adjustment CAUTION Typically, the Main Relief Valve (MRV) should NOT be adjusted in the field for general purposes. Increasing the setting of the MRV past its specified setting may damage truck.

CAUTION Do not permit dirt or other contaminants to enter the hydraulic system. Disconnected hoses, tubes, open valves, cylinder fittings, and ports should be protected with clean caps or plugs. 2. Remove panels that cover MRV. Remove cover from diagnostic port and install pressure gauge. See Figure 9050-43-1, Page 9050-43-3,

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9050-43-1

Tests and Adjustments-Gear Pump

Hydraulic Systems

Figure 9050-43-2, Page 9050-43-3 and Figure 9050-43-3, Page 9050-43-4. 3. Operate the hydraulic system until the oil temperature is at test specifications. See Tests and Adjustments-Gear Pump, Hydraulic Warm-up Procedure, Page 9050-43-1.

6. Cycle lever over relief to verify the setting is within specification. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439. 7. Remove test equipment and reinstall cap onto diagnostic port.

WARNING Forks contacting overhead electrical wires or fixtures can cause serious injury or death. Make sure area is clear of hazards before raising forks to maximum height. 4. Raise the mast until it stops. Hold the lever and check the reading of the gauge when the relief valve opens. Compare to specifications.

Table 9050-43-3. Service Tools 275 - 345 MPa (4000 - 5000 psi) Pressure Gauge Excess Flow (EF) Test Plug Port Size

SAE #4 O-ring Port (7/16-20 UNF)

5. Replace primary relief valve, if not within specification, by unscrewing the relief cartridge from the inlet section and installing a new relief cartridge. Table 9050-43-4. Test Specifications Lift Truck

Capacity

Main Relief Pressure

Pump Flow

ERP15-20VT (ERP030-040VT) (G807)

1.5-2.0 Tons

17.9 MPa (2596 psi)

63.6 liter/min (16.8 gal/min)

ERC22-35VG (ERC045070VG) (A968)ERP22-35VL (ERP040-070VL) (A976)

2.2-2.75 Tons

21.9 MPa (3176 psi)

81.4 liter/min (21.5 gal/min)

ERC22-35VG (ERC045070VG) (A968)ERP22-35VL (ERP040-070VL) (A976)

3.0-3.5 Tons

23.9 MPa (3466 psi)

81.4 liter/min (21.5 gal/min)

9050-43-2

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Hydraulic Systems

Tests and Adjustments-Gear Pump

1. DIAGNOSTIC PORT WITH GAUGE 2. SECONDARY RELIEF VALVE LOCATION 3. PRIMARY RELIEF VALVE LOCATION

1. DIAGNOSTIC PORT WITH GAUGE 2. OPTIONAL SECONDARY RELIEF VALVE LOCATION 3. PRIMARY RELIEF VALVE LOCATION

Figure 9050-43-2. Manual Valve for Lift Trucks ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

Figure 9050-43-1. Manual Valve for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (A955) Shown

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9050-43-3

Tests and Adjustments-Gear Pump

Hydraulic Systems

A. FRONT VIEW

B. BOTTOM VIEW

1. DIAGNOSTIC PORT WITH GAUGE 2. ANTI-CAVITATION CHECK

3. PRIMARY RELIEF VALVE LOCATION 4. SECONDARY RELIEF VALVE LOCATION

Figure 9050-43-3. E-Hydraulic Valve for Lift Trucks ERP15-20VT (ERP030-040VT) (G807). ERP16-20VF (A955), ERC22-35VG (ERC045-070VG) (A968), and ERP22-35VL (ERP040-070VL) (A976) Shown

Secondary Relief Valve Test and Adjustment It may be necessary to adjust the setting of the Optional Relief Valve (ORV) depending on what attachments are used for the auxiliary function. NOTE: The Relief Pressure setting is the working range that the secondary relief can be set to meet requirements of attachments. The Factory Default setting is the pressure that the secondary relief is set at the factory. NOTE: Secondary relief valves for manual control valves on lift trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (A955) are installed into auxiliary sections for special attachments. Standard relief pressure for these lift trucks is set with primary relief valve only.

9050-43-4

Table 9050-43-5. Test Specifications for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (A955) Oil Temperature

50 - 65°C (122 - 150 °F)

Secondary Relief Pressure

17.9 MPa (2596 psi)

Factory Default Setting

15.0 - 16.0 MPa (2180 - 2320 psi)

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Hydraulic Systems

Tests and Adjustments-Gear Pump

Table 9050-43-6. Test Specifications for Lift Trucks ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Oil Temperature

50 - 65°C (122 - 150 °F)

Secondary Relief Valve Setting

15.0 - 16.0 MPa (2180 - 2320 psi)

Factory Default Setting

15.0 - 16.0 MPa (2180 - 2320 psi)

Legend for Figure 9050-43-4 1. DIAGNOSTIC PORT WITH GAUGE 2. OPTIONAL SECONDARY RELIEF VALVE LOCATION 3. PRIMARY RELIEF VALVE LOCATION

Table 9050-43-7. Service Tools 0 - 35.0 MPa (0 - 5000 psi) Pressure Gauge Excess Flow (EF) Test Port Plug Size

SAE #4 O-ring Port (7/16-20 UNF)

1. DIAGNOSTIC PORT WITH GAUGE 2. SECONDARY RELIEF VALVE LOCATION 3. PRIMARY RELIEF VALVE LOCATION

Figure 9050-43-5. Manual Control Valve for Lift Trucks ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976) Shown

Figure 9050-43-4. Manual Control Valve for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (A955) Shown

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9050-43-5

Tests and Adjustments-Gear Pump

WARNING

Hydraulic Systems

WARNING

Hot hydraulic oil can cause serious burns to skin. Do not touch hydraulic components or oil during test. Make sure hydraulic oil has cooled to safe temperature before installing or removing test equipment.

Hydraulic oil under pressure can be injected into skin. Lower forks to ground and relieve all circuit pressure before removing test plugs from valve.

A. FRONT VIEW

B. BOTTOM VIEW

1. DIAGNOSTIC PORT WITH GAUGE 2. ANTI-CAVITATION CHECK 3. PRIMARY RELIEF VALVE LOCATION

4. OPTIONAL SECONDARY RELIEF VALVE LOCATION

1. Lower forks to ground and turn key or keyless switch to OFF position. Apply park brake.

Figure 9050-43-6. E-Hydraulic Control Valve for Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (A955) Shown

9050-43-6

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Hydraulic Systems

Tests and Adjustments-Gear Pump

A. FRONT VIEW

B. BOTTOM VIEW

1. DIAGNOSTIC PORT WITH GAUGE 2. ANTI-CAVITATION CHECK

3. PRIMARY RELIEF VALVE LOCATION 4. SECONDARY RELIEF VALVE LOCATION

Figure 9050-43-7. E-Hydraulic Control Valve for Lift Trucks ERC22-35VG (ERC045-070VG) (A968), and ERP22-35VL (ERP040-070VL) (A976) Shown

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9050-43-7

Tests and Adjustments-Gear Pump

Hydraulic Systems Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439.

CAUTION Setting relief valve above specification can cause damage to hydraulic and mechanical components of lift truck. Do not increase pressure above specifications.

7. If relief pressure cannot be maintained or adjusted up, the control valve may have contamination or have excess leakage in Load Sense (LS) circuit. See Tests and Adjustments-Gear Pump, Main Control Valve LS Leakage Test (E-Valve), Page 905043-11. 8. Remove test equipment and reinstall diagnostic port cap.

3. Operate the hydraulic system until the oil temperature is at test specifications. See Tests and Adjustments-Gear Pump, Hydraulic Warm-up Procedure, Page 9050-43-1. 4. Tilt the mast back until it stops. Hold the lever and check the reading of the gauge when the relief valve opens. Compare to test specifications. NOTE: Cycling the tilt or auxiliary function over relief after adjustment gives the relief valve spring opportunity to reposition itself inside the valve. This must be done after each adjustment until pressure is repeatable on gauge. 5. If pressure is not within specifications, remove hex plug (see Figure 9050-43-8, Page 9050-43-8), while holding tilt hydraulics over relief, slowly turn the adjustment screw, in (clockwise) to increase pressure, out (counterclockwise) to reduce pressure. Cycle the tilt or auxiliary control lever on and off against the relief three times to see if pressure is repeatable. 6. Insert hex plug. Cycle lever over relief a few more times to verify the setting is still correct. If setting does not stabilize, clean or replace relief valve. Depending on your lift truck see, Main Control

9050-43-8

1. 2. 3. 4. 5. 6. 7. 8.

SEAT O-RING BACKUP RING POPPET SPRING ADJUSTMENT SCREW HEX PLUG RELIEF CARTRIDGE

Figure 9050-43-8. Optional/Secondary Relief Valve

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Hydraulic Systems

Tests and Adjustments-Gear Pump

Hydraulic Pump Flow Test This test is done to accurately check the hydraulic pump output. This will isolate if performance problems are in hydraulic pump or elsewhere in hydraulic circuit. NOTE: If a flowmeter is not available, use lift speed charts. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442 to determine pump output. If lift raise times with capacity load on forks is more than 25% greater than specifications, the pump should be replaced.

Table 9050-43-8. Test Specifications Oil Temperature

50 - 65°C (122 - 150 °F)

Minimum Pump Output for Lift Truck ERP15-20VT (ERP030040VT) (G807) and ERP16-20VF (A955)

Pump: 63.6 liter/min (16.8 gal/min)

Minimum Pump Output for Lift Truck ERC22-35VG (ERC045070VG) (A968) and ERP22-35VL (ERP040070VL) (A976)

Pump: 81.4 liter/min (21.5 gal/min)

Excess Flow (EF) Test Pressure

Tilt Function Over Relief (Optional/Secondary Relief Valve Setting)

1. Lower forks to ground and turn key or keyless switch to the OFF position. Apply park brake.

CAUTION Do not permit dirt or other contaminants to enter the hydraulic system. Disconnected hoses, tubes, open valves, cylinder fittings, and ports should be protected with clean caps or plugs. 2. Remove floor panels. Remove hose assembly to hydraulic pump and install flowmeter. Install hose assembly from flow meter to hydraulic pump. Install pressure gauge to the diagnostic port of control valve if flowmeter does not have internal gauge. See Figure 9050-43-9, Page 9050-43-10.

CAUTION Hydraulic pump will be damaged if flowmeter gate valve is closed. Open the gate valve all the way open (counterclockwise) on the flowmeter before running lift truck. 3. Operate the hydraulic system until the oil temperature is to test specifications. See Tests and Adjustments-Gear Pump, Hydraulic Warm-up Procedure, Page 9050-43-1. 4. Raise empty mast and hold over relief, record pump flow. Compare pump flow to specifications.

Table 9050-43-9. Service Tools 125 liter/min (33 gal/min) Flowmeter, Rated at 24.0 MPa (3500 psi) 0 - 35.0 MPa (0 - 5000 psi) Pressure Gauge Excess Flow (EF) Test Port Plug Size

SAE #4 O-ring Port (7/16-20 UNF)

Steering Control Valve Inlet Port Size

SAE #12 O-ring Port (1-1/16-12 UNF)

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5. Return forks to ground level and turn key or keyless switch to OFF position. NOTE: A collapsed suction hose or plugged suction screen in hydraulic tank could affect pump flow. Be sure to check these components before replacing pump. 6. If the flow is less than the specifications, inspect suction hoses to pump and suction screen in hydraulic tank. If they are OK then replace pump. Depending on your lift truck, see Hydraulic System 1900 YRM 1367, or Hydraulic System 1900 YRM 1333.

9050-43-9

Tests and Adjustments-Gear Pump 7. Remove test equipment, reinstall hoses and floor panel.

Hydraulic Systems 8. Check oil level in hydraulic tank. Add oil, as required.

NOTE: CONTROL VALVE SHOWN IS FOR LIFT TRUCKS ERP15-20VT (ERP030-040VT) (G807) AND ERP1620VF (A955). 1. DIAGNOSTIC PORT WITH GAUGE 2. HOSE ASSEMBLY

3. FLOWMETER 4. HYDRAULIC PUMP

Figure 9050-43-9. E-Hydraulic Pump Shown

9050-43-10

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Hydraulic Systems

Tests and Adjustments-Gear Pump

Main Control Valve LS Leakage Test (E-Valve) This test is done to check if there is leakage in the LoadSense (LS) pressure circuit. Table 9050-43-10. Test Specifications Oil Temperature

50 - 65°C (122 - 150 °F)

WARNING Hydraulic oil under pressure can be injected into skin. Lower forks to ground and relieve all circuit pressure before removing test plugs from valve.

Hydraulic Warm-up Procedure, Page 9050-43-1. Operate until temperature is at test specifications. 2. Turn key or keyless switch to ON position and apply park brake. 3. Measure and record the lift rate with lift lever fully actuated at: • No Load • Rated Load 4. If the difference from specified rates in chart, it is likely that the LS passage has an internal leakage within the monoblock section. Replace the valve monoblock section. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439.

1. Check hydraulic temperature. If not within specifications, see Tests and Adjustments-Gear Pump,

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9050-43-11

Tests and Adjustments-Gear Pump

Hydraulic Systems

Main Control Valve Unloader Margin Test This test is done to check if unloader pressure margin is within test specification. Table 9050-43-11. Test Specifications Oil Temperature

50 to 65°C (122 to 150 °F)

Maximum Unloader Pressure Margin

1034 to 1138 kPa (150 to 165 psi)

Flow Rate

For [A968], ERC22-35VG (ERC045-070VG): Primary Pump: 81.4 liter/min (21.5 gal/min) For [A976] ERP22-35VL (ERP040-070VL): Primary Pump: 81.4 liter/min (21.5 gal/min) [G807], ERP16-20TH (ERP030040TH), Primary Pump: 63.6 liter/min (16.8 gal/min) For [A955] ERP16-20VF: Primary Pump: 63.6 liter/min (16.8 gal/min)

CAUTION Do not permit dirt or other contaminants to enter the hydraulic system. Disconnected hoses, tubes, open valves, cylinder fittings, and ports should be protected with clean caps or plugs. 3. Install a hose in load sense port and the other hose in the reduced pressure port on the control valve. See Figure 9050-43-10, Page 9050-43-13. NOTE: Test gauges must be calibrated. Gauge accuracy is very important for this test. A pressure differential gauge or switching block should be used so both readings are on same gauge. If you do not have this equipment, you will need to switch gauges to verify gauge readings. 4. Check hydraulic temperature. If not within specifications, see Tests and Adjustments-Gear Pump, Hydraulic Warm-up Procedure, Page 9050-43-1. Operate until temperature is at test specifications. 5. Measure pressure. If the pressure margin is below specification, go to Step 6. 6. If the pressure margin is below specification, proceed as follows:

Table 9050-43-12. Service Tools 0-3450 kPa (0-500 psi) Pressure Gauge 1. Lower forks to ground, turn key or keyless switch to OFF position, and apply park brake. 2. Remove floor plates that cover main control valve.

WARNING Hydraulic oil under pressure can be injected into skin. Lower forks to ground and relieve all circuit pressure before removing test plugs from valve.

9050-43-12

• Remove unloader spool and check for a broken spring or contamination. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439. • Check main relief valve for contamination or broken spring. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439. 7. If actions performed in Step 6 do not solve the problem, replace hydraulic control valve inlet section. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439. 8. Remove test equipment and reinstall plugs in control valve.

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Hydraulic Systems

Tests and Adjustments-Gear Pump A. LEFT VIEW B. RIGHT VIEW 1. LOAD SENSE PORT WITH GAUGE 2. REDUCED PRESSURE PORT WITH GAUGE

Figure 9050-43-10. Unloader Valve Test Setup

NOTE: E-HYDRAULIC CONTROL VALVE FOR LIFT TRUCKS ERC22-35VG (ERC045-070VG) (A968) AND ERP22-35VL (ERP040-070VL) (A976) SHOWN.

Confidential/Proprietary - Do Not Copy or Duplicate

9050-43-13

Tests and Adjustments-Gear Pump

Hydraulic Systems

E-Hydraulic Valve Leakage Test This test is to determine if the E-Hydraulic Valve spool is damaged or if there is internal leakage between the section housing and the spool. This test should only be performed after doing the Lift Cylinder Leakage Test and leakage has been diagnosed to be in control valve. 1. Lower forks to ground, turn key or keyless switch to ON position and apply park brake. 2. Remove floor mats and floor plates.

WARNING Hydraulic oil under pressure can be injected into skin. Lower forks to ground and relieve all circuit pressure before removing EHPV assembly.

CAUTION Do not permit dirt or other contaminants to enter the hydraulic system. Disconnected hoses, tubes, open valves, cylinder fittings, and ports should be protected with clean caps or plugs.

9050-43-14

3. Ensure that tank port is connected to the return line. NOTE: Purge cool oil out of leakage hose until oil is 42°C (108°F) before connecting to the first work port. NOTE: Work port leakage for port 1A must exceed 10 cc/min and ports 2A, 2B, 3A, 3B, 4A, and 4B must exceed 4 cc/min. 4. Connect "leakage" supply hose to each individual work port while spools are in neutral. 5. Operate hydraulic functions, read the pressure and compare to specifications. Disconnect "leakage" supply hose from work port. 6. Repeat Step 4 and Step 5 for each work port.

If the pressure is not within specification, replace control valve section. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439.

8. Install floor plates and floor mats. 9. Lower forks to ground, turn key or keyless switch to OFF position and apply park brake.

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Hydraulic Systems

Tests and Adjustments-Gear Pump

Table 9050-43-13. Test Specifications Oil Temperature

42°C (108°F) or Higher

Maximum Leakage For ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (A955) with 3-Function Control Valve

1A Port: 16.6 cc/min @ 16.8 MPa (2450 psi)

2A or 2B Port: 12.2 cc/min @ 6.8 MPa (1000 psi)

3A or 3B Port: 14.4 cc/min @ 6.8 MPa (1000 psi)

For ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (A955) with 4-Function Control Valve

1A Port: 16.6 cc/min @ 16.8 MPa (2450 psi)

2A or 2B Port: 12.2 cc/min @ 6.8 MPa (1000 psi)

3A, 3B, 4A, or 4B Port: 14.4 cc/min @ 6.8 MPa (1000 psi)

For ERC22-30VG (ERC045-060VG) (A968)ERP22-30VL (ERP040-000VL) (A976) with 3-Function Control Valve

1A Port: 18.6 cc/min @ 19.6 MPa (2850 psi)

2A or 2B Port: 22.0 cc/min @ 8.2 MPa (1200 psi)

3A or 3B Port: 14.4 cc/min @ 6.8 MPa (1000 psi)

For ERC22-30VG (ERC045-060VG) (A968)ERP22-30VL (ERP040-060VL) (A976) with 4-Function Control Valve

1A Port: 18.6 cc/min @ 19.6 MPa (2850 psi)

2A or 2B Port: 22.0 cc/min @ 8.2 MPa (1200 psi)

3A, 3B, 4A, or 4B Port: 14.4 cc/min @ 6.8 MPa (1000 psi)

For ERC30-35VG (ERC060-070VG) (A968)ERP30-35VL (ERP060-070VL) (A976) with 3-Function Control Valve

1A Port: 21.1 cc/min @ 21.3 MPa (3100 psi)

2A or 2B Port: 22.0 cc/min @ 8.2 MPa (1200 psi)

3A or 3B Port: 14.4 cc/min @ 6.8 MPa (1000 psi)

For ERC30-35VG (ERC060-070VG) (A968)ERP30-35VL (ERP060-070VL) (A976) with 4-Function Control Valve

1A Port: 21.1 cc/min @ 21.3 MPa (3100 psi)

2A or 2B Port: 22.0 cc/min @ 8.2 MPa (1200 psi)

3A, 3B, 4A, or 4B Port: 14.4 cc/min @ 6.8 MPa (1000 psi)

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9050-43-15

Tests and Adjustments-Gear Pump

Hydraulic Systems

Figure 9050-43-11. E-Hydraulic Control Valve Fittings

9050-43-16

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Hydraulic Systems

Tests and Adjustments-Gear Pump

Legend for Figure 9050-43-11 A. 3-FUNCTION CONTROL VALVE FOR LIFT TRUCK MODELS ERP15-20VT (ERP030-040VT) (G807) AND ERP16-20VF (A955) B. 3-FUNCTION CONTROL VALVE FOR LIFT TRUCK MODELS ERC22-35VG (ERC045-070VG) (A968) AND ERP22-35VL (ERP040-070VL) (A976) C. 4-FUNCTION CONTROL VALVE FOR LIFT TRUCK MODELS ERP15-20VT (ERP030-040VT) (G807) AND ERP16-20VF (A955) D. 4-FUNCTION CONTROL VALVE FOR LIFT TRUCK MODELS ERC22-35VG (ERC045-070VG) (A968) AND ERP22-35VL (ERP040-070VL) (A976) 1. TANK PORT 2. 1A PORT (LIFT/LOWER) 3. 2A, 2B PORTS (TILT)

Confidential/Proprietary - Do Not Copy or Duplicate

4. 3A, 3B, 4A, 4B PORTS (AUXILIARY) 5. DIAGNOSTIC PORT WITH GAUGE

9050-43-17

Tests and Adjustments-Gear Pump

Hydraulic Systems

Steering Relief Pressure Test and Adjustment Table 9050-43-14. Test Specifications Oil Temperature

50 to 65°C (122 to 150 °F)

Steering Relief Pressure

For [A968], ERC22-35VG (ERC045-070VG): 8.9 MPa (1291 psi) For [A976], ERP22-35VL (ERP040-070VL): 12.4 MPa (1798 psi) For [G807], ERP16-20TH (ERP030- 040TH): 7.5 MPa (1088 psi)

3. Connect pressure gauge to steering hose as shown in Figure 9050-43-13, Page 9050-43-19 and Figure 9050-43-14, Page 9050-43-20. 4. Operate hydraulic system until the oil temperature is at test specifications. See Tests and Adjustments-Gear Pump, Hydraulic Warm-up Procedure, Page 9050-43-1. 5. Turn steering wheel to stop. Apply turning effort against stop, causing steering system pressure to go over relief. 6. Check pressure gauge reading. Compare reading to specifications.

For [A955], ERP16-20VF: 7.5 MPa (1088 psi)

Table 9050-43-15. Service Tools 0 - 35.0 MPa (0 to 5000 psi) Pressure Gauge 6 mm Hex wrench 8 mm Hex wrench T-Fitting Yale Part No. 580094669 1. Lower forks to ground and turn key or keyless switch to OFF. Apply park brake.

WARNING

1. STEERING CONTROL UNIT (SCU) 2. PLUG 3. RELIEF VALVE ADJUSTER

Figure 9050-43-12. SCU Adjustment

Hydraulic oil under pressure can be injected into skin. Lower forks to ground and relieve all circuit pressure before removing test plugs from valve.

NOTE: Steering relief adjuster is very sensitive. Make changes in 1/8 turn increments to avoid over pressurizing system.

2. Remove steering column covers, floor mat, and floor plates.

7. If pressure is lower or higher than specifications, perform steps below: See Figure 9050-43-12, Page 9050-43-18.

CAUTION Do not permit dirt or other contaminants to enter the hydraulic system. Disconnected hoses, tubes, open valves, cylinder fittings, and ports should be protected with clean caps or plugs.

9050-43-18

a. Remove steering control unit (SCU) from steering column. See Steering System 1600 YRM 1331 for lift truck model ERP15-20VT (ERP030-040VT) (G807) or Steering System 1600 YRM 1363 for lift truck models ERC22-35VG (ERC045-070VG) (A968),

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems ERP22-35VL (ERP040-070VL) (A976), and ERP16-20VF (ERP30-40VF) (A955) for procedures. b. If pressure is less than specifications, install hex wrench (1) and turn relief valve adjuster clockwise. See Figure 9050-43-12, Page 905043-18. c. If pressure is higher than specifications, install hex wrench (1) and turn relief valve adjuster counterclockwise. See Figure 9050-43-12, Page 9050-43-18.

Tests and Adjustments-Gear Pump d. Install hex wrench (2) in placement shown in Figure 9050-43-13, Page 9050-43-19 or Figure 9050-43-14, Page 9050-43-20. Apply turning effort against stop causing steering system pressure to go over relief. e. Check pressure gauge reading. reading to specifications. f.

Compare

Repeat Step b through Step d. If pressure is to specifications, install steering control unit (SCU) onto steering column and remove test equipment. Install test port and adjuster plug.

A. PLACEMENT OF HEX WRENCH (2) TO TURN STEERING COLUMN. 1. TEST GAUGE HOSE 2. STEERING CONTROL UNIT (SCU) HOSE CONNECTIONS 3. T-FITTING

Figure 9050-43-13. Steer Relief Pressure for Lift Truck models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (A955)

Confidential/Proprietary - Do Not Copy or Duplicate

9050-43-19

Tests and Adjustments-Gear Pump

Hydraulic Systems

A. PLACEMENT OF HEX WRENCH (2) TO TURN STEERING COLUMN. 1. TEST GAUGE HOSE 2. STEER ACCUMULATOR

3. STEERING CONTROL UNIT (SCU) 4. T-FITTING

Figure 9050-43-14. Steer Relief Pressure for Lift Truck models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976)

9050-43-20

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Tests and Adjustments-Gear Pump

Steering Control Unit LS Pressure Test This test checks if LS (Load-Sense) pressure is correct to operate the flow divider spool functions of the Steering Control Unit (SCU). Table 9050-43-16. Test Specifications Oil Temperature

50 - 65°C (122 - 150 °F)

Minimum LS Pressure

For [A968], ERC22-35VG (ERC045-070VG): 8.9 MPa (1291 psi) For [A976] ERP22-35VL (ERP040-070VL): 12.4 MPa (1798 psi) [G807], ERP16-20TH (ERP030- 040TH): 7.5 MPa (1088 psi) For [A955] ERP16-20VF: 7.5 MPa (1088 psi)

Table 9050-43-17. Service Tools Pressure differential gauge or switching block 0 - 35.0 MPa (0 - 5000 psi) Pressure Gauge Steering Control Unit (SCU) "P" & "LS" Test Port Size

SAE #4 O-ring Port (7/16-20 UNF)

T-Fitting

Yale Part No. 580094669

Confidential/Proprietary - Do Not Copy or Duplicate

WARNING Hydraulic oil under pressure can be injected into skin. Lower forks to ground and relieve all circuit pressure before removing test plugs from valve. 1. Lower forks to ground, turn key or keyless switch to OFF position, and apply park brake. 2. Remove steering column covers to access Steering Control Unit (SCU); remove floor plates to access main control valve and hydraulic lines.

CAUTION Do not permit dirt or other contaminants to enter the hydraulic system. Disconnected hoses, tubes, open valves, cylinder fittings, and ports should be protected with clean caps or plugs. 3. Install one test hose in LS port and the other test hose in fitting on (P) main pressure port hose of the SCU. See Figure 9050-43-15, Page 9050-43-22. 4. Check hydraulic temperature. If not within specifications. See Tests and Adjustments-Gear Pump, Hydraulic Warm-up Procedure, Page 9050-43-1. 5. Hold steering over relief and measure relief pressure, then LS pressure and compare to specifications. 6. If LS pressure is not within specifications, remove SCU. Inspect and clean LS orifices. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439. 7. Remove test equipment and reinstall test plugs.

9050-43-21

Tests and Adjustments-Gear Pump

Hydraulic Systems

NOTE: E-HYDRAULIC CONTROL VALVE FOR LIFT TRUCK MODEL ERP15-20VT (ERP030-040VT) (G807) SHOWN. 1. "LS" LOAD SENSE PORT 2. "P" MAIN PRESSURE PORT HOSE

3. T-FITTING 4. TEST GAUGE HOSE

Figure 9050-43-15. SCU LS Pressure Test

9050-43-22

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Tests and Adjustments-Gear Pump

Lift Cylinder Leakage Test Hydraulic leakage causes heat and poor performance in a hydraulic system. This test is done to determine if the leakage is in the cylinder or the hydraulic control valve. Table 9050-43-18. Test Specifications Oil Temperature

50°C (122 °F)

Maximum Carriage Travel in 10 minutes

102 mm (4.0 in.)

Table 9050-43-19. Service Tools

WARNING Lowering of forks with load can cause personal injury. Do not place body parts under load. 4. Put a capacity load on the forks, and raise and lower the load several times. Lower the load and tilt the mast forward and backward several times. Check for external cylinder or hose leaks. 5. Raise the carriage and load 2.5 m (8.2 ft). Observe load, if the carriage slowly lowers when the control valve is in the neutral position, there are leaks in the hydraulic system. Go to Step 7.

Tape measure or ruler Ball Valve rated at 24 MPa (3500 psi) minimum Control Valve Lift Port Size

SAE #12 O-ring Port (1-1/16 - 12 UNF)

WARNING

6. If carriage is not dropping fast enough for visual check, use a tape measure and record movement. Turn key or keyless switch to the OFF position and let truck sit for 10 minutes. If movement exceeds specifications, go to Step 7. 7. To check the lift cylinders for internal leaks, close the ball valve in the supply line between the main control valve and the mast. Let truck sit for 10 minutes and measure movement. If it does not meet specifications, the seals in the lift cylinders have leaks. Repair cylinder. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382.

Hydraulic oil under pressure can be injected into skin. Lower forks to ground and relieve all circuit pressure before removing hoses from cylinders.

NOTE: Contamination in the hydraulic system can cause the control valve to leak. Remove and clean valve before replacing.

1. Lower forks to ground, turn key or keyless switch to OFF position, and apply park brake.

8. If the carriage does not move, open the ball valve and check the movement again. If the carriage lowers when the ball valve is open, check for leaks in the hydraulic lines and fittings. If no leaks are found, the main control valve could be worn, contaminated, or damaged. Remove and clean hydraulic control valve. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439.

CAUTION Do not permit dirt or other contaminants to enter the hydraulic system. Disconnected hoses, tubes, open valves, cylinder fittings, and ports should be protected with clean caps or plugs. 2. Slowly loosen hose fitting to relieve pressure. Remove hose and install ball valve in the supply line between the main control valve and the lift cylinder. Open ball valve fully to allow maximum flow during warm-up procedure. See Figure 9050-43-16, Page 9050-43-24, Figure 9050-43-17, Page 9050-43-24, and Figure 9050-43-18, Page 9050-43-25.

9. Remove the load from the forks and remove ball valve.

3. Check hydraulic temperature. If not within specifications, see Tests and Adjustments-Gear Pump, Hydraulic Warm-up Procedure, Page 9050-43-1.

Confidential/Proprietary - Do Not Copy or Duplicate

9050-43-23

Tests and Adjustments-Gear Pump

1. 2. 3. 4. 5. 6. 7. 8.

LIFT PORT LIFT VALVE SECTION TILT VALVE SECTION AUXILIARY VALVE SECTION OPTIONAL RELIEF VALVE LOCATION LIFT CYLINDER BALL VALVE MAIN RELIEF VALVE

Figure 9050-43-16. Lift Cylinder Leakage Test E-Hydraulic Control Valve

9050-43-24

Hydraulic Systems

1. 2. 3. 4. 5. 6. 7. 8.

LIFT PORT LIFT VALVE SECTION TILT VALVE SECTION AUXILIARY VALVE SECTION OPTIONAL RELIEF VALVE LOCATION LIFT CYLINDER BALL VALVE MAIN RELIEF VALVE

Figure 9050-43-17. Lift Cylinder Leakage Test Manual Control Valve for Lift Trucks ERP16-20VT (ERP030-040VT) (G807) and ERP16-20VF (A955)

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Tests and Adjustments-Gear Pump

Legend for Figure 9050-43-18 1. 2. 3. 4. 5. 6. 7. 8.

LIFT PORT LIFT VALVE SECTION TILT VALVE SECTION AUXILIARY VALVE SECTION OPTIONAL RELIEF VALVE LOCATION LIFT CYLINDER BALL VALVE MAIN RELIEF VALVE

Figure 9050-43-18. Lift Cylinder Leakage Test Manual Control Valve for Lift Trucks ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976)

Tilt Cylinder Leakage Test Hydraulic leakage causes heat and poor performance in a hydraulic system. This test is done to determine if the leakage is in the cylinder or the hydraulic control valve. Table 9050-43-20. Test Specifications Oil Temperature

50°C (122 °F)

Maximum Rod Travel in 10 minutes

5° rotation of mast

Table 9050-43-21. Service Tools Angle Meter

WARNING Hydraulic oil under pressure can be injected into skin. Lower forks to ground and relieve all circuit pressure before removing hoses from cylinders.

CAUTION

Ball Valve rated at 24 MPa (3500 psi) minimum Tilt Valve Section Port Size

SAE #8 O-ring Port (3/4-16 UNF)

Do not permit dirt or other contaminants to enter the hydraulic system. Disconnected hoses, tubes, open valves, cylinder fittings, and ports should be protected with clean caps or plugs.

1. Lower forks to ground, turn key or keyless switch to OFF position, and apply park brake.

2. Slowly loosen hose fitting to relieve pressure. Remove hose and install ball valve inline with hose on

Confidential/Proprietary - Do Not Copy or Duplicate

9050-43-25

Tests and Adjustments-Gear Pump cylinder to be tested. Open ball valve fully to allow maximum flow during warm-up procedure.

Hydraulic Systems 9. Remove the load from the forks and remove ball valve. Reconnect all hoses.

3. Check hydraulic temperature. If not within specifications, see Tests and Adjustments-Gear Pump, Hydraulic Warm-up Procedure, Page 9050-43-1. Operate until temperature is at test specifications. 4. Put a capacity load on the forks, and raise the capacity load to 2.5 m (8.2 ft) and lower the load several times. Lower the load and slowly tilt the mast forward to 90° to floor and backward several times. 5. Check for external cylinder or hose leaks. 6. Slowly tilt the mast forward to 90° to floor. If the mast continues to slowly tilt forward when the control valve is in the neutral position, there are leaks inside the hydraulic system. Go to Step 8. 7. If mast is not dropping forward fast enough for visual check, use angle meter to record mast movement. Stop lift truck and let machine sit for 10 minutes. If movement exceeds specifications go to Step 8. 8. To check the tilt cylinders for internal leaks, close the ball valve in the supply line between the main control valve and the tilt cylinders. Measure movement and compare to specifications. • If movement does not meet test specifications, the seals in the tilt cylinders have leaks. Repair cylinder. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. • NOTE: Contamination in the hydraulic system can cause the control valve to leak, remove and clean valve before replacement. If the mast does not move, open the ball valve and check the movement again. If the mast moves when the ball valve is open, check for leaks in the hydraulic lines and fittings. If no leaks are found, the main control valve can be worn or damaged. Remove and clean hydraulic control valve. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439.

9050-43-26

1. 2. 3. 4. 5. 6. 7. 8.

LIFT VALVE SECTION TILT VALVE SECTION AUXILIARY VALVE SECTION OPTIONAL RELIEF VALVE LOCATION TILT PORT TILT CYLINDERS BALL VALVE MAIN RELIEF VALVE

Figure 9050-43-19. Tilt Cylinder Leakage Test E-Hydraulic Control Valve

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

1. 2. 3. 4. 5. 6. 7. 8.

LIFT VALVE SECTION TILT VALVE SECTION AUXILIARY VALVE SECTION OPTIONAL RELIEF VALVE LOCATION TILT PORT TILT CYLINDERS BALL VALVE MAIN RELIEF VALVE

Figure 9050-43-20. Tilt Cylinder Leakage Test Manual Control Valve for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (A955)

Tests and Adjustments-Gear Pump

1. 2. 3. 4. 5. 6. 7. 8.

LIFT VALVE SECTION TILT VALVE SECTION AUXILIARY VALVE SECTION OPTIONAL RELIEF VALVE LOCATION TILT PORT TILT CYLINDERS BALL VALVE MAIN RELIEF VALVE

Figure 9050-43-21. Tilt Cylinder Leakage Test Manual Control Valve for Lift Trucks ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP040-070VL) (A976)

Confidential/Proprietary - Do Not Copy or Duplicate

9050-43-27

Tests and Adjustments-Gear Pump

Hydraulic Systems

Steering Cylinder Leakage Test Cylinder leakage causes heat and poor performance in a steering system. This test is done to determine if the leakage is in the steering cylinder or the steering control unit. Table 9050-43-22. Test Specifications Oil Temperature

21 - 43°C (70 - 110 °F)

Maximum Leakage

10 ml (0.35 oz) Per Minute

Table 9050-43-23. Service Tools Container Left and Right Work Port Size

SAE #8 O-ring Port (3/4-16 UNF)

T-Fitting

Yale Part No. 580094669

1. Lower forks to ground and turn steering wheel until steer axle is against right axle stop. Turn key or keyless switch to OFF position and apply park brake. 2. Remove floor plates to expose steering cylinder hose connections. 3. Check hydraulic temperature. If not within specifications, see Tests and Adjustments-Gear Pump, Hydraulic Warm-up Procedure, Page 9050-43-1.

WARNING Hydraulic oil under pressure can be injected into skin. Lower forks to ground and relieve all circuit pressure before removing hoses from cylinders.

open valves, cylinder fittings, and ports should be protected with clean caps or plugs. 4. Slowly loosen left steering hose fitting that goes into SCU top left port marked (L). Remove left steering hose and keep it elevated so oil is not lost. Install O-ring Face Seal (ORFS) high pressure cap on left port fitting of SCU to seal valve against high pressure leakage when steering wheel is turned. NOTE: Turning the steering wheel by hand with lift truck off will generate hydraulic pressure in cylinder. If leakage is noted at this lower pressure, cylinder has excessive leakage. 5. Attempt to turn the steering wheel by hand. If oil flows out of hose at noticeable rate (approximately 50% of test specification), steering cylinder needs repair. Stop test and repair steering cylinder. If no oil flow, go to Step 6.

WARNING A open steering port can expel hydraulic oil under pressure and it can be injected into skin. Seal SCU port with high pressure ORFS cap before turning lift truck on. 6. Turn key or keyless switch ON and hold steering against right axle stop. Measure oil after it starts to flow from end of removed steering hose for 1 minute. 7. Turn key or keyless switch to OFF position and compare measured oil to test specifications. • If leakage is below specifications, the steering cylinder is OK. • If leakage is more than specifications, remove and repair steering cylinder. Depending on your lift truck, see Steering System 1600 YRM 1331 or Steering System 1600 YRM 1363. 8. Remove caps and reinstall hose and valve covers.

CAUTION Do not permit dirt or other contaminants to enter the hydraulic system. Disconnected hoses, tubes,

9050-43-28

Confidential/Proprietary - Do Not Copy or Duplicate

Hydraulic Systems

Tests and Adjustments-Gear Pump

1. TEST GAUGE HOSE

2. FITTING

Figure 9050-43-22. Steering Cylinder Leakage Test

Confidential/Proprietary - Do Not Copy or Duplicate

9050-43-29

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

9050-43-30

SECTION 9060

OPERATORS STATION TABLE OF CONTENTS Group 10 - Principles of Operation Operator Station General Description and Principles of Operation....................................................... General Description and Location....................................................................................................... Display Panel......................................................................................................................................... General Description ............................................................................................................................ Common Display Panel Features...................................................................................................... Premium Display Panel ..................................................................................................................... Display Panel .................................................................................................................................... LCD Screen and Warning and Indicator Lights................................................................................. Programming - Menus ........................................................................................................................... Menu ................................................................................................................................................... Operator Cycle Main Menu ............................................................................................................... Supervisor/Service Cycle Main Menu ............................................................................................... Activity Log ..................................................................................................................................... Calibration....................................................................................................................................... Diagnostic ....................................................................................................................................... Truck Set-Up ................................................................................................................................... Truck Status .................................................................................................................................... Display Adjustments ....................................................................................................................... Display Menu Flowchart ........................................................................................................................ Display Menu Flowchart ................................................................................................................... Display Menu Flowchart...................................................................................................................... Manual Hydraulic Control Levers ........................................................................................................ General Description .......................................................................................................................... System Components......................................................................................................................... Lift/Lower......................................................................................................................................... Tilt ................................................................................................................................................... Auxiliary 1 ....................................................................................................................................... Auxiliary 2 ....................................................................................................................................... Emergency Disconnect Switch ....................................................................................................... E-Hydraulic System Interface .............................................................................................................. General Description to E-Hydraulic System Interface ....................................................................... Lift/Lower......................................................................................................................................... Tilt ................................................................................................................................................... Return-To-Set-Tilt (RTST)............................................................................................................. Auxiliary 1 ....................................................................................................................................... Auxiliary 2 ....................................................................................................................................... Emergency Disconnect Switch ....................................................................................................... Lighting Control ................................................................................................................................... General Description .......................................................................................................................... Front Work Lights ............................................................................................................................ Front Marker Lights ......................................................................................................................... Front/Rear Turn Signal Lights ......................................................................................................... Rear Tail Lights ............................................................................................................................... Rear Work Light .............................................................................................................................. Rear Backup Lights.........................................................................................................................

Confidential/Proprietary - Do Not Copy or Duplicate

9060-10-1 9060-10-1 9060-10-3 9060-10-3 9060-10-3 9060-10-3 9060-10-4 9060-10-6 9060-10-7 9060-10-7 9060-10-7 9060-10-7 9060-10-7 9060-10-7 9060-10-7 9060-10-8 9060-10-8 9060-10-8 9060-10-8 9060-10-8 9060-10-8 9060-10-30 9060-10-30 9060-10-30 9060-10-30 9060-10-30 9060-10-30 9060-10-31 9060-10-31 9060-10-32 9060-10-32 9060-10-33 9060-10-33 9060-10-33 9060-10-33 9060-10-34 9060-10-34 9060-10-34 9060-10-34 9060-10-34 9060-10-34 9060-10-34 9060-10-35 9060-10-35 9060-10-35

9060-1

Section 9060

Operators Station

TABLE OF CONTENTS (Continued) Rear Stop Lights ............................................................................................................................. Strobe Light..................................................................................................................................... Dome Light...................................................................................................................................... Cab Panels .......................................................................................................................................... General Description .......................................................................................................................... Covers and Floor Plates.................................................................................................................. Hood and Seat ................................................................................................................................ Hood ............................................................................................................................................. Seat .............................................................................................................................................. Cab Heating System ....................................................................................................................... Control Panel ................................................................................................................................ Heater Core .................................................................................................................................. Heater Fan .................................................................................................................................... Wiper/Washer System ....................................................................................................................

9060-2

9060-10-35 9060-10-35 9060-10-35 9060-10-36 9060-10-36 9060-10-36 9060-10-36 9060-10-36 9060-10-36 9060-10-36 9060-10-36 9060-10-36 9060-10-37 9060-10-37

Confidential/Proprietary - Do Not Copy or Duplicate

Operators Station

Principles of Operation

Group 10

Principles of Operation Operator Station General Description and Principles of Operation GENERAL DESCRIPTION AND LOCATION The major components of the operator station for the lift truck are shown in Figure 9060-10-1, Page 9060-10-1. The conventional hydraulic steering, braking, and drive

system elements are not included in this section. Refer to the Operating Manual for related information on common systems. See Figure 9060-10-1, Page 906010-1.

A. E-HYDRAULIC CONTROL

B. MANUAL HYDRAULIC CONTROL

1. 2. 3. 4. 5. 6. 7. 8.

10. EMERGENCY DISCONNECT SWITCH 11. FOOT DIRECTIONAL CONTROL (FDC) PEDAL (OPTIONAL) 12. BRAKE PEDAL 13. AUTOMATIC PARKING BRAKE MANUAL OVERRIDE HANDLE (OPTIONAL) 14. STEERING WHEEL 15. STEERING COLUMN TILT MEMORY LEVER 16. DIRECTION CONTROL SWITCH (OPTIONAL)

HORN BUTTON ACCELERATOR PEDAL (OPTIONAL) DISPLAY PANEL KEY SWITCH OR KEYLESS SWITCH LIGHT SWITCHES LIFT/LOWER CONTROL LEVER TILT CONTROL LEVER CONTROL LEVER FOR AUXILIARY HYDRAULIC FUNCTIONS (3RD LEVER) 9. CONTROL LEVER FOR AUXILIARY HYDRAULIC FUNCTIONS (4TH LEVER)

Figure 9060-10-1. Operator Station Components

Confidential/Proprietary - Do Not Copy or Duplicate

9060-10-1

Principles of Operation The components shown in Figure 9060-10-1, Page 9060-10-1 include multiple options which are customer determined. These options are explained in greater detail in the appropriate sections of this manual. The indicated devices are used for various control inputs and operation of the lift truck systems. Display Panel provides: • Power ON/OFF selection • Display and Input for menu-driven data entry, navigation, and readout • Manual Hydraulic Levers (if equipped) provides: • • • • • • •

Control of lift Lower Tilt Sideshift Fork spread functions Emergency disconnect switch Directional Control Switch (Optional)

Mini Lever Module (MLM) (if equipped) provides: • • • • • • • •

Control of lift Lower Tilt Sideshift Fork spread functions Emergency disconnect switch Horn Directional Control Switch (Optional)

Vehicle System Manager (VSM) provides: • Controls or monitors most electrical operations of the lift truck • Safe shutdown for critical faults • Manages operator inputs and stores operational/ fault data history Steering Wheel provides: • The steering wheel controls the movement of the steer wheels. Rotate the steering wheel clockwise to make a right turn, and counterclockwise to make a left turn. Horn provides • Push the horn button to warn pedestrians and others when approaching intersections and other blind areas. • If lift truck is equipped with E-Hydraulic controls, there is another horn button located on the armrest.

9060-10-2

Operators Station Light Switches provides rocker switches for the following light functions: • Front Driving/Brake/Reverse/Parking lights. • Rear Driving light and the Strobe light or Strobe light only. • Operator Compartment light (if equipped with a cab) or Strobe light only. Tilt Memory Lever provides: • The ability to move the steering column so that the hood can be raised. Lift and hold the lever while moving the steering column. Release the lever when the steering column is in the desired position. Standard Accelerator provides: • Accelerator function for speed control on lift trucks equipped with a FWD/ REV Directional Control Switch (DCS); which may be located on the armrest of lift trucks equipped with e-hydraulics, or on the lift/lower hydraulic control lever of lift trucks equipped with manual hydraulics. Foot Directional Control (FDC) pedal provides: • Foot pedal input control for FWD or REV travel. • Accelerator function for speed control. The foot pedal direction control is configured with analog position sensors that input the direction command to the VSM. Pressing on the right side of the pedal selects the REV direction with corresponding backup lights and backup alarm activated. Pressing the left side of the pedal selects the FWD direction. The foot pedal direction control also serves as the accelerator pedal, pushing it down further will increase the speed of the truck in the applied direction. Service Brake Provides: • Includes a hydraulically operated brake mechanism at the drive wheels. These wheel brakes are controlled by movement of the brake pedal, providing braking proportional to the applied pedal force. • When the service brake is applied, the E-Boost feature is activated. This will direct the traction system to brake the vehicle. Parking Brake provides: • Mechanical brake operated through a separate pedal; it applies parking-brake mechanisms at the two drive wheels

Confidential/Proprietary - Do Not Copy or Duplicate

Operators Station

Principles of Operation

Auto Park Brake provides: • Automatic braking to the traction motor; slowing it down and eventually bringing it to a stop. • If the lift truck loses power and has to be towed, there is a manual override handle that will disable the auto park brake. The manual override handle is located underneath the floor mat and floor plate and mounted to the front bulkhead. • The auto park brake will activate under the following condition when the operator:

– Gets up from the seat without applying the parking brake and turning the lift truck power OFF. – Takes his foot off of the accelerator pedal or Foot Directional Control (FDC) pedal (if equipped) while the lift truck is moving. – The lift truck does not move for a period of 15 minutes. – To release the auto park brake, the operator needs to either return to the seat or depress the accelerator pedal or Yale Foot Directional Control (FDC) pedal (if equipped).

Display Panel GENERAL DESCRIPTION There are two display panel options, Standard and Premium. See Figure 9060-10-2, Page 9060-10-3. Both displays look identical. The only difference is in the display software and the resulting functionality.

Common Display Panel Features NOTE: The following features are common to both the Standard and Premium Display Panel:

• Operator checklist where the operator must answer YES or NO to a set of questions before the lift truck can be operated. • Hydraulic fluid low icon. This icon will appear if the system detects low hydraulic fluid. Available with the Hydraulic Fluid Level Monitoring option. • Hydraulic filter restriction icon. This icon will appear if the system detects a restriction in the hydraulic filter. This is an optional feature.

• Liquid Crystal Display (LCD) screen • Battery Discharge Indicator (BDI) with lift interrupt when enabled • Status Codes • System time/date display • Hourmeter for the traction motor and hydraulic pump motor. • Numeric push key pad • Preassigned service passwords to control access to Service Functions available through the dash display panel.

Premium Display Panel NOTE: The features listed below are the additional features only used on the Premium Display Panel: • Preassigned operator passwords to control operator access to the lift truck. • Four driving Performance Modes that are accessed through the key pad. • Scheduled maintenance reminders to be programmed in and will alert the operator through an audible and visual alarm when scheduled maintenance is due.

Confidential/Proprietary - Do Not Copy or Duplicate

Figure 9060-10-2. Display Panel

9060-10-3

Principles of Operation

Operators Station

Display Panel WARNING If any of the instruments, levers, or pedals do not operate as described in the following tables, report the problem immediately. Injury to personnel can occur if the instruments, levers, or pedals do not operate as described. DO NOT operate the lift truck until the problem is corrected. The display panel is equipped with 10 numeric keys, two arrow keys (left and right arrows) and two symbol keys (the Star (*) Key and the Pound (#) Key).

All key presses are accepted for a single entry and key entries cannot be repeated by holding down the key. For example, holding the 5 key down while entering a password number, will only result in one instance of 5 being entered regardless of how long the user presses the 5 key. To enter multiple 5’s, the user must press the 5 key multiple times. Each lift truck can be equipped with several different options and configurations. Depending on the equipment on the lift truck, the key functions described in Table 9060-10-1, Page 9060-10-4 will vary and may not apply to your lift truck.

If multiple keys are pressed at the same time, by default the display panel will ignore all keys. If a key has already been pressed and a second one is pressed immediately, the display panel will ignore the second key. Table 9060-10-1. Display Panel Item No. 1

9060-10-4

Item 1 Key

Function Premium Display: When an operator is in the Password Screen for entering and administering passwords (if the password feature is enabled), this key is enabled to enter the number 1 for password purposes. Once a password has been successfully entered, the display panel will go to the Operator Screen. This screen contains all the necessary components for normal operation of the lift truck. While in this screen, key 1 is enabled to decrease Performance Mode of operation. Press the 1 key to go to the next lowest level of Performance Mode. Mode number 1 is the slowest mode and mode number 4 is the fastest mode. Standard Display: If lift truck is equipped with a Standard Display panel, the Operator Screen will appear after truck has been turned ON. The ability to increase or decrease the Performance Mode is only available with the Premium Display Panel. On the Standard Display Panel, the Performance Mode is always set to 4. Premium and Standard Displays: When an operator, if authorized, is in any of the additional menus that are available (Calibrations, Diagnostics, and Truck Setup menus) the 1 key is enabled to enter the number 1 for data entry purposes.

Confidential/Proprietary - Do Not Copy or Duplicate

Operators Station

Principles of Operation

Table 9060-10-1. Display Panel (Continued) Item No.

Item

Function

4 Key

Premium Display: When an operator is in the Password Screen for entering and administering passwords (if the password feature is enabled), this key is enabled to enter the number 4 for password purposes. The Operator Password feature is only available on the Premium Display panel. Once a password has been successfully entered, the display panel will go to the Operator Screen. This screen contains all the necessary components for normal operation of the lift truck. While in this screen, key 4 is enabled to increase Performance Mode of operation. Press the 4 key to go to the next highest level of Performance Mode. Standard Display: If lift truck is equipped with a Standard Display panel, the Operator Screen will appear after truck has been turned ON. The ability to increase or decrease the Performance Mode is only available with the Premium Display Panel. On the Standard Display Panel, the Performance Mode is always set to 4. Premium and Standard Displays: When an operator, if authorized, is in any of the additional menus that are available (Calibrations, Diagnostics, and Truck Setup menus) the 4 key is enabled to enter the number 4 for data entry purposes.

2 and 3 Keys

Premium Display: When an operator is in the Password Screen for entering and administering passwords (if the password feature is enabled), these keys are enabled to enter the numbers 2 and 3 for password purposes. The Operator Password feature is only available on the Premium Display panel. Standard Display: If lift truck is equipped with a Standard Display panel, the Operator Screen will appear after truck has been turned ON. Premium and Standard Displays: When an operator is working in a specific menu (for example, the Operator Screen) the 2 and 3 keys allow the operator to scroll up or down within the menu. Press the 2 key to scroll up and press the 3 key to scroll down. When an operator, if authorized, is working in any of the menus, other than the Password menu, is prompted to enter a data value that contains numbers, the scrolling feature for the 2 and 3 keys will be disabled and keys 2 and 3 can be used to enter numeric values. Once the numeric data value has been entered and the enter key pressed, the scrolling feature for keys 2 and 3 will be enabled again.

5 Key

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9060-10-5

Principles of Operation

Operators Station

Table 9060-10-1. Display Panel (Continued) Item No. 5

Item

Function

Scroll Back (Left Arrow Key)

This key is used for the following functions:

(#) Pound Key

If the Operator Checklist is enabled on the lift truck, the (#) Pound Key is used to indicate an issue with the current item in the list. See Operating Manual for your lift truck to obtain more information on using the Operator Checklist.

• Scrolling backwards through a list of possible menu selections.

• Scrolling through a list of possible menu selections. 7

(*) Enter Key (STAR Key)

This key is used for menu entry and menu navigation. Use the (*) STAR key to select a menu to be viewed. Within the selected menu, use the (*) STAR key to select sub menus associated with the selected menu. • Scrolling through a list of possible menu selections.

Scroll Forward (Right Arrow Key)

This key is used for the following functions:

6, 7, 8, 9, and 0 Keys

The 6, 7, 8, 9, and 0 keys are enabled to enter the numbers 6, 7, 8, 9, and 0 for data entry purposes.

Keyless Start Switch or Key Switch

The lift trucks covered in this manual can be equipped with either a key switch or keyless switch. Both options will have two positions:

• Scrolling forward through a list of possible menu selections.

• OFF position. Deenergizes all electric circuits except for the horn. • ON position. Energizes all electric circuits. The key or keyless switch will be in this position during normal operation.

LCD Screen and Warning and Indicator Lights The LCD screen uses a series of icons and numeric values to communicate important truck information to the operator, supervisor, and service technician. The warning and indicator icons appear when the LCD screen is displaying the Operator Screen. The Operator Screen contains all the components necessary for normal operation of the lift truck. After 10 seconds, the seat belt, low brake fluid, service due (if equipped), motor temperature icons, and low hydraulic fluid (if equipped) will no longer be illuminated and will illuminate again only if there is a problem in that particular area. Detailed information for Warning and Indicator lights can be found in the Operating Manual.

9060-10-6

The following icons are displayed at all times on the LCD screen when the truck is running, and the LCD screen is displaying the Operator Screen: • The current performance mode the truck is operating under (Premium Display Panel only) • The Battery Display Indicator (BDI) • The direction indicators showing which direction the truck is traveling in • The neutral/park brake indicator • The truck hourmeter • System time See Figure 9060-10-3, Page 9060-10-7:

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Operators Station

Principles of Operation

Legend for Figure 9060-10-3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

FASTEN SEAT BELT ICON, DIRECTION INDICATOR ICON BATTERY DISPLAY INDICATOR (BDI) ICON LOAD WEIGHT ICON SYSTEM TIME ICON STEER TIRE ANGLE ICON SERVICE DUE ICON MOTOR TEMPERATURE HIGH WARNING ICON PERFORMANCE MODE ICON LOW BRAKE FLUID ICON

Figure 9060-10-3. Display Panel - LCD Screen / Warning and Information Icons

Programming - Menus MENU The On-Board Menu Structure is accessible while the system power is on by pressing the “*” button. If accessed without a password or by an operator password, the menu structure will automatically exit if no button presses have been detected for 30 seconds. Unless otherwise specified, menu items are only accessible with a service password. See Principles of Operation, Display Menu Flowchart, Page 9060-10-8 for further details.

Operator Cycle Main Menu • • • •

Operating Screen Password Entry Load Weight (Optional) Checklist (Optional

Supervisor/Service Cycle Main Menu • • • • • • • •

Operating Screen Password Entry Load Weight (Optional) Checklist (Optional Activity Log Calibration Diagnostics Truck Set-Up

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• Truck Status • Display Adjustment

Activity Log • Check List Log • Password Log • Impact Log

Calibration • • • • • •

Load Weight Manual Hydraulic Valve Steer Axle Steer Wheel Hydraulic Valve Threshold Return to Set Tilt (RTST)

Diagnostic • • • • • • • • •

Fault Logs/Controllers/Other CAN Device Steering Sensor Battery/Other Power Supplies Mast Sensor Hydraulic Valve Hydraulic Inputs Hydraulic Pump Motor Brakes Seat (Operator Presence)

9060-10-7

Principles of Operation • • • •

Operators Station • • • • •

Traction Motor 2 Traction Motor 1 Directional Indicator Operation Speedometer

Truck Set-Up • • • • • • • • • • • • • • • •

Passwords Restore Defaults Optional Hydraulic (Diverter Valve) ON/OFF Rear Lamp Assembly OFF/ON Hydraulic Function Hydraulic Function 1a, 1b, 2a, 2b, 3a, 3b, 4a, 4b (E-Hydraulics Only) Hydraulic Function 1a, 1b, 2a, 2b, 3a, 3b, 4a, 4b (Manual Hydraulics Only Motion Alarm OFF/ON Impact Thresholds Auto Power OFF Return To Set Tilt (RTST) Traction Speed Limit Scheduled Maintenance (Deferred) Minimum Pump Speed Check List Impact Shutdown

Hour Meter Acceleration BDI Adjustment Battery Braking

Truck Status • • • • • • • • • •

VSM Version Impact Sensor Version Light 1 Controller Version Traction 2 Controller Version Traction 1 Controller Version Pump Controller Version Hydraulic Input Controller Version Hour Meters Serial Number Display Version

Display Adjustments • • • •

Date/Time Format Units Selection (Imperial/Metric) Date and Time Daylight Savings

Display Menu Flowchart DISPLAY MENU FLOWCHART Note: This chart indicates all available menu options for this model series. Only those options ordered on your specific truck will be displayed and accessible using the Service Level password. DTC’s are stored in the DTC LOGS, where a history of repeat failures is maintained, until cleared by an authorized service technician. All DTC’s are to be cleared prior to operating the lift truck. DTC logs should only be cleared once the data is recorded by a authorized service technician.

9060-10-8

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Operators Station

Principles of Operation

1. 1/Soft Key

6. 6 Key

11. Scroll (Right Arrow Key)

2. 4/Soft Key

7. 9 Key

12. 8 Key

3. (#) Pound Key/Soft Key

8. 2/Soft Key

13. 7 Key

4. Scroll Back (Left Arrow Key)

9. 3/Soft Key

14. 0 Key

5. 5 Key

10. (*) STAR Key Select/Enter/ Accept DISPLAY MENU FLOWCHART (Con’t)

Return to Previous Menu Scroll 

Scroll 

Power ON Power ON

Operator Cycle

Select/Enter/Accept *

Enter/Accept *

Scroll Up/Down

Increase/Decrease Performance

Power OFF Enter Password

Supervisor/Service Cycle

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Hour Meter Displayed for 5 seconds Power OFF

Power ON

Operator Cycle

9060-10-9

Principles of Operation

Operators Station

OPERATOR CYCLE Legend A. Operating Screen

E. Load Weight

J. Display Adjustment

B. Password Entry

F. Tare Weight

K. Activity Log

C. Enter Password

G. Checklist

L. Truck Setup

D. Calibration

H. Truck Status

M. Diagnostics

Standard

Load Weight Option

Check List Option

SERVICE CYCLE

Truck-Setup

9060-10-10

Truck Status

Display Adjustments

Activity Logs

Calibration

Diagnostics

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Operators Station

Principles of Operation

Table 9060-10-2. Activity Logs ACTIVITY LOGs

Check List

No Logs

Check List OK

No Logs

Operator/Supervisor/Service

Check List Not OK

Password Log

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9060-10-11

Principles of Operation

Operators Station

Impact Log

9060-10-12

No Logs

Soft Impact/Hard Impact

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Operators Station

Principles of Operation

Table 9060-10-3. Calibration CALIBRATION

Load Weight

No Load Entry

Known Load Entry

Test Load Entry

Manual Hydraulic Valve

Move each lever to end of travel

)*H

X = Calibration Fail ,

3 seconds)* Repeat Calibration

Steer Axle

Rotate Fully CCW

Rotate Fully CW

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9060-10-13

Principles of Operation

Operators Station

Steer Wheel

Set Steering Wheel to desired (Spinner) Position

Hydraulic Valve Threshold

Operate Indicated Control until movement is detected

Repeat for each function

Return To Set Tilt (RTST)

9060-10-14

Set Tilt Angle

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Operators Station

Principles of Operation

Table 9060-10-4. Diagnostics DIAGNOSTICS

Fault Logs / Controllers / Other CAN Device Previous

Delete All Logs

VSM

Navigation example

VSM

Traction 1

Light

MLM

Next Log Record

Previous Log Record

Traction 2

Pump

Impact

Display

Steering Sensor

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9060-10-15

Principles of Operation

Operators Station

Battery / Other Power Supplies

)* Mast Sensor

Hydraulic Valve

Hydraulic Inputs

Hydraulic Pump Motor

9060-10-16

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Operators Station

Principles of Operation

Brakes

Seat (Operator Presence)

Traction Motor 2

Traction Motor 1

Directional Indication Operation

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9060-10-17

Principles of Operation

Operators Station

Speedometer

Imperial

9060-10-18

Metric

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Operators Station

Principles of Operation

Table 9060-10-5. Truck-Setup TRUCK SETUP

Passwords Incorrect

+Password

Enter / Re-Enter Password

Set Max Performance

Delete Password

Select Operator / Supervisor / Service for Password

Restore Defaults

)*To restore defaults

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9060-10-19

Principles of Operation

Operators Station

Optional Hydraulic (Diverter Valve) ON/OFF

)*( Valve ON/OFF

Rear Lamp Assembly OFF/ON

)* Rear Lamp OFF

)* Rear Lamp ON

Hydraulic Function 1a, 1b, 2a, 2b, 3a, 3b, 4a, 4b (E Hydraulics Only)

)* Scroll to Function

)* To Select

Enter Value Using Number Buttons

Repeat for other functions

Hydraulic Function 1a, 1b, 2a, 2b, 3a, 3b, 4a, 4b (Manual Hydraulics Only)

9060-10-20

)* Enter Value Using Number Buttons )*

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Operators Station

Principles of Operation

Motion Alarm OFF/ON

)* Motion Alarm OFF

)* Motion Alarm ON

Impact Thresholds

)* Scroll to function )* To Select

Enter Value Using Number Buttons or Scroll

Repeat for other functions

Auto Power OFF

)*Enter Value Using Number Buttons )*

Return To Set Tilt (RTST)

)*Scroll to Function

)* ( To Select

Next Function

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)* Enter Value Using Number Buttons )*

9060-10-21

Principles of Operation

Operators Station

Traction Speed Limit

)* Enter Value Using Number Buttons )*

Scheduled Maintenance

Minimum Pump Speed

)* Enter Value 0 % to 100 % Using Number Buttons )*

Check List

9060-10-22

)9(*) Active ) X (#) Inactive

Scroll to Next Check List Item

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Operators Station

Principles of Operation

Impact Shutdown

)*Scroll to Function

)* ( To Select

Next Function

)* Enter Value Using Number Buttons )*

Hour Meter

)*Scroll to Function

)* To Select

Enter Value Using Number Buttons

Next Function

Acceleration

)*Scroll to Function

)* ( To Select

Next Function

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)* Enter Value Using Number Buttons )*

9060-10-23

Principles of Operation

Operators Station

BDI Adjustment

)* Scroll to Function

)* To Select

Enter Zero then desired number using Number Buttons

Battery

)*Scroll to Function

)* To Select

Enter Value Using Number Buttons

Next Function

Braking

)*Scroll to Function

9060-10-24

)* ( To Select

Next Function

)* Enter Value Using Number Buttons )*

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Operators Station

Principles of Operation

Table 9060-10-6. Truck Status TRUCK STATUS

VSM Version

Hardware/Software Versions

Impact Sensor Version

Light 1 Controller Version

Traction 2 Controller Version

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9060-10-25

Principles of Operation

Operators Station

Traction 1 Controller Version

Pump Controller Version

Hardware/Software Versions

Hydraulic Input Controller Version

Hour Meters

Traction/Pump/Truck/Secure

Serial Number

9060-10-26

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Operators Station

Principles of Operation

Display Version

Hardware/Software Versions

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9060-10-27

Principles of Operation

Operators Station

Table 9060-10-7. Display Adjustments DISPLAY ADJUSTMENTS

Date/Time Format

)* Scroll to Function

)*Select

Scroll

12 - 24

)* Scroll to Function

)*Select

Scroll

MM/DD/YY - DD/MM/YY - YY/MM/DD

Units Selection (Imperial/Metric)

9060-10-28

Scroll

Imperial - Metric

)* 

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Operators Station

Principles of Operation

Date and Time

Enter Hours

Enter Minutes

Scroll

AM - PM

*( Enter Year

Enter Month

*(Enter Day

Daylight Savings

Daylight Savings OFF/ON

Daylight Savings Start Month

)*(

Scroll to Month

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Scroll to other Setups

9060-10-29

Principles of Operation

Operators Station

Daylight Savings Daylight Savings Start Day

Daylight Savings End Month

Daylight Savings End Day

Scroll to Day

Scroll to Month

Scroll to Day

Manual Hydraulic Control Levers GENERAL DESCRIPTION

mast and forks forward. Pull the lever backward toward operator to tilt the mast and forks backward.

The Manual Control Levers (if installed) are used to control hydraulic operation of the mast lift/lower, tilt, and auxiliary functions.

Auxiliary 1

SYSTEM COMPONENTS

The third control lever is installed to the right of the tilt control lever. This lever can have two methods of operation, depending on the attachment.

The control levers are located to the right of the operator’s seat. Each lever is explained below. See Figure 9060-10-4, Page 9060-10-31.

Lift/Lower The lift/lower control lever is the first lever to the right of the operator’s seat. Pull backward toward operator to raise the carriage and forks. Push forward to lower the carriage and forks.

Tilt

• Trucks with clamp attachment: To engage the clamp attachment, press and hold the button on the left top side of the lever and move lever forward. When finger is removed from the button, the lever is locked in the neutral position and cannot be moved. To disengage the clamp function, press the button again and move lever backward. • Trucks without clamp attachment: The lever is operated by moving it forward and backward. The lever is spring loaded to return to the neutral position when released.

The tilt control lever is the second lever to the right of the operator’s seat. Push the lever forward to tilt the

9060-10-30

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Operators Station

Principles of Operation

1. LIFT/LOWER CONTROL LEVER (1ST LEVER) 2. TILT CONTROL LEVER (2ND LEVER) 3. CONTROL LEVER FOR AUXILIARY HYDRAULIC FUNCTIONS (3RD LEVER)

4. CONTROL LEVER FOR AUXILIARY HYDRAULIC FUNCTIONS (4TH LEVER) 5. EMERGENCY DISCONNECT SWITCH

Figure 9060-10-4. Manual Hydraulic Control Levers

Auxiliary 2

Emergency Disconnect Switch

The fourth control lever is installed to the right of the third control lever. This lever can have two methods of operation, depending on the attachment.

NOTE: The emergency disconnect switch does not remove power to the front or rear service lights.

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The emergency disconnect switch, is located behind the Auxiliary 2 lever. The operator can disconnect all electrical power to the lift truck by pushing the emergency disconnect switch in until it clicks. To reset the emergency disconnect switch and energize the electrical circuits, the operator must turn the switch clockwise until it pops out.

9060-10-31

Principles of Operation

Operators Station

E-Hydraulic System Interface GENERAL DESCRIPTION TO E-HYDRAULIC SYSTEM INTERFACE

To operate the Mini Lever Module (MLM), the operator must be positioned on the seat.

Lift trucks may be equipped with an optional Electro-Hydraulic (E-Hydraulic) system. It controls hydraulic operation of the mast lift/lower, tilt, and auxiliary functions. This E-Hydraulic option replaces the manual control levers with simple, single-handed, finger-operated electronic controls, located on the right-hand armrest. The E-Hydraulic system is controlled by the VSM that provides drive commands to the hydraulic valves based on the operator inputs. This system automatically adjusts the flow control based on conditions such as speed, load, and functions activated, etc., to provide better controllability, and flexibility with the controls necessary to operate the E-Hydraulics. The VSM also monitors the performance of the system and reports faults to the operator through the Display Panel (DP).

The MLM commands are sent to the VSM through the CANbus. The VSM supplies proportional commands to drive the electro-hydraulic valves. The VSM monitors the input and outputs signals, hydraulic response, and adjust the system performance as required. Faults or interlock conflicts are detected by the VSM which sends an error message (fault codes) to the Display Panel for operator awareness and correction.

1. LIFT/LOWER MINI-LEVER (1ST LEVER) 2. TILT MINI-LEVER (2ND LEVER) 3. MINI-LEVER FOR AUXILIARY HYDRAULIC FUNCTIONS (3RD LEVER)

4. MINI-LEVER FOR AUXILIARY HYDRAULIC FUNCTIONS (4TH LEVER) 5. EMERGENCY DISCONNECT SWITCH

The MLM consists of up to four individual proportional levers and may have additional momentary switches. The control levers are located on the armrest. See Figure 9060-10-5, Page 9060-10-32.

Figure 9060-10-5. E-Hydraulic Mini Lever Module

9060-10-32

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Operators Station

Lift/Lower The electronic lift/lower control lever is the first minilever to the right of the operator’s seat. Pull backward toward operator to raise the carriage and forks. Push forward to lower the carriage and forks.

Tilt The electronic tilt control lever is the second mini-lever to the right of the operator’s seat. Push the lever forward to tilt the mast and forks forward. Pull the lever backward toward operator to tilt the mast and forks backward.

Return-To-Set-Tilt (RTST) Optional: Return-To-Set-Tilt (RTST) — The RTST option assists the operator in positioning the mast at a predetermined set point. Note that the RTST function does not provide for "hands free" activation of the tilt valve. The operator must manually control both tilt speed and direction of the mast toward the set point. When the mast is far away from the stop point, the operator is allowed to tilt at the maximum tilt flow rate. When the mast is close to the set point, the maximum tilt flow rate is limited.

Principles of Operation If the RTST override button is depressed before pushing the tilt lever, and the RTST override button is depressed for 1/20 th of a second and the tilt lever is moved out of neutral within one second of the button being released, the RTST control will not stop the mast at the set point. Once the lever is returned to neutral the override command will be cancelled and the RTST control will become active. NOTE: The following time delay adjustments are available: • Disable RTST • 8 increments of time delay from 0.1 to 3.0 seconds • "Continuous" time delay. If the time delay is set to continuous the operator MUST press the override button to resume tilt control. A service technician may adjust the time delay.

Auxiliary 1 The third mini-lever is installed to the right of the tilt control lever. This lever can have two methods of operation, depending on the attachment.

If the RTST override button is not depressed before pushing the tilt lever. The RTST control soft stops the mast at the set point and disables the tilt valve even if the operator command is not at neutral. Once stopped the system waits for one of three options: 1. Return the tilt control lever back to neutral position, which places the tilt control to neutral. 2. Depress the RTST override button, which will override the RTST control and allow the tilt control to function. If the delay time is set to "continuous", the operator MUST press the override button to resume tilt control past the set point. 3. Waits for the RTST time delay of 0.1 to 3 seconds to time out, at which time the tilt control will be enabled and the mast will continue to tilt in the direction the control lever is pushed.

• Trucks with clamp attachment: To engage the clamp, move the mini-lever backward. To disengage the clamp, press the override button located directly behind the mini-levers, and push the mini-lever forward. • Trucks without clamp attachment three levers, and three function control valve: The lever is operated by moving it forward and back. The lever is spring loaded to return to the neutral position when released. • Trucks with clamp attachment, three levers, and four function control valve: The third lever becomes a dual function lever. Move the lever forward and back to operate the auxiliary 1 function. Press and hold the lever down and move lever either forward or backward to operate the auxiliary 2 function. Remove hand from lever to disable the auxiliary 2 function and return lever to auxiliary 1 position. Do not press the override button. If the override button is pressed, the clamp will be engaged.

Confidential/Proprietary - Do Not Copy or Duplicate

9060-10-33

Principles of Operation

Operators Station

Auxiliary 2 NOTE: If truck is equipped with four function control valve, four levers and clamp attachment, the last (4th) lever controls clamp functions. If truck is equipped with five function control valve, four levers and clamp attachment, the clamp is the fifth function and the last (4th) lever controls clamp functions. The fourth mini-lever is installed to the right of the control lever. This lever can have two methods of operation, depending on the attachment. • Trucks with clamp attachment: To engage the clamp, move the mini-lever backward. To disengage the clamp, press the override button located directly behind the mini-levers, and push the mini-lever forward. • Trucks without clamp attachment, four levers, and four function control valve: The lever is operated by moving it forward and back. The lever is spring loaded to return to the neutral position when released. • Trucks with clamp attachment, four levers, and five function control valve: The third lever becomes a dual

function lever. Move the lever forward and back to operate the auxiliary 1 function. Press and hold the lever down and move lever either forward or backward to operate the auxiliary 2 function. Remove hand from lever to disable the auxiliary 2 function and return lever to auxiliary 1 position. Do not press the override button. If the override button is pressed, the clamp will be engaged.

Emergency Disconnect Switch NOTE: The emergency disconnect switch does not remove power to the front or rear service lights. The emergency disconnect switch, is located on the right side of the armrest. The operator can disconnect all electrical power to the lift truck by pushing the emergency disconnect switch in until it clicks. To reset the emergency disconnect switch and energize the electrical circuits, the operator must turn the switch clockwise until it pops out.

Lighting Control GENERAL DESCRIPTION WARNING Before replacing any of the lights, fully lower the mast and tilt the mast forward until the tips of the forks touch the ground. This action will prevent the mast from lowering suddenly if the control lever is accidently moved. Never have any metal on your fingers, arms, or neck. These metal items can cause short circuit and possible damage or injury.

The lighting control system consists of work lights, marker lights, strobe light, turn signal lights, stop/ backup lights and dome light. The work lights are controlled by rocker switches located on the right side of the dash; turn signal lights are controlled by a lever on the steering column.

Front Work Lights The front work lights rocker switch is located on the right side of the dash. The front work lights can be operated when the truck system power is ON or OFF. If the power is turned OFF, the work lights will continue to operate until the light switch on the dash is turned OFF.

9060-10-34

Front Marker Lights The front marker lights operate with the front work lights.

Front/Rear Turn Signal Lights The front/rear turn signal lights are activated by a lever mounted on the left of the steering column. The activated signal light will continue to operate until the lever is manually returned to the center position or until system power is turned to OFF.

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Operators Station

Principles of Operation

Rear Tail Lights The rear tail light operate with the operation of the front work lights.

NOTE: LIGHT LOCATION ON LIFT TRUCK MODELS ERP16-20VF (A955), ERC22-35VL (ERC040-070VL) (A968), ERP22-35VL (ERP040-070VL) (A976), AND ERP15-20VT (ERP030-040)(G807) ARE THE SAME. J1.5-2.0XNT (J30-40NT) (K160) IS SHOWN. A. FRONT VIEW

B. REAR VIEW

1. FRONT WORK LIGHTS 2. FRONT MARKER/TURN SIGNAL LIGHTS* 3. STROBE LIGHT

4. LED TAIL, BACKUP, AND BRAKE LIGHTS 5. REAR WORK LIGHT

* FRONT MARKER/TURN SIGNAL LIGHTS USED ONLY ON ERP16-20VF (A955), ERP22-35VL (ERP040-070VL) (A976), AND ERP15-20VT (ERP030-040)(G807) LIFT TRUCK MODELS.

Figure 9060-10-6. Lights Arrangement

Rear Work Light

Rear Stop Lights

The rear work light switch is located on the right side of the dash. The rear work lights can only be operated when the truck system power is ON or OFF. If the power is turned OFF, the work lights will continue to operate until the light switch on the dash is turned OFF.

The rear stop lights operate when the brake pedal is pressed.

Rear Backup Lights The rear backup lights operate when Reverse direction is selected.

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Strobe Light The strobe light operate when the truck power is ON or when a programmed function is selected.

Dome Light The dome light is located on the left behind the operator. There is an ON/OFF switch on the dome light. The

9060-10-35

Principles of Operation

Operators Station

dome light is powered through an unswitched battery

source and will operate with or without system power turned ON.

Cab Panels GENERAL DESCRIPTION Cab panels are offered as an option with the lift truck. The cab unit consists of individual panels installed on the overhead guard using cap screws. The panels include, a roof, side doors, front and rear windows. Front and rear window wipers, and heater system are available.

Covers and Floor Plates Various covers and floor plates provide access to components during service and securely cover areas during normal operation. Covers in the floor of the operator compartment allow access to the traction controllers, AC drive motors, service and parking brakes. A cover on the top of the counterweight provides access to the hydraulic tank, hydraulic pump and motor assembly, and the hoist controller.

Hood and Seat Hood The hood is a stamped steel battery cover. Two hinges at the back attach to the overhead guard. The hood is the platform for the seat assembly and is located above the battery. It functions as a battery restraint that completely covers the battery compartment.

Seat The seat assembly slides on seat rails that are fastened to the hood by four capscrews. A lever at the left front side of the base controls the adjustment of the seat to the forward and backward positions. Optional seats are available in cloth or vinyl with features such as non-suspension, full suspension, and limited swivel. All seats have a seat switch installed in the bottom cushion that senses operator presence. When the operator is not on the seat, the seat switch opens and interrupts the controller stopping operation of the lift truck.

unit with keypad, primary filter media, secondary filter media, and mounting hardware. The fan draws outside air through the cab vent and into both filters before finally entering the plenum. A thermostat regulates operation of the electric heating element. Cab air is heated until plenum air temperature reaches a maximum of 35°C (95°F). At this maximum temperature the thermostat will automatically cut power to the element as a protective measure. Operator keypad inputs command the control unit ON or OFF, change temperature and fan speed. Temperature settings can be adjusted in 1° increments shown on corresponding LCD screen. Operators can choose to display temperature in Celsius (C) or Fahrenheit (F). Fan speed is also adjusted using the keypad and corresponding displayed on a segmented graph. By monitoring input voltage and current flow through components this heater will trigger error codes in the event of a malfunction. Basic onboard diagnostics guide service personnel in troubleshooting by displaying a variety of error codes. For details see Operator’s Cab 100 YRM 1446.

Control Panel Controls the speed of the heater fan. The operator may choose to have the fan off or select from three fan speeds (low, medium, or high). Plastic casing 85 x 72 x 25mm, for retractable or standalone mounting. 2 digits indicate selected temperature. The selected fan speed is indicated with a LED ladder. Quartz crystal controlled microprocessor with program memory of flash type and EEPROM memory for operating parameters. Operating voltage 12VDC from control board. Communication via RS- 485 interface. Different cable lengths up to 4m are available.

Heater Core

Cab Heating System If included, the cab heater is located on the right hand door. The optional cab heater consists of the main plenum assembly, motor, fan, wiring harness, control

9060-10-36

Functions as a heat exchanger allowing air that passes through the core to be heated. Battery power heats the elements within the core.

Confidential/Proprietary - Do Not Copy or Duplicate

Operators Station

Principles of Operation

Heater Fan

Wiper/Washer System

Consists of a motor and two drum fans. Air is drawn in from outside the cab and is directed to flow across the heater core. The air is warmed by the heater core and flows out through adjustable vents located on the interior RH door housing.

The wiper/washer system consists of the wiper motors, wiper arms, wiper blades and a washer bottle and pump. The front wiper and washer is operated by switches located on the dash. The rear wiper and washer switch is located in the headliner on the right side of the truck.

24 VDC max 80W, of commutator or brush-less type. Driven by DC-DC converter with 8 speed levels at 14-24V

Confidential/Proprietary - Do Not Copy or Duplicate

9060-10-37

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

9060-10-38

SECTION 9070

FRONT END (MAST) AND CHASSIS TABLE OF CONTENTS Group 10 - Principles of Operation Front End, Mast ..................................................................................................................................... Description .......................................................................................................................................... Carriages............................................................................................................................................... Description .......................................................................................................................................... Principles of Operation........................................................................................................................ Integral Sideshift Carriage ................................................................................................................ Mast Mounts.......................................................................................................................................... Description .......................................................................................................................................... Principles of Operation........................................................................................................................ Two-Stage Full Free-Lift (FFL) Mast...................................................................................................... Description .......................................................................................................................................... Principles of Operation........................................................................................................................ Two-Stage Limited Free-Lift (LFL) Mast ................................................................................................ Description .......................................................................................................................................... Principles of Operation........................................................................................................................ Three-Stage Full Free-Lift (FFL) Mast................................................................................................... Description .......................................................................................................................................... Principles of Operation........................................................................................................................ Four-Stage Full Free-Lift (FFL) Mast................................................................................................... Description ........................................................................................................................................ Principles of Operation...................................................................................................................... Cylinder Cushion During Lifting Sequence.......................................................................................... Description ........................................................................................................................................ Principles of Operation...................................................................................................................... Cylinder Cushion During Lowering Sequence..................................................................................... Description ........................................................................................................................................ Principles of Operation...................................................................................................................... Tilt and Sideshift Cylinders.................................................................................................................. Description ........................................................................................................................................ Tilt Cylinder ..................................................................................................................................... Sideshift Cylinder ............................................................................................................................ Lowering Control Valves...................................................................................................................... Description ........................................................................................................................................ Principles of Operation...................................................................................................................... Chassis................................................................................................................................................ Description ........................................................................................................................................ Overhead Guard ............................................................................................................................ Counterweight ................................................................................................................................. Group 30 - Observed Symptoms Abnormal Channel Wear ....................................................................................................................... Abnormal Hose Wear ............................................................................................................................ Abnormal Mast Noise ............................................................................................................................ Body Panels Making Noise ................................................................................................................... External Leakage From Free-Lift or Main Lift Cylinders ...................................................................... FFL Mast Banging During Phasing .....................................................................................................

Confidential/Proprietary - Do Not Copy or Duplicate

9070-10-1 9070-10-1 9070-10-2 9070-10-2 9070-10-2 9070-10-2 9070-10-4 9070-10-4 9070-10-4 9070-10-4 9070-10-4 9070-10-5 9070-10-6 9070-10-6 9070-10-7 9070-10-8 9070-10-8 9070-10-9 9070-10-11 9070-10-11 9070-10-12 9070-10-14 9070-10-14 9070-10-14 9070-10-15 9070-10-15 9070-10-15 9070-10-15 9070-10-15 9070-10-15 9070-10-15 9070-10-16 9070-10-16 9070-10-16 9070-10-18 9070-10-18 9070-10-18 9070-10-18 9070-30-1 9070-30-3 9070-30-5 9070-30-9 9070-30-10 9070-30-11

9070-1

Section 9070

Front End (Mast) and Chassis

TABLE OF CONTENTS (Continued) High Tire Wear - Drive Axle................................................................................................................. High Tire Wear - Steer Axle ................................................................................................................ Hoses Not Tracking Correctly .............................................................................................................. Integral Sideshift Moving Too Fast ...................................................................................................... Integral Sideshift Not Moving or Slow.................................................................................................. Mast is Loose ...................................................................................................................................... Mast Lift Chains Are Loose ................................................................................................................. Mast or Carriage Binding..................................................................................................................... Mast/Carriage Bounces or is Spongy.................................................................................................. Misphasing of Full Free-Lift Mast ........................................................................................................ Overhead Guard Loose or Damaged .................................................................................................. Racking During Lift .............................................................................................................................. Racking During Tilt .............................................................................................................................. Truck Feels Unstable ........................................................................................................................... Truck Wanders, Does Not Track Straight or Steer Well ....................................................................... Wheel Studs Breaking.........................................................................................................................

9070-2

9070-30-13 9070-30-14 9070-30-16 9070-30-17 9070-30-18 9070-30-21 9070-30-23 9070-30-24 9070-30-26 9070-30-27 9070-30-29 9070-30-30 9070-30-32 9070-30-33 9070-30-34 9070-30-35

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Principles of Operation

Group 10

Principles of Operation Front End, Mast DESCRIPTION This section provides general Principles of Operation for front end components. Therefore, the illustrations used are intended to provide only a general description of front end components. Since many details and specific repair procedures, vary, depending on your lift truck, see Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. Depending on your lift truck, the description and repair for the tilt cylinders see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. The mast is used to lift a load vertically. The mast has two movements controlled by hydraulic cylinders: forward and backward tilt, and the lifting and lowering of

Confidential/Proprietary - Do Not Copy or Duplicate

the mast and carriage. The outer mast tilts on the pivot pins at the mast mounts. The operation of the tilt cylinders causes the mast to tilt forward and backward. The tilt cylinders are fastened between the frame of the lift truck and the outer mast. Hydraulic lift cylinders are installed vertically in the mast. The lift cylinders raise and lower the intermediate/inner masts and the carriage. There are four types of masts available: • • • •

Two-Stage Limited Free-Lift Two-Stage Full Free-Lift Three-Stage Full Free-Lift Four-Stage Full Free-Lift.

Each type of mast is described separately in this section.

9070-10-1

Principles of Operation

Front End (Mast) and Chassis

Carriages DESCRIPTION

PRINCIPLES OF OPERATION

The carriage is a part of the mast assembly and moves within the vertical channels of the inner weldment. Load rollers, attached to the carriage, travel in the channels of the inner weldment. Forks or other types of load handling equipment are attached to the carriage. A load backrest extension is attached to the carriage and adds support for a load that has multiple pieces. See Figure 9070-10-1, Page 9070-10-2.

Integral Sideshift Carriage The integral sideshift carriage lets the operator move the forks and load from side to side. This function makes it easier for the operator to align the forks with a load or align the load with a stack. The integral sideshift carriage is a complete inner carriage and outer frame assembly. The sideshift cylinder moves the outer frame assembly on the inner carriage. The fork spread control lever is the fourth manual lever. PUSH the lever FORWARD to move the forks apart. PULL the lever BACKWARD toward the operator to move the forks together. See Figure 9070-10-2, Page 9070-10-3.

1. STANDARD CARRIAGE 2. FORKS 3. LOAD BACKREST EXTENSION

Figure 9070-10-1. Carriage

9070-10-2

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Principles of Operation

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

INNER CARRIAGE OUTER FRAME SIDESHIFT CYLINDER UPPER BEARING LOWER BEARING LOWER HOOK CAPSCREW WASHER CLEVIS PIN HAIRPIN PIN

LUBE FITTING PIN CHAIN ANCHOR SNAP RING PIN COTTER PIN LOAD ROLLER SHIMS SPACER SNAP RING SPACER

Figure 9070-10-2. Integral Sideshift Carriage

Confidential/Proprietary - Do Not Copy or Duplicate

9070-10-3

Principles of Operation

Front End (Mast) and Chassis

Mast Mounts DESCRIPTION The lower crossmember of the outer mast has castings to mount the mast mounting stubshaft. The mounting stubshafts are installed in the castings and the mast is hung on the hangers of the drive axle housing. Capscrews secure the mounting stubshaft to the drive axle housing. See Figure 9070-10-3, Page 9070-10-4. The mast tilt cylinders are attached to the mast upper attachment castings using rod end fittings. Pins attach the rod end fittings to the casting and are secured with anchor pins and capscrews.

PRINCIPLES OF OPERATION The mast and attached forks can tilt forward and backward. Tilt cylinders are fastened between the lift truck frame and the outer mast upper attachment points. The operator uses the Mini Lever Module controls to extend or retract the tilt cylinders, changing the angle of the mast that pivots on the mounting stubshafts mounted on the drive axle housing.

1. 2. 3. 4. 5. 6.

RETAINER CAP CAPSCREWS SHIM BUSHING MAST MOUNT STUBSHAFT GREASE FITTING

Figure 9070-10-3. Mast Mounts

Two-Stage Full Free-Lift (FFL) Mast DESCRIPTION The Two-Stage Full Free-Lift Mast has an inner mast and an outer mast. See Figure 9070-10-4, Page 907010-5. It is called a full free-lift mast because the carriage can travel to the top of the inner mast without extending the inner mast. The full free-lift mast has the same load roller and strip bearing arrangements as the two-stage, limited free-lift mast. The two main lift cylinders are installed at the back of the outer mast. The base of each lift cylinder sits in a mount on the bottom crossmember of the outer mast. The

9070-10-4

top of each lift cylinder rod fits into a guide on the top crossmember of the inner mast. The free-lift cylinder is installed in the inner mast. Each of the lift cylinders has an internal lowering control valve. A single external lowering control valve is connected by tubing and hoses to all the lift cylinders. The free-lift chains connect at one end to the mid-crossmember of the inner mast. Two chain sheaves are installed on a crosshead on the rod of the free-lift cylinder. The chains go over sheaves on the crosshead and connect to the carriage.

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Principles of Operation

Legend for Figure 9070-10-4 NOTE: TYPICAL MAST ASSEMBLY IS SHOWN. 1. 2. 3. 4. 5. 6.

OUTER MAST INNER MAST FREE-LIFT CHAIN FREE-LIFT CYLINDER MAIN LIFT CYLINDER(S) LOWERING CONTROL VALVE (EXTERNAL)

PRINCIPLES OF OPERATION The three lift cylinders are connected by hoses and tubing as shown in Figure 9070-10-5, Page 9070-10-6. When the mast is extended, oil flows from the main control valve to the base of the main lift cylinders. The oil flows through the left-hand cylinder rod and through tubing to the base of the free-lift cylinder. The free-lift cylinder raises only the carriage. When the free-lift cylinder is fully extended, the two main lift cylinders extend the inner mast. The free-lift cylinder extends first because it has less weight to lift and a lower operating pressure. When the load is lowered, the main lift cylinders lower first because they have a greater load and a higher operating pressure. The oil flows from the main lift cylinders, through the lowering control valve to the hydraulic tank. Oil from the free-lift cylinder flows from the cylinder through tubing to the left-hand main lift cylinder rod. The oil flows from the left-hand main lift cylinder to the hydraulic tank. The free-lift cylinder must have 150 cc (5 oz) of oil above the piston. This oil provides a hydraulic cushion when the cylinder reaches the top of its stroke. An orifice system in the piston provides the hydraulic cushioning. When the cylinder is fully extended, any excess oil above the piston is forced through the check valve in the piston. The right-hand main lift cylinder has an orifice system in the bottom of the rod assembly. This system provides a hydraulic cushion when the cylinder reaches the bottom of its stroke.

Figure 9070-10-4. Two-Stage (FFL) Mast

Confidential/Proprietary - Do Not Copy or Duplicate

9070-10-5

Principles of Operation

1. 2. 3. 4. 5. 6.

Front End (Mast) and Chassis

RIGHT-HAND LIFT CYLINDER LEFT-HAND LIFT CYLINDER FREE-LIFT CYLINDER LOWERING CONTROL VALVE (INTERNAL) LOWERING CONTROL VALVE (EXTERNAL) TO/FROM MAIN CONTROL VALVE

7. 8. 9. 10. 11.

OUTER MAST INNER MAST FREE-LIFT CHAINS CARRIAGE CHAIN SHEAVES

Figure 9070-10-5. Operation of Two-Stage (FFL) Mast

Two-Stage Limited Free-Lift (LFL) Mast DESCRIPTION The Two-Stage Limited Free-Lift Mast has an outer mast, an inner mast, and two lift cylinders. See Figure 9070-10-6, Page 9070-10-6. At the base of the inner mast there is one load roller on each side. These load rollers travel along the flanges inside the outer mast channel. At the top of the outer mast there is also one load roller on each side. These load rollers travel along the flanges on the outside of the inner mast. The angle of the load rollers permits them to control the forces from the front, back, and sides of the mast. The strip bearings are installed at the top of the outer mast. The strip bearings can be adjusted by shims to help keep the correct clearance between the outer mast and the inner mast.

9070-10-6

The two single-stage lift cylinders are installed at the back of the outer mast. The base of each lift cylinder sits in a mount on the bottom crossmember of the outer mast. The top of each lift cylinder rod fits into a guide on the top crossmember of the inner mast. Operation of the lift cylinders extends and retracts the inner mast. See Figure 9070-10-7, Page 9070-10-8.

Legend for Figure 9070-10-6 NOTE: TYPICAL MAST ASSEMBLY IS SHOWN. 1. 2. 3. 4. 5.

OUTER MAST INNER MAST LIFT CHAIN(S) LIFT CYLINDER(S) LOWERING CONTROL VALVE (EXTERNAL)

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Principles of Operation

PRINCIPLES OF OPERATION Two lift chains move the carriage. The chains fasten to mounts that are near the top of the lift cylinder shells as shown in Figure 9070-10-7, Page 9070-10-8. The chains go up and over the chain sheaves and connect to the carriage. The chain sheaves are installed at the top crossmember of the inner mast. When the lift cylinders extend, the lift chains transfer the force from the lift cylinders to the carriage. The inner mast and carriage raise a small amount before the overall height of the mast increases. During lifting, the inner mast moves at the same speed as the lift cylinders. The carriage moves at twice the speed of the inner mast/lift cylinders. When the lift cylinders retract, the weight of the load, carriage, forks, load backrest extension and attachment, and inner mast pushes the oil from the lift cylinders. The oil flows from the lowering control valves in the lift cylinders, through the external lowering control valve to the hydraulic tank. Each cylinder has a check valve in the bottom of the rod assembly. When the cylinder is fully extended, any oil above the piston is forced through the check valve.

Figure 9070-10-6. Two-Stage (LFL) Mast

Confidential/Proprietary - Do Not Copy or Duplicate

9070-10-7

Principles of Operation

1. 2. 3. 4. 5.

Front End (Mast) and Chassis

LIFT CYLINDER LOWERING CONTROL VALVE (INTERNAL) LOWERING CONTROL VALVE (EXTERNAL) TO/FROM MAIN CONTROL VALVE OUTER MAST

6. 7. 8. 9.

INNER MAST LIFT CHAINS CARRIAGE CHAIN SHEAVES

Figure 9070-10-7. Operation of Two-Stage (LFL) Mast

Three-Stage Full Free-Lift (FFL) Mast DESCRIPTION The Three-Stage Full Free-Lift Mast has three masts: outer, intermediate, and inner. See Figure 9070-10-8, Page 9070-10-9. Two single-stage main lift cylinders and a free-lift cylinder are used to raise the carriage and extend the intermediate and inner mast. It is called a full free-lift mast because the carriage can travel to the top of the inner mast without extending the inner mast. The masts are telescopic and have the load roller and strip bearing arrangements similar to the two-stage mast.

9070-10-8

The load rollers are installed at the top of the outer and intermediate masts. Load rollers are also used at the bottom of the intermediate and inner masts. These load rollers travel along the flanges of the mast channels. The angle of the load rollers permits them to control the forces from the front, back, and sides of the mast. The strip bearings are installed at the top of the outer and intermediate masts and help keep the correct clearance between the masts. The load rollers and strip bearings are adjustable with shims.

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Principles of Operation

The two main lift cylinders are installed at the back of the outer mast. The base of each main lift cylinder sits in a mount on the bottom crossmember of the outer mast. The top of each main lift cylinder rod fits into a guide in the top crossmember of the intermediate mast. The free-lift cylinder is installed to the inner mast. Each lift cylinder has an internal lowering control valve. A single external lowering control valve is connected by tubing and hoses to all of the lift cylinders. The two main lift chains are connected to mounts that are welded near the top of the main lift cylinder shells. The lift chains go over sheaves at the top of the intermediate mast and fasten at the bottom of the inner mast. The free-lift chains connect at one end to the mid-crossmember of the inner mast. Two chain sheaves are installed on a crosshead on the cylinder rod of the free-lift cylinder. The chains go over sheaves on the crosshead and connect to the carriage.

PRINCIPLES OF OPERATION The three hydraulic cylinders are connected by hoses and tubing as shown in Figure 9070-10-9, Page 907010-10. When the mast is extended, oil from the main control valve flows to all cylinders at the same time. The free-lift cylinder extends first because it lifts the least amount of weight and has a lower operating pressure. The free-lift cylinder raises only the carriage. After the free-lift cylinder reaches the end of its stroke, the main lift cylinders begin to extend. As the main lift cylinders extend, the intermediate mast is raised by the main lift cylinders and the inner mast is raised by the main lift chains. During lowering, the main lift cylinders lower first because they have a greater load and higher operating pressure. After the main lift cylinders have retracted, the free-lift cylinder lowers. All oil from the lift cylinders flows through the lowering control valves to the hydraulic tank.

NOTE: TYPICAL MAST ASSEMBLY IS SHOWN. 1. 2. 3. 4. 5. 6. 7. 8.

OUTER MAST INTERMEDIATE MAST INNER MAST FREE-LIFT CHAIN MAIN LIFT CHAIN(S) FREE-LIFT CYLINDER MAIN LIFT CYLINDER(S) LOWERING CONTROL VALVE (EXTERNAL)

Figure 9070-10-8. Three-Stage (FFL) Mast

Confidential/Proprietary - Do Not Copy or Duplicate

9070-10-9

Principles of Operation

Front End (Mast) and Chassis

The free-lift cylinder must have 150 cc (5 oz) of oil above the piston. This oil provides a hydraulic cushion when the cylinder reaches the top of its stroke. An orifice system in the piston provides the hydraulic cushioning. When the cylinder is fully extended, any excess oil above the piston is forced through the check valve.

Each main lift cylinder has an orifice system and a check valve in the bottom of the rod assembly. When the cylinder is fully extended, any oil between the rod end and the gland is forced through the check valve. The orifice system provides a hydraulic cushion when the cylinder reaches the bottom of its stroke.

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11. 12.

LIFT CYLINDER FREE-LIFT CYLINDER LOWERING CONTROL VALVE (INTERNAL) LOWERING CONTROL VALVE (EXTERNAL) TO/FROM MAIN CONTROL VALVE OUTER MAST

INTERMEDIATE MAST INNER MAST MAIN LIFT CHAINS CARRIAGE FREE-LIFT CHAINS CHAIN SHEAVES

Figure 9070-10-9. Operation of Three-Stage (FFL) Mast

9070-10-10

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Principles of Operation

Four-Stage Full Free-Lift (FFL) Mast DESCRIPTION The Four-Stage Full Free-Lift (FFL) Mast has four masts: outer, first intermediate, second intermediate, and inner. See Figure 9070-10-10, Page 9070-10-11. Two single-stage main lift cylinders and a free-lift cylinder are used to raise the carriage and extend the intermediate and inner masts. It is called a full free-lift mast because the carriage can travel to the top of the inner mast without extending the inner mast. The masts are telescopic and have load roller and strip bearing arrangements similar to the three-stage mast. The load rollers are installed at the top of the outer, first, and second intermediate masts. Load rollers are also used at the bottom of the first and second intermediate masts and the inner mast. These load rollers travel along the flanges of the mast channels. The angle of the load rollers permits them to control the forces from the front, back, and sides of the mast. The strip bearings are installed at the top of the outer, first, and second intermediate masts and help keep the correct clearance between the masts. The load rollers and strip bearings are adjustable with shims. The two main lift cylinders are installed at the back of the outer mast. The base of each main lift cylinder sits in a mount on the bottom crossmember of the outer mast. The top of each main lift cylinder rod fits into a guide in the top crossmember of the first intermediate mast. The free-lift cylinder is installed to the inner mast. The free-lift and left-hand main lift cylinder has an internal lowering control valve. A single external lowering control valve is connected by tubing and hoses to all of the lift cylinders. The main lift chains connect to mounts that are near the top of the outer mast. The lift chains then go over sheaves at the top of the first intermediate mast and fasten at the bottom of the second intermediate mast. The intermediate lift chains connect to mounts that are near the top of the first intermediate mast. The lift chains then go over sheaves at the top of the second intermediate mast and fasten at the bottom of the inner mast. The free-lift chains connect at one end to the mid-crossmember of the inner mast. Two chain sheaves are installed on a crosshead on the cylinder rod of the freelift cylinder. The chains then go over sheaves on the crosshead and connect to the carriage.

Confidential/Proprietary - Do Not Copy or Duplicate

1. 2. 3. 4. 5. 6. 7. 8.

OUTER MAST FIRST INTERMEDIATE MAST SECOND INTERMEDIATE MAST INNER MAST FREE-LIFT CHAINS FREE-LIFT CYLINDER MAIN LIFT CYLINDERS LIFT CHAINS

Figure 9070-10-10. Four-Stage (FFL) Mast

9070-10-11

Principles of Operation

Front End (Mast) and Chassis

PRINCIPLES OF OPERATION The three hydraulic cylinders are connected by hoses and tubing as shown in Figure 9070-10-11, Page 907010-12. When the mast is extended, oil flows from the main control valve to the base of the main cylinders. The oil flows through the right-hand cylinder rod and through a tube and hose to the base of the free-lift cylinder. The free-lift cylinder extends first because it lifts the least amount of weight and has a lower operating pressure. The free-lift cylinder raises only the carriage. After the free-lift cylinder reaches the end of its stroke, the main lift cylinders begin to extend. As the main lift cylinders extend, the first intermediate mast is raised by the main lift cylinders. The second intermediate and inner masts are raised by the main and intermediate lift chains. See Figure 9070-10-12, Page 9070-10-12.

of the left-hand main cylinder. The orifice system in the bottom of the left-hand main cylinder provides a hydraulic cushion when the cylinder reaches the bottom of its stroke.

During lowering, the main lift cylinders lower first because they have a greater load and higher operating pressure. After the main lift cylinders have retracted, the free-lift cylinder lowers. All oil from the lift cylinders flows through the lowering control valves to the hydraulic tank. The free-lift cylinder must have 150 cc (5 oz) of oil above the piston. This oil provides a hydraulic cushion when the cylinder reaches the top of its stroke. An orifice system in the piston provides the hydraulic cushioning. When the cylinder is fully extended, any excess oil above the piston is forced through the check valve in the piston. The left-hand main cylinder has an orifice system and check valve in the bottom of the rod assembly. The top of the right-hand cylinder is connected to the left-hand main cylinder by a tube. When the main cylinders are fully extended, any oil between the rod end and the gland is forced through the check valve in the bottom

1. 2. 3. 4.

MAIN LIFT CYLINDER (LEFT-HAND) FREE-LIFT CYLINDER MAIN LIFT CYLINDER (RIGHT-HAND) SECONDARY LOWERING CONTROL VALVE (EXTERNAL) 5. PRIMARY LOWERING CONTROL VALVE (EXTERNAL) 6. TO/FROM MAIN CONTROL VALVE

Figure 9070-10-11. Hydraulic Schematic for Mast Cylinders

Legend for Figure 9070-10-12 A. LOWERED B. FREE-LIFT

C. FULLY RAISED

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11. 12.

MAIN LIFT CYLINDER OUTER MAST FIRST INTERMEDIATE MAST SECOND INTERMEDIATE MAST FREE-LIFT CYLINDER INNER MAST

9070-10-12

CARRIAGE FORK MAIN LIFT CHAINS INTERMEDIATE LIFT CHAINS FREE-LIFT CHAINS CHAIN SHEAVES

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Principles of Operation

Figure 9070-10-12. Operation of Four-Stage (FFL) Mast

Confidential/Proprietary - Do Not Copy or Duplicate

9070-10-13

Principles of Operation

Front End (Mast) and Chassis

Cylinder Cushion During Lifting Sequence DESCRIPTION The hydraulic action at the end of the free-lift stroke provides a cushion effect for the free-lift cylinder and a smooth transition between the free-lift phase and the mast extension phase (main cylinder extension). All masts with a free-lift cylinder in this section use this design.

PRINCIPLES OF OPERATION There is hydraulic oil on the rod side of the piston of the free-lift cylinder. When the cylinder rod extends to the last 25 mm (1.0 in.) of its stroke, the gland at the top of the cylinder closes the larger hole. During this part of the cylinder stroke, the hydraulic oil must flow through the orifice to the air cavity. This action increases the hydraulic pressure so the main lift cylinders begin to extend. See Figure 9070-10-13, Page 9070-10-14. 1. 2. 3. 4.

CYLINDER ROD CYLINDER SHELL LARGE ORIFICE SMALL ORIFICE

5. PISTON 6. INTERNAL CHECK VALVE 7. AIR CAVITY

Figure 9070-10-13. Free-Lift Cylinder Operation

9070-10-14

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Principles of Operation

Cylinder Cushion During Lowering Sequence DESCRIPTION This cushion effect prevents a sudden stop of the main cylinders, which causes smoother operation during lowering. All masts in this section, except Two-Stage Limited Free-Lift Masts, use this design in the main lift cylinders.

PRINCIPLES OF OPERATION NOTE: An internal check valve is not used on the TwoStage Full Free-Lift Mast. When the main lift cylinders retract, the hydraulic oil flows out of the cylinder through the hydraulic port until the cushion ring moves past the hydraulic port. During the last 20 mm (0.79 in.) of the retraction stroke, the hydraulic oil must flow through the orifice. See Figure 9070-10-14, Page 9070-10-15. This action causes the cylinder rod to move much more slowly at the end of the retraction stroke. NOTE: LEFT-HAND LIFT CYLINDER SHOWN. 1. 2. 3. 4. 5. 6. 7. 8.

CYLINDER ROD CYLINDER SHELL PISTON INTERNAL CHECK VALVE HYDRAULIC PORT ORIFICE PISTON SEAL CUSHION RING

Figure 9070-10-14. Main Lift Cylinder Operation

Tilt and Sideshift Cylinders DESCRIPTION

the cylinder rod into the tilt cylinder. The oil behind the piston returns to the hydraulic tank.

Tilt Cylinder The tilt cylinders are used to move the mast forward and backward. To extend the cylinder rod (tilt forward), oil enters the tilt cylinder port behind the piston. The oil pressure pushes the cylinder rod out of the cylinder. Oil in front of the piston returns to the hydraulic tank. To retract the cylinder rod (tilt backward), the oil enters the port in front of the piston. The oil pressure pushes

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Sideshift Cylinder The sideshift cylinder is removable for service. It is a double-acting, non-differential, piston-type cylinder, which allows the sideshift to attain the same speed moving either left or right. The cylinder also has flow restricting orifices in the ports.

9070-10-15

Principles of Operation

Front End (Mast) and Chassis

Lowering Control Valves DESCRIPTION The lowering control system permits easy entry of hydraulic oil into the cylinder during lifting, but restricts flow when rod is retracted to limit the speed at which a load maybe lowered. A pressure-compensated lowering control valve regulates the lowering speed to a more uniform value over the entire capacity range. The two types of lowering control valves used are designated as primary and secondary.

PRINCIPLES OF OPERATION The Primary lowering control valve limits the lowering speed of the mast to a maximum controlled rate over the full range of loads. This valve is mounted externally on the middle crossmember of the outer mast. This type of lowering control valve uses these basic parts: (1) valve body, (2) spring, (3) special washer, (5) orifice sleeve, (6) plunger, and (7) main sleeve. The orifice sleeve position is controlled completely by oil flow. The plunger position is controlled by oil pressure and spring tension. During lifting, oil entering the lift cylinder goes through the center of the main sleeve to the large holes. The oil flow through the plunger and bore moves the orifice sleeve to the end of the plunger. The flange of the orifice sleeve is then aligned with the large part of the bore in the body. This alignment lets the oil flow past the orifice sleeve to the cylinder. During lowering, oil from the lift cylinder moves the orifice sleeve. The orifice sleeve moves away from the larger inner diameter area of the bore in the valve body. This movement

9070-10-16

makes a restriction to the oil flow. As the pressure increases, the plunger begins to move against the spring. The movement begins to close the openings of the large holes in the main sleeve. Additional pressure will push the plunger against the main sleeve to close the large holes completely. All the oil must then go through the small holes to the center of the main sleeve. This restriction permits the piston rod to lower only at a maximum controlled speed. See Figure 9070-10-15, Page 9070-10-17. The Secondary lowering control valve is installed in each cylinder and is used only for emergency lowering. In the event an hydraulic line ruptures, this valve will lower the mast at a controlled rate. This type of lowering control valve uses these parts: (1) special fitting for the valve body, (2) spring, (3) special washer, and (4) cylinder. There is a variation in the shapes of the special washer. The volume of the hydraulic oil flowing through the inlet port controls the shape of the special washer. When the piston rod is lowered, the oil flow pushes against the special washer and spring. When the oil flow reaches the limit, the special washer is moved against the special fitting. The oil then flows only through the hole in the center of the special washer. This restriction permits the piston rod to lower only at a maximum controlled speed. See Figure 9070-10-16, Page 9070-10-17.

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Front End (Mast) and Chassis

Principles of Operation

A. LIFTING B. LOWERING

C. FREE FLOW D. RESTRICTED FLOW

1. 2. 3. 4.

5. ORIFICE SLEEVE 6. PLUNGER 7. MAIN SLEEVE

SPECIAL FITTING OR VALVE BODY SPRING SPECIAL WASHER NOT SHOWN, CYLINDER (SECONDARY ONLY)

Figure 9070-10-15. Primary Lowering Control Valve

A. LIFTING B. LOWERING

C. FREE FLOW D. RESTRICTED FLOW

1. SPECIAL FITTING OR VALVE BODY 2. SPRING

3. SPECIAL WASHER 4. CYLINDER (SECONDARY ONLY)

Figure 9070-10-16. Secondary Lowering Control Valve

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9070-10-17

Principles of Operation

Front End (Mast) and Chassis

Chassis DESCRIPTION The chassis consists of the following components as shown in Figure 9070-10-17, Page 9070-10-18. The frame is one weldment which includes the hydraulic tank which can be accessed with removal of the counterbalance. The counterweight is attached to the frame and varies in weight depending on truck capacity.

Overhead Guard

a tip over. A high visibility design allows for an unobstructed view while maintaining structural integrity. Removal of the battery is simplified by the slot in the overhead guard. This provides access to the battery with an overhead lifting device without removing the overhead guard. See Figure 9070-10-17, Page 9070-10-18.

Counterweight

The overhead guard is designed to provide protection to the operator from falling objects and in the event of

A one-piece, cast iron counterweight is used to offset the weight of the load and attached to the rear suspension of the lift truck. See Figure 9070-10-17, Page 9070-10-18.

1. OVERHEAD GUARD 2. COUNTERWEIGHT 3. STEER AXLE MOUNTS

4. STEER AXLE AND WHEEL 5. DRIVE AXLE AND WHEEL 6. DRIVE AXLE MOUNTS

Figure 9070-10-17. Chassis Component Location

9070-10-18

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Front End (Mast) and Chassis

Observed Symptoms

Group 30

Observed Symptoms Abnormal Channel Wear POSSIBLE CAUSE A. MAST DAMAGED B. MAST CHANNELS LACK LUBRICATION C. CHAINS ARE LOOSE OR NOT EQUAL D. MAST IS SHIMMED INCORRECTLY E. LOAD ROLLERS ARE NOT ROTATING FREELY WITHIN CHANNEL F. DAMAGED OR WORN LOAD ROLLERS OR STRIP BEARINGS G. LIFT CYLINDER BINDING CAUSE A - MAST DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast for damage. Is the mast in good condition? YES: Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - MAST CHANNELS LACK LUBRICATION PROCEDURE OR ACTION: Inspect grease on mast channels.

Is a thin coat of grease spread evenly on channels? YES: Go to Cause C. NO: Apply grease to mast sliding surfaces. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. CAUSE C - CHAINS ARE LOOSE OR NOT EQUAL PROCEDURE OR ACTION: Inspect lift chains. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are chains adjusted correctly and in good condition? YES: Go to Cause D. NO: Adjust or repair chains.

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9070-30-1

Observed Symptoms

Front End (Mast) and Chassis

Abnormal Channel Wear (Cont) CAUSE D - MAST IS SHIMMED INCORRECTLY PROCEDURE OR ACTION: NOTE: A mast that is shimmed too loose will cause the rollers to ride up on the flange edge and produce a flaring wear pattern. Inspect mast and carriage shimming. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Is mast shimmed correctly? YES: Go to Cause E. NO: Adjust or repair as required. CAUSE E - LOAD ROLLERS ARE NOT ROTATING FREELY WITHIN CHANNEL PROCEDURE OR ACTION: Inspect mast channel rollers. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Do the rollers rotate freely? YES: Go to Cause F. NO: Replace load rollers. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE F - DAMAGED OR WORN LOAD ROLLERS OR STRIP BEARINGS PROCEDURE OR ACTION: Inspect load rollers and strip bearings. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are the load rollers and strip bearings in good condition? YES: Go to Cause G. NO: Adjust, repair, or replace load rollers and strip bearings as required. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE G - LIFT CYLINDER BINDING PROCEDURE OR ACTION: 1. Remove and repair cylinder. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. 2. Manually extend cylinder exterior.

Does cylinder extend freely? YES: Mast is loose. See Observed Symptoms, Mast is Loose, Page 9070-30-21. NO: Service or replace cylinder. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9070-30-2

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Front End (Mast) and Chassis

Observed Symptoms

Abnormal Hose Wear POSSIBLE CAUSE A. B. C. D. E.

MAST DAMAGED HOSES RUBBING ON COMPONENTS IMPROPER HOSE ROUTING HYDRAULIC RELIEF PRESSURE SET TOO HIGH TOO HIGH/LOW HYDRAULIC OIL TEMPERATURE

CAUSE A - MAST DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast for damage. Is the mast in good condition? YES: Go to Cause D. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - HOSES RUBBING ON COMPONENTS PROCEDURE OR ACTION: Inspect hoses for wear and tension.

Is hose tension correct? YES: Go to Cause C. NO: Adjust or replace hoses or sheaves as required. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE C - IMPROPER HOSE ROUTING PROCEDURE OR ACTION: Inspect and adjust lift cylinder hoses. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are the hoses in good condition and adjusted correctly? YES: Go to Cause D. NO: Adjust or replace hoses as required. CAUSE D - HYDRAULIC RELIEF PRESSURE SET TOO HIGH PROCEDURE OR ACTION: Test hydraulic relief pressure. See Main System Relief Test and Adjustment. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439.

Is pressure within test specifications? YES: Go to Cause E. NO: Adjust pressure to test specifications. See Tests and Adjustments-Gear Pump, Primary Relief Valve Test and Adjustment, Page 9050-43-1.

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9070-30-3

Observed Symptoms

Front End (Mast) and Chassis

Abnormal Hose Wear (Cont) CAUSE E - TOO HIGH/LOW HYDRAULIC OIL TEMPERATURE NOTE: See Operating Manual. PROCEDURE OR ACTION: Insure that hydraulic oil temperature is within the recommended operating range for the lift truck. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9070-30-4

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Front End (Mast) and Chassis

Observed Symptoms

Abnormal Mast Noise POSSIBLE CAUSE A. MAST DAMAGED B. LOOSE OR MISSING MAST MOUNTING HARDWARE C. LOOSE FORK FIT TO CARRIAGE D. DAMAGED CHAIN SHEAVES E. AIR IN HYDRAULIC SYSTEM F. MAST CHANNELS LACK LUBRICATION G. MAST MOUNTING BUSHINGS LACK LUBRICATION OR DAMAGED H. MAST TILT BUSHINGS LACK LUBRICATION OR DAMAGED I. CHAINS LOOSE OR NOT EQUAL J. WORN LOAD ROLLERS OR STRIP BEARINGS K. MAST CHANNELS ARE WORN L. NOISY LIFT CYLINDER SEALS CAUSE A - MAST DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast for damage. Is the mast in good condition? YES: Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - LOOSE OR MISSING MAST MOUNTING HARDWARE PROCEDURE OR ACTION: Inspect mast mounting hardware.

Is hardware in good condition and torqued correctly? YES: Go to Cause C. NO: Replace mast mounting hardware. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE C - LOOSE FORK FIT TO CARRIAGE PROCEDURE OR ACTION: Inspect carriage bar and fork hooks for wear.

Do forks fit correctly and in good condition? YES: Go Cause D. NO: Replace carriage or forks if worn. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

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9070-30-5

Observed Symptoms

Front End (Mast) and Chassis

Abnormal Mast Noise (Cont) CAUSE D - DAMAGED CHAIN SHEAVES PROCEDURE OR ACTION: Inspect chain sheaves.

Do chain sheaves rotate freely without noise? YES: Go to Cause E. NO: Replace chain sheaves. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE E - AIR IN HYDRAULIC SYSTEM PROCEDURE OR ACTION: Inspect oil condition and level in hydraulic tank. Is the hydraulic oil level in the operating range and in good condition? YES: Cause F. NO: If oil level is low, add oil. If hydraulic oil is aerated, locate source of suction side leak and repair. CAUSE F - MAST CHANNELS LACK LUBRICATION PROCEDURE OR ACTION: Inspect grease on mast channels.

Is a thin coat of grease spread evenly on channels? YES: Go to Cause G. NO: Apply grease to mast sliding surfaces. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. CAUSE G - MAST MOUNTING BUSHINGS LACK LUBRICATION OR DAMAGED PROCEDURE OR ACTION: Inspect mast bushings. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are the mast bushings greased and in good condition? YES: Go Cause H. NO: Lubricate mast bushings. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9070-30-6

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Front End (Mast) and Chassis

Observed Symptoms

Abnormal Mast Noise (Cont) CAUSE H - MAST TILT BUSHINGS LACK LUBRICATION OR DAMAGED PROCEDURE OR ACTION: Inspect mast tilt bushings. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are the mast tilt bushings greased and in good condition? YES: Go to Cause I. NO: Lubricate mast tilt bushings. Replace as required. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. CAUSE I - CHAINS LOOSE OR NOT EQUAL PROCEDURE OR ACTION: Inspect chains. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are chains adjusted correctly and in good condition? YES: Go to Cause J. NO: Adjust or repair chains. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE J - WORN LOAD ROLLERS OR STRIP BEARINGS PROCEDURE OR ACTION: Inspect load rollers and strip bearings. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are the load rollers and strip bearings in good condition? YES: Go to Cause K. NO: Adjust, repair, or replace load rollers and strip bearings as required. CAUSE K - MAST CHANNELS ARE WORN PROCEDURE OR ACTION: Inspect mast channels for wear or damage. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are the mast channels in good condition? YES: Go to Cause L. NO: Repair or replace worn mast components.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

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9070-30-7

Observed Symptoms

Front End (Mast) and Chassis

Abnormal Mast Noise (Cont) CAUSE L - NOISY LIFT CYLINDER SEALS NOTE: Confirm that correct hydraulic oil is being used, see Operating Manual. PROCEDURE OR ACTION: On 2-Stage LFL, 3-Stage FFL, and 4-Stage FFL, apply thin film of hydraulic oil on cylinder rods.

Does the noise stop? YES: Remove gland and add hydraulic oil. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. NO: Install new cylinder seal. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. END SYMPTOM

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9070-30-8

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Front End (Mast) and Chassis

Observed Symptoms

Body Panels Making Noise POSSIBLE CAUSE A. ATTACHING HARDWARE IS LOOSE B. FAILED LATCHES OR HINGES CAUSE A - ATTACHING HARDWARE IS LOOSE PROCEDURE OR ACTION: Visually inspect mounting points for damage and loose or missing hardware. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442.

Are body panels and attaching hardware in good condition? YES: Inspect and repair hinges and latches. Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck, see Frame 100 YRM 1329 or Frame 100 YRM 1342. CAUSE B - FAILED LATCHES OR HINGES PROCEDURE OR ACTION: Inspect hinges and latches for correct operation.

Are the hinges and latches in good condition? YES: Operating lift truck too fast on rough surface, reduce speed. NO: Adjust or repair latches and hinges as required. Depending on your lift truck, see Frame 100 YRM 1329 or Frame 100 YRM 1342. END SYMPTOM

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9070-30-9

Observed Symptoms

Front End (Mast) and Chassis

External Leakage From Free-Lift or Main Lift Cylinders POSSIBLE CAUSE A. B. C. D.

MAST DAMAGED CYLINDER HOSES OR FITTINGS LOOSE OR DAMAGED CYLINDER SEAL DAMAGE OR INCORRECT INSTALLATION CYLINDER ROD DAMAGE

CAUSE A - MAST DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast for damage. Is the mast in good condition? YES: Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - CYLINDER HOSES OR FITTINGS LOOSE OR DAMAGED PROCEDURE OR ACTION: Inspect hoses and fittings for damage and proper torque.

Are hose and fittings in good condition and torqued correctly? YES: Go to Cause C. NO: Adjust or replace hoses or fittings as required. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE C - CYLINDER SEAL DAMAGE OR INCORRECT INSTALLATION PROCEDURE OR ACTION: Inspect lift cylinder seals.

Are the seals in good condition and installed correctly? YES: Go to Cause D. NO: Adjust or replace seals as required. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. CAUSE D - CYLINDER ROD DAMAGE PROCEDURE OR ACTION: Inspect cylinder rod for damage. Is cylinder rod in good condition? YES: Problem solved. Resume operations. NO: Replace cylinder rod or cylinder. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9070-30-10

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Observed Symptoms

FFL Mast Banging During Phasing POSSIBLE CAUSE A. B. C. D. E.

MAST DAMAGED FREE-LIFT CYLINDER TOP STROKE CUSHIONING NOT OPERATING MAIN CYLINDER CUSHION NOT OPERATING WHEN FULLY LOWERED CARRIAGE BINDING IN INNER MAST CARRIAGE CONTACTS STOP AT TOP OF INNER MAST

CAUSE A - MAST DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast for damage. Is the mast in good condition? YES: Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - FREE-LIFT CYLINDER TOP STROKE CUSHIONING NOT OPERATING PROCEDURE OR ACTION: Confirm that cushioning oil is on top side of cylinder piston. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382.

Is cushioning oil level correct? YES: Go to Cause C. NO: Add oil. CAUSE C - MAIN CYLINDER CUSHION NOT OPERATING WHEN FULLY LOWERED PROCEDURE OR ACTION: Operate lift lower and note speed as cylinder reached end of stroke.

Does cylinder speed slow during final 25 mm (1.0 in.) of cylinder stroke? YES: Go to Cause D. NO: Repair or replace cylinder. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. CAUSE D - CARRIAGE BINDING IN INNER MAST PROCEDURE OR ACTION: Observe carriage travels to the end of free lift cylinder stroke. Does the carriage go to end of free lift cylinder stroke? YES: Go to Cause E. NO: Shim carriage rollers. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

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9070-30-11

Observed Symptoms

Front End (Mast) and Chassis

FFL Mast Banging During Phasing (Cont) CAUSE E - CARRIAGE CONTACTS STOP AT TOP OF INNER MAST PROCEDURE OR ACTION: Inspect free lift chains. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Can lift chains be adjusted? YES: Adjust chains. NO: Replace free lift chains. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9070-30-12

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Observed Symptoms

High Tire Wear - Drive Axle POSSIBLE CAUSE A. RUNNING OVER OIL/SOLVENTS AND DEBRIS B. LOW PNEUMATIC TIRE INFLATION C. HIGH PNEUMATIC TIRE INFLATION D. EXCESSIVE SPEED ON TURNS AND STOPS E. EXCESSIVE LOADS F. FAILED WHEEL BEARINGS CAUSE A - RUNNING OVER OIL/SOLVENTS AND DEBRIS PROCEDURE OR ACTION: Visually inspect work area for contaminates and debris. CAUSE B - LOW PNEUMATIC TIRE INFLATION PROCEDURE OR ACTION: Check and adjust tire inflation. See Operating Manual. CAUSE C - HIGH PNEUMATIC TIRE INFLATION PROCEDURE OR ACTION: Check and adjust tire inflation. See Operating Manual. CAUSE D - EXCESSIVE SPEED ON TURNS AND STOPS PROCEDURE OR ACTION: Reduce speed and spinning of wheels. CAUSE E - EXCESSIVE LOADS NOTE: See Serial Number plate or Operating Manual for lift capacity. PROCEDURE OR ACTION: Check load weight and compare to truck capacity rating. CAUSE F - FAILED WHEEL BEARINGS PROCEDURE OR ACTION: Inspect wheel bearings.

Are bearings in good condition? YES: Tires are defective. See tire manufacture for warranty. NO: Replace wheel bearing. Depending on your lift truck, see Transaxle 1300 YRM 1330, Transaxle 1300 YRM 1370, or Drive Axle, Speed Reducer, and Differential 1300 YRM 1366. END SYMPTOM

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9070-30-13

Observed Symptoms

Front End (Mast) and Chassis

High Tire Wear - Steer Axle POSSIBLE CAUSE A. RUNNING OVER OIL/SOLVENTS AND DEBRIS B. EXCESSIVE SPEED ON TURNS AND STOPS C. TURNING WITH MACHINE STOPPED OR NO LOAD ON FORKS D. LOW PNEUMATIC TIRE INFLATION E. HIGH PNEUMATIC TIRE INFLATION F. FAILED WHEEL BEARINGS G. LOOSE TIE RODS CAUSE A - RUNNING OVER OIL/SOLVENTS AND DEBRIS PROCEDURE OR ACTION: Visually inspect work area for contaminates and debris. CAUSE B - EXCESSIVE SPEED ON TURNS AND STOPS PROCEDURE OR ACTION: Reduce speed and spinning of wheels. CAUSE C - TURNING WITH MACHINE STOPPED OR NO LOAD ON FORKS PROCEDURE OR ACTION: NOTE: Steering without load on forks puts the highest load on steer axle because of counterweight. Avoid steering wheels when not moving to reduce tire wear. Steer while moving whenever possible. CAUSE D - LOW PNEUMATIC TIRE INFLATION PROCEDURE OR ACTION: Check and adjust tire inflation. See Operating Manual. CAUSE E - HIGH PNEUMATIC TIRE INFLATION PROCEDURE OR ACTION: Check and adjust tire inflation. See Operating Manual. CAUSE F - FAILED WHEEL BEARINGS PROCEDURE OR ACTION: Inspect wheel bearings.

Are bearings in good condition? YES: Tires are defective. See tire manufacturer for warranty. NO: Replace wheel bearing. Depending on your lift truck, see Transaxle 1300 YRM 1330 or Steering Axle 1600 YRM 1360.

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9070-30-14

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Front End (Mast) and Chassis

Observed Symptoms

High Tire Wear - Steer Axle (Cont) CAUSE G - LOOSE TIE RODS PROCEDURE OR ACTION: Inspect joint where tie rods are attached to pinion assembly.

Is the tie rod tight in bore? YES: See Wheels Appear Tipped or Misaligned. NO: Replace tie rod. Depending on your lift truck, see Transaxle 1300 YRM 1330 or Steering Axle 1600 YRM 1360. END SYMPTOM

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9070-30-15

Observed Symptoms

Front End (Mast) and Chassis

Hoses Not Tracking Correctly POSSIBLE CAUSE A. B. C. D.

MAST DAMAGED IMPROPER HOSE TENSION IMPROPER HOSE ROUTING HOSES WORN

CAUSE A - MAST DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast for damage. Is the mast in good condition? YES: Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - IMPROPER HOSE TENSION PROCEDURE OR ACTION: Check hose tension. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Is hose tension correct? YES: Go to Cause C. NO: Adjust hose tension. CAUSE C - IMPROPER HOSE ROUTING PROCEDURE OR ACTION: Inspect lift cylinder hoses. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are the hoses in good condition and adjusted correctly? YES: Go to Cause D. NO: Adjust or replace hoses as required. CAUSE D - HOSES WORN PROCEDURE OR ACTION: Inspect hoses for uneven or excessive wear. Are hoses wearing evenly? YES: Locate cause of hoses wear. See Observed Symptoms, Abnormal Hose Wear, Page 9070-30-3. NO: Adjust or replace hoses as required. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. END SYMPTOM

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9070-30-16

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Front End (Mast) and Chassis

Observed Symptoms

Integral Sideshift Moving Too Fast POSSIBLE CAUSE A. ORIFICES IN SIDESHIFT CYLINDER MISSING OR INSTALLED BACKWARD B. ELECTRO-HYDRAULIC CONTROL VALVE OUT OF CALIBRATION CAUSE A - ORIFICES IN SIDESHIFT CYLINDER MISSING OR INSTALLED BACKWARD PROCEDURE OR ACTION:

CAUTION Cylinder orifices are made from soft metal and can be easily damaged. Do not alter cylinder orifice size while cleaning. Inspect cylinder port orifices. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382.

Are the orifices clean and installed correctly? YES: Reduce engine speed or control lever speed of movement to slow function. See Parts Manual to see if smaller size orifices are available. NO: Adjust or install orifices. CAUSE B - ELECTRO-HYDRAULIC CONTROL VALVE OUT OF CALIBRATION PROCEDURE OR ACTION: Check electro-hydraulic control valve calibration. Install Service Tool.

Is valve calibration correct? YES: Calibrate valve to operator’s preference or reduce engine speed to slow function. NO: Resume operation. END SYMPTOM

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9070-30-17

Observed Symptoms

Front End (Mast) and Chassis

Integral Sideshift Not Moving or Slow POSSIBLE CAUSE A. NO OIL OR NOT ENOUGH OIL IN HYDRAULIC TANK B. LINKAGE TO CONTROL VALVE DISCONNECTED OR DAMAGED (MANUAL CONTROL VALVE) C. WIRING CONNECTOR LOOSE OR DISCONNECTED ON CONTROL VALVE (E-VALVE) D. INTEGRAL SIDESHIFT CARRIAGE DAMAGED E. CLAMP BLOCKS TOO TIGHT F. CONTAMINATION OR LACK OF LUBRICATION IS BINDING BEARINGS G. DAMAGED CARRIAGE BEARINGS H. HOSES NOT INSTALLED CORRECTLY I. NO OIL FLOW TO SIDESHIFT CYLINDER J. INCORRECT HYDRAULIC RELIEF PRESSURE SETTING K. INSUFFICIENT OIL FLOW TO CYLINDER L. DEFECTIVE SIDESHIFT CYLINDER CAUSE A - NO OIL OR NOT ENOUGH OIL IN HYDRAULIC TANK NOTE: See Operating Manual. PROCEDURE OR ACTION: Check hydraulic tank oil level and adjust as required. CAUSE B - LINKAGE TO CONTROL VALVE DISCONNECTED OR DAMAGED (MANUAL CONTROL VALVE) PROCEDURE OR ACTION: Inspect valve linkage.

Is the linkage moving the valve spool full travel? YES: Go to Cause D. NO: Repair or adjust linkage. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439. CAUSE C - WIRING CONNECTOR LOOSE OR DISCONNECTED ON CONTROL VALVE (E-VALVE) PROCEDURE OR ACTION: Inspect wiring connections at valve and MLM controller. Are the connectors in good condition and installed correctly? YES: Go to Cause D. NO: Repair or replace wiring connectors. See Wire Harness Repair 2200 YRM 1128. CAUSE D - INTEGRAL SIDESHIFT CARRIAGE DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect carriage for damage.

Is the carriage in good condition? YES: Go to Cause E. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

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9070-30-18

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Observed Symptoms

Integral Sideshift Not Moving or Slow (Cont) CAUSE E - CLAMP BLOCKS TOO TIGHT PROCEDURE OR ACTION: Adjust clamp blocks. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE F - CONTAMINATION OR LACK OF LUBRICATION IS BINDING BEARINGS PROCEDURE OR ACTION: Inspect bearings. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are bearings worn or need lubrication? YES: Lubricate or replace bearings. NO: Go to Cause G. CAUSE G - DAMAGED CARRIAGE BEARINGS PROCEDURE OR ACTION: Disassemble outer frame. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are bearings in good condition? YES: Go to Cause H. NO: Service or replace bearings. CAUSE H - HOSES NOT INSTALLED CORRECTLY NOTE: Check maintenance records to determine last repairs done to truck. PROCEDURE OR ACTION: Inspect hose routing and connections. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are hoses adjusted correctly and in good condition? YES: Go to Cause I. NO: Adjust or repair hoses. CAUSE I - NO OIL FLOW TO SIDESHIFT CYLINDER PROCEDURE OR ACTION: 1. Remove pin from rod end of cylinder. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. 2. Slowly operate sideshift cylinder control and observe cylinder rod movement.

Does the cylinder rod move when controls are activated? YES: Install cylinder rod pin. Go to Cause J. NO: Determine if problem is in cylinder or control valve. Go to Cause K.

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9070-30-19

Observed Symptoms

Front End (Mast) and Chassis

Integral Sideshift Not Moving or Slow (Cont) CAUSE J - INCORRECT HYDRAULIC RELIEF PRESSURE SETTING PROCEDURE OR ACTION: Test secondary relief valve pressure. Depending on your lift truck see, Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 orMain Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1439.

Is the secondary relief pressure at specifications? YES: Go to Cause K. NO: Adjust or replace secondary relief valve. CAUSE K - INSUFFICIENT OIL FLOW TO CYLINDER PROCEDURE OR ACTION: 1. Perform Cycle Times. Depending on your lift truck, see Capacities and Specifications 8000 YRM 1340, Capacities And Specifications 8000 YRM 1374, Capacities and Specifications 8000 YRM 1376, Capacities And Specifications 8000 YRM 1375, or Capacities and Specifications 8000 YRM 1443.

Is the sideshift the only hydraulic function that is slow. YES: Go to Step 2. NO: Problem is in hydraulic pump circuit. See Tests and Adjustments-Gear Pump, Hydraulic Pump Flow Test, Page 9050-43-9. 2. Check electro-hydraulic control valve calibration. Install Service Tool. Is valve calibration correct? YES: Go to Cause L. NO: Calibrate valve to operator’s preference. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. CAUSE L - DEFECTIVE SIDESHIFT CYLINDER PROCEDURE OR ACTION:

CAUTION Cylinder orifices are made from soft metal and can be easily damaged. Do not alter cylinder orifice size while cleaning. Inspect and clean cylinder port orifices. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382.

Are the orifices clean and installed correctly? YES: Remove and repair cylinder. NO: Adjust or replace orifices. END SYMPTOM

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9070-30-20

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Front End (Mast) and Chassis

Observed Symptoms

Mast is Loose POSSIBLE CAUSE A. B. C. D. E.

MAST DAMAGED LOOSE OR MISSING MAST MOUNTING HARDWARE MAST NOT SHIMMED CORRECTLY DAMAGED LOAD ROLLERS OR WORN STRIP BEARINGS CHANNELS WORN

CAUSE A - MAST DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast for damage. Is the mast in good condition? YES: Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - LOOSE OR MISSING MAST MOUNTING HARDWARE PROCEDURE OR ACTION: Inspect mast mounting hardware.

Is mounting hardware in good condition and torqued correctly? YES: Go to Cause C. NO: Replace mast mounting hardware. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE C - MAST NOT SHIMMED CORRECTLY PROCEDURE OR ACTION: Inspect mast shimming. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Is the mast shimmed correctly? YES: Go to Cause D. NO: Shim or adjust as required. CAUSE D - DAMAGED LOAD ROLLERS OR WORN STRIP BEARINGS PROCEDURE OR ACTION: Inspect load rollers and strip bearings. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are the load rollers and strip bearings in good condition? YES: Go to Cause E. NO: Adjust, repair, or replace load rollers and strip bearings as required. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

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9070-30-21

Observed Symptoms

Front End (Mast) and Chassis

Mast is Loose (Cont) CAUSE E - CHANNELS WORN PROCEDURE OR ACTION: Repair or replace mast components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. END SYMPTOM

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9070-30-22

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Front End (Mast) and Chassis

Observed Symptoms

Mast Lift Chains Are Loose POSSIBLE CAUSE A. MAST DAMAGED B. DAMAGED CHAIN SHEAVES C. INCORRECT CHAIN ADJUSTMENT CAUSE A - MAST DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast for damage. Is the mast in good condition? YES: Go to Cause C. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - DAMAGED CHAIN SHEAVES PROCEDURE OR ACTION: Inspect chain sheaves.

Do chain sheaves rotate freely without noise? YES: Go to Cause C. NO: Replace chain sheaves. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE C - INCORRECT CHAIN ADJUSTMENT PROCEDURE OR ACTION: Inspect lift chains. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are the chains in good condition and adjusted correctly? YES: See Observed Symptoms, Mast or Carriage Binding, Page 9070-30-24. NO: Adjust or replace chain. END SYMPTOM

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9070-30-23

Observed Symptoms

Front End (Mast) and Chassis

Mast or Carriage Binding POSSIBLE CAUSE A. MAST OR CARRIAGE DAMAGED B. MAST CHANNELS LACK LUBRICATION C. MAST NOT SHIMMED CORRECTLY D. CHAINS ARE LOOSE OR NOT EQUAL E. CONTAMINATION IN CHANNELS IS BINDING LOAD ROLLERS F. DAMAGED OR WORN LOAD ROLLERS OR STRIP BEARINGS G. LIFT CYLINDER BINDING CAUSE A - MAST OR CARRIAGE DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast and carriage for damage. Are components in good condition? YES: Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - MAST CHANNELS LACK LUBRICATION PROCEDURE OR ACTION: Inspect grease on mast channels.

Is a thin coat of grease spread evenly on channels? YES: Go to Cause C. NO: Apply grease to mast sliding surfaces. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442. CAUSE C - MAST NOT SHIMMED CORRECTLY PROCEDURE OR ACTION: Inspect mast shimming. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Is the mast shimmed correctly? YES: Go to Cause E. NO: Shim or adjust as required.

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9070-30-24

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Observed Symptoms

Mast or Carriage Binding (Cont) CAUSE D - CHAINS ARE LOOSE OR NOT EQUAL PROCEDURE OR ACTION: Inspect lift chains. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are chains adjusted correctly and in good condition? YES: Go to Cause E. NO: Adjust or repair chains. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE E - CONTAMINATION IN CHANNELS IS BINDING LOAD ROLLERS PROCEDURE OR ACTION: Inspect mast channels. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are the load rollers and strip bearings in good condition? YES: Go to Cause G. NO: Adjust, repair, or replace load rollers and strip bearings as required. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE G - LIFT CYLINDER BINDING PROCEDURE OR ACTION: 1. Remove cylinder. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. 2. Manually extend cylinder exterior.

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9070-30-25

Observed Symptoms

Front End (Mast) and Chassis

Mast/Carriage Bounces or is Spongy POSSIBLE CAUSE A. B. C. D.

MAST DAMAGED AIR IN HYDRAULIC SYSTEM TRAPPED AIR IN LIFT CYLINDER(S) TWO-STAGE FFL MAST MAIN CYLINDERS NOT BLED OF AIR

CAUSE A - MAST DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast for damage. Is the mast in good condition? YES: Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - AIR IN HYDRAULIC SYSTEM PROCEDURE OR ACTION: Inspect oil condition and level in hydraulic tank.

Is the hydraulic oil level in the operating range and in good condition? YES: Go to Cause C. NO: • If oil level is low, add oil. • If hydraulic oil is aerated, locate source of suction side leak and repair. CAUSE C - TRAPPED AIR IN LIFT CYLINDER(S) PROCEDURE OR ACTION: 1. Fully extend and lower the mast several times.

Does the mast raise and lower without hesitation? YES: Go to Cause D. NO: Go to Step 2. 2. Open mast, lower valve, and operate all hydraulic functions in both directions. 3. Close mast lower valve. 4. Repeat Step 1 to see if problem has been solved. CAUSE D - TWO-STAGE FFL MAST MAIN CYLINDERS NOT BLED OF AIR PROCEDURE OR ACTION: Bleed air from cylinders. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. END SYMPTOM

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9070-30-26

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Observed Symptoms

Misphasing of Full Free-Lift Mast POSSIBLE CAUSE A. MAST DAMAGED B. COLD OPERATING CONDITIONS C. CARRIAGE IS BINDING D. HYDRAULIC RESTRICTION TO FREE-LIFT CYLINDER E. EXCESSIVE OIL ON TOP SIDE OF FREE-LIFT CYLINDER PISTON CAUSE A - MAST DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast for damage. Is the mast in good condition? YES: Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - COLD OPERATING CONDITIONS NOTE: See Operating Manual. PROCEDURE OR ACTION: Confirm that oil is at correct operating temperature. See Tests and Adjustments-Gear Pump, Hydraulic Warm-up Procedure, Page 9050-43-1.

Does mast misphase after oil is at operating temperature? YES: Go to Cause C. NO: Incorrect hydraulic oil is being used. Consult Operating Manual for correct grade of hydraulic oil for your operating conditions. CAUSE C - CARRIAGE IS BINDING PROCEDURE OR ACTION: Check carriage shimming. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Is carriage shimmed correctly? YES: Go to Cause D. NO: Adjust or repair carriage. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

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9070-30-27

Observed Symptoms

Front End (Mast) and Chassis

Misphasing of Full Free-Lift Mast (Cont) CAUSE D - HYDRAULIC RESTRICTION TO FREE-LIFT CYLINDER PROCEDURE OR ACTION: Visually inspect hoses and fittings for damage

Are hoses and fitting in good condition? YES: Go to Cause E. NO: Replace damaged hoses and fittings. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE E - EXCESSIVE OIL ON TOP SIDE OF FREE-LIFT CYLINDER PISTON PROCEDURE OR ACTION: 1. Raise mast to full lift height without load and hold at relief pressure for 5 seconds. 2. Recheck for misphasing. Does the mast still misphase? YES: Remove cylinder, check piston seal, and check valve. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. NO: Problem solved. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9070-30-28

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Observed Symptoms

Overhead Guard Loose or Damaged POSSIBLE CAUSE A. OVERHEARD GUARD DAMAGED B. ATTACHING HARDWARE IS LOOSE C. OPERATING TOO FAST OVER ROUGH FLOORS CAUSE A - OVERHEARD GUARD DAMAGED PROCEDURE OR ACTION:

WARNING Death or injury can occur from falling objects. Do not operate lift truck with a damaged overhead guard. Inspect overhead guard. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442.

Is the overhead guard in good condition? YES: Go to Cause B. NO: Replace overhead guard. Depending on your lift truck, see Frame 100 YRM 1329 or Frame 100 YRM 1342. CAUSE B - ATTACHING HARDWARE IS LOOSE PROCEDURE OR ACTION: Visually inspect mounting points for damage and loose or missing hardware. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442.

Is overhead guard and attaching hardware in good condition? YES: Go to Cause C. NO: Repair or replace damaged components. Depending on your lift truck, see Frame 100 YRM 1329 or Frame 100 YRM 1342. CAUSE C - OPERATING TOO FAST OVER ROUGH FLOORS PROCEDURE OR ACTION: Reduce speed and listen for noise.

Does noise reduce with reduction in ground speed? YES: Reduce speed or install softer tires. NO: Depending on your lift truck, see Frame 100 YRM 1329 or Frame 100 YRM 1342. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

Confidential/Proprietary - Do Not Copy or Duplicate

9070-30-29

Observed Symptoms

Front End (Mast) and Chassis

Racking During Lift POSSIBLE CAUSE A. B. C. D. E.

MAST DAMAGED MAIN LIFT CYLINDER NOT SHIMMED CORRECTLY MAIN LIFT CYLINDER CHAINS LOOSE OR UNEQUAL UNEQUAL MAIN LIFT CYLINDER ROD STROKE LIFT CYLINDER BINDING

CAUSE A - MAST DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast for damage. Is the mast in good condition? YES: Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - MAIN LIFT CYLINDER NOT SHIMMED CORRECTLY PROCEDURE OR ACTION: Check cylinder shimming. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382.

Is cylinder shimmed correctly? YES: Go to Cause C. NO: Adjust or repair cylinder. CAUSE C - MAIN LIFT CYLINDER CHAINS LOOSE OR UNEQUAL PROCEDURE OR ACTION: Check chains. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441.

Are the chains adjusted correctly? YES: Go to Cause D. NO: Adjust or replace chains. CAUSE D - UNEQUAL MAIN LIFT CYLINDER ROD STROKE PROCEDURE OR ACTION: Operate lift and compare each cylinder rod stroke. Are the cylinder rod strokes equal? YES: Go to Cause E. NO: Replace cylinder or cylinders spacers (if equipped). Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9070-30-30

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Observed Symptoms

Racking During Lift (Cont) CAUSE E - LIFT CYLINDER BINDING PROCEDURE OR ACTION: 1. Remove cylinder. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. 2. Manually extend cylinder.

Does cylinder extend freely? YES: Cylinder is OK. See Observed Symptoms, Mast is Loose, Page 9070-30-21. NO: Repair or replace cylinder. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

Confidential/Proprietary - Do Not Copy or Duplicate

9070-30-31

Observed Symptoms

Front End (Mast) and Chassis

Racking During Tilt POSSIBLE CAUSE A. MAST DAMAGED B. TILT ROD OUT OF ADJUSTMENT C. UNEQUAL LENGTH OF BACK TILT SPACERS CAUSE A - MAST DAMAGED NOTE: See Operating Manual. PROCEDURE OR ACTION: Visually inspect mast for damage. Is the mast in good condition? YES: Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck see, Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386, Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405, Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338, or Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441. CAUSE B - TILT ROD OUT OF ADJUSTMENT PROCEDURE OR ACTION: Inspect tilt rod. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382.

Is tilt rod adjusted correctly? YES: Go to Cause C. NO: Adjust tilt rod. CAUSE C - UNEQUAL LENGTH OF BACK TILT SPACERS PROCEDURE OR ACTION: Inspect length of spacers. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382.

Are back tilt spacers equal? YES: Mast is too loose. See Observed Symptoms, Mast is Loose, Page 9070-30-21. NO: Adjust or replace spacers. Depending on your lift truck see, Cylinder Repair 2100 YRM 1440 or Cylinder Repair 2100 YRM 1382. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9070-30-32

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Observed Symptoms

Truck Feels Unstable POSSIBLE CAUSE A. OPERATING WITH TOO LARGE A LOAD B. LOW PNEUMATIC TIRE INFLATION C. LOAD IS BEING CARRIED TOO HIGH D. OPERATING AT TOO HIGH A SPEED E. OPERATING OFF HARD SURFACES F. MAST IS TOO LOOSE CAUSE A - OPERATING WITH TOO LARGE A LOAD NOTE: See Serial Number plate or Operating Manual for lift capacity. PROCEDURE OR ACTION: NOTE: Carrying a load that exceeds truck capacity will cause the steer axle wheels to loose contact with ground and negatively affect control of truck. Check load weight and compare to truck capacity rating. CAUSE B - LOW PNEUMATIC TIRE INFLATION PROCEDURE OR ACTION: Check and adjust tire inflation. See Operating Manual. CAUSE C - LOAD IS BEING CARRIED TOO HIGH PROCEDURE OR ACTION: Carry load as low as possible to lower center of gravity and improve stability. CAUSE D - OPERATING AT TOO HIGH A SPEED PROCEDURE OR ACTION: See Operating Manual for correct operating speeds. CAUSE E - OPERATING OFF HARD SURFACES PROCEDURE OR ACTION: Operate truck only on hard surfaces. CAUSE F - MAST IS TOO LOOSE PROCEDURE OR ACTION: See Observed Symptoms, Mast is Loose, Page 9070-30-21. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

Confidential/Proprietary - Do Not Copy or Duplicate

9070-30-33

Observed Symptoms

Front End (Mast) and Chassis

Truck Wanders, Does Not Track Straight or Steer Well POSSIBLE CAUSE A. B. C. D. E.

EXCESSIVE LOADS LOW PNEUMATIC TIRE INFLATION HIGH PNEUMATIC TIRE INFLATION DAMAGED UPPER AXLE MOUNTING EAR STEERING VALVE PROBLEM

CAUSE A - EXCESSIVE LOADS NOTE: See Serial Number plate or Operating Manual for lift capacity. PROCEDURE OR ACTION: NOTE: Carrying a load that exceeds truck capacity will cause the steer axle wheels to loose contact with ground and negatively affect control of truck. Check load weight and compare to truck capacity rating. CAUSE B - LOW PNEUMATIC TIRE INFLATION PROCEDURE OR ACTION: Check and adjust tire inflation. See Operating Manual. CAUSE C - HIGH PNEUMATIC TIRE INFLATION PROCEDURE OR ACTION: Check and adjust tire inflation. See Operating Manual. CAUSE D - DAMAGED UPPER AXLE MOUNTING EAR PROCEDURE OR ACTION: NOTE: The upper axle ear can be bent if lift truck suddenly drops its load while rear steer axle wheels are off the ground. Inspect axle pinion bearings vertical movement.

Does pinion bearings have excessive endplay? YES: Replace axle. Depending on your lift truck, see Transaxle 1300 YRM 1330 or Steering Axle 1600 YRM 1360. NO: Go to Cause E. CAUSE E - STEERING VALVE PROBLEM PROCEDURE OR ACTION: Check steering hydraulics. Perform Tests and Adjustments-Gear Pump, Steering Control Unit LS Pressure Test, Page 9050-43-21. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

9070-30-34

Confidential/Proprietary - Do Not Copy or Duplicate

Front End (Mast) and Chassis

Observed Symptoms

Wheel Studs Breaking POSSIBLE CAUSE A. ATTACHING HARDWARE IS LOOSE B. WHEEL STUDS ARE OVER TORQUED CAUSE A - ATTACHING HARDWARE IS LOOSE PROCEDURE OR ACTION: Visually inspect wheel studs for damage and loose or missing hardware. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442.

Do wheels and attaching hardware appear to be in good condition? YES: Go to Cause B. NO: Repair or replace damaged components. Depending on your lift truck, see Transaxle 1300 YRM 1330, Transaxle 1300 YRM 1370, Steering Axle 1600 YRM 1360, or Drive Axle, Speed Reducer, and Differential 1300 YRM 1366. CAUSE B - WHEEL STUDS ARE OVER TORQUED PROCEDURE OR ACTION: Check wheel stud torque. Depending on your lift truck see, Periodic Maintenance 8000 YRM 1364, Periodic Maintenance 8000 YRM 1372, Periodic Maintenance 8000 YRM 1339, Periodic Maintenance 8000 YRM 1373, or Periodic Maintenance 8000 YRM 1442.

Are the wheels studs at correct torque? YES: Check maintenance records to see what repairs were made that may have caused problem. NO: Replace all studs and torque correctly. Depending on your lift truck, see Transaxle 1300 YRM 1330, Transaxle 1300 YRM 1370, Steering Axle 1600 YRM 1360, or Drive Axle, Speed Reducer, and Differential 1300 YRM 1366. END SYMPTOM

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins

Confidential/Proprietary - Do Not Copy or Duplicate

9070-30-35

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

9070-30-36

SECTION 9080

SUPPLEMENTARY DATA TABLE OF CONTENTS Group 50 - Abbreviations and Acronyms Abbreviations and Acronyms................................................................................................................. Group 70 - Fault Mode Indicator Reference Fault Mode Indicator (FMI) Reference List ............................................................................................

Confidential/Proprietary - Do Not Copy or Duplicate

9080-50-1 9080-70-1

9080-1

9080-2

Supplementary Data

Abbreviations and Acronyms

Group 50

Abbreviations and Acronyms ABBREVIATIONS AND ACRONYMS Table 9080-50-1. Abbreviations and Acronyms Term

Definition or Description

Alternating Current

ACC

Accessory

A/D

Analog to Digital

AUX

Auxiliary

BAT

Battery

Baud

A line’s signaling rate, the switching speed, or number of voltage or frequency changes made per second

BIT

Smallest element of binary data storage

BDI

Battery Discharge Indicator

bit

Smallest element of binary data storage

°C

Celsius Temperature

Calbr

Adjustment to accommodate truck-to-truck variations. Typical usage in system specifications applies to software processes to “learn” and store sensor baseline or extreme values. Calibration procedures may require repeating when controllers are replaced or if a specific sensor or mounting mechanism is replaced.

CANbus

Controller Area Network bus

CBDC

Counter Balanced Development Center

CD or CD-ROM

Compact Disc Read-Only Memory - a compact disc format used to hold text, graphics and hi-fi stereo sound in excess of 650MB of data, which is equivalent to about 250,000 pages of text

CDF

Configuration Data File (previously known as Cal Data) - factory-created file defining truck configuration details, dependent on truck model and option permutations (considered unique for a given truck). Not modified by service technicians, but a replacement file (with alternate options) may be factory-generated and loaded into a truck’s controller by a service technician

Carbon Monoxide

COP

Computer Operating Properly

CMP

Cam Position Sensor

CPS

Connector Plug Socket

CPU

Central Processing Unit

CRC

Cyclic Redundancy Checksum

CRP

Connector Receptacle Pin

CRS

Connector Receptacle Socket

Direct Current

DCS

Direction Control Selector

Deactivated

A feature which is not currently Activated

Defaults

The set of factory values for all truck parameters. A setup menu function can restore the default values of all parameters.

Disabled

A Software Enabled Feature which is NOT present on a given truck

Confidential/Proprietary - Do Not Copy or Duplicate

9080-50-1

Abbreviations and Acronyms

Supplementary Data

Table 9080-50-1. Abbreviations and Acronyms (Continued) Term

Definition or Description

Diagnostic Message

DMM

Digital Multi-Meter

Display Panel – equipped with 10 numeric keys, two arrow keys (left and right arrows) and two symbol keys (the Star (*) key and the pound (#) key).

DSC

Display Switch Cluster

DTC

Diagnostic Troubleshooting Code

DTM

Diagnostic Troubleshooting Manual

EDBP

Extended Drawbar Pull

EEPROM

Electronically Erasable Programmable Read Only Memory

Excess Flow

EFI

Electronic Fuel Injection

EGI

Electronic Gasoline Injection

EGO

Exhaust Gas Oxygen

EHP

Electro-Hydraulic Pilot

EHPV

Electro-Hydraulic Poppet Valve

E-Hyd

Electro-Hydraulic - hydraulic option utilizing electronic inputs and electrically-driven valves to actuate hydraulic functions, as opposed to manual hydraulics using mechanical levers

Embedded

Software that is installed on Lift Truck control system

EMI

Electro-Magnetic Interference

Enabled

A Software Enabled Feature which is present on a given truck, but not necessarily Activated (i.e., purchased but not necessarily in use)

EPA

Environmental Protection Agency

EPR

Electronic Pressure Regulator

EST

Electronic Spark Timing

ETC

Electronic Throttle Control

FFL

Full-Free Lift

FIFO

First In, First Out

FMI

Fault Mode Indicator

FOSI

Format Output Specification Instances - an instance of the Output Specification (OS) that assigns values to the style characteristics for a particular document type declaration. The FOSI uses the syntax of an SGML/XML document instance and is designed to format documents for paper delivery.

FWD

Forward travel direction command signal to system

Gigabyte - equal to 1024 Megabytes

Henry - Unit of measurement of electrical inductance

HYDR

Hydraulic

Basic unit of frequency measurement, 1 Hz = 1 periodic interval in one second

IAC

Idle Air Control

IAT

Intake Air Temperature

IBPP

Inching/Brake Pedal Position

9080-50-2

Confidential/Proprietary - Do Not Copy or Duplicate

Supplementary Data

Abbreviations and Acronyms

Table 9080-50-1. Abbreviations and Acronyms (Continued) Term

Definition or Description

ISR

Interrupt Service Routine

kBps

KiloBytes per second

kHz

KiloHertz - common frequency measurement of Hertz X 1000

kilobit

1,000 bits

kilobyte

A standard quantity measurement for disk and diskette storage. One kilobyte of memory equals 1024 bytes (8-bit characters) of computer memory.

Kilogram, equal to 1000 grams

kPa

Kilo-Paschals, metric unit of pressure measurement X 1000

kph

Kilometers per Hour

Liter

LAN

Local Area Network

lbf ft

Foot Pounds

lbf in

Inch Pounds

LCD

Liquid Crystal Display

LED

Light Emitting Diode

LFL

Limited Free Lift

Megabyte - 1,048,576 bytes, equal to 1,024 kilobytes. The basic unit of measurement of mass storage

MHz

Megahertz - a unit of frequency equal to 1024 kilohertz. A common method for describing the speed of a computer CPU

MIL

Malfunction Indicator Lamp

MLCV

Mast Lowering Control Valve

MLM

Mini Lever Module

Milli-Henry, 1 one thousandth of a Henry

Modem

Modulator-Demodulator - a device that adapts a terminal or computer to a telephone line converting the computer’s digital pulses into audio frequencies (analog) for the telephone system and converts the frequencies back into digital pulses at the receiving side

MPH

Miles Per Hour

MRV

Main Relief Valve

Milli-second, 1 one thousandth of a second

MSB

Most Significant Bit

NEU

Neutral travel direction command signal to system

N•m

Newton Meters

NOR

Normal

OBD

On Board Diagnostics

Open Circuit - indicates an open connection or break in an electrical path

OORH

Out-Of-Range High

OORL

Out-Of-Range Low

OPS

Operator Presence System

Confidential/Proprietary - Do Not Copy or Duplicate

9080-50-3

Abbreviations and Acronyms

Supplementary Data

Table 9080-50-1. Abbreviations and Acronyms (Continued) Term

Definition or Description

Operating System - the embedded system of instructions and applications that control the operation of the processor

Parameter

A system characteristic which may be adjusted by a technician, e.g., Auto-Deceleration, which may be set on a scale of from 1 to 10. Each parameter will also have a default value.

Personal Computer

PC Tool

Any software that is installed on a PC that is used to service the lift truck control system

PCB

Printed Circuit Board

PDM

Power Distribution Module

PGN

Parameter Group Number

PPRV

Proportional Pressure Reducing Valve

PTC

Positive Temperature Coefficient Resistor

RAM

Random Access Memory - the computer’s primary workspace where the contents of each byte can be accessed directly without regard to the bytes before or after it

REV

Reverse travel direction command signal to system

Rev.

Revision - the issue control or version number of an item

Relay

ROM

Read Only Memory

RPM

Revolutions Per Minute

RTST

Return to Set Tilt

SAE

Society of Automotive Engineers

Scroll Repeat

The repeating, incrementing, or decrementing of a displayed value when continuously pressing the scroll buttons

Scroll Wrap-around

In the setup menu, if wrap-around is specified, when extreme-adjustment values are reached while scrolling, the value shall change to the other extreme of adjustment. I.e., scrolling down to lowest point on menu shall jump back to the top of the menu.

SCU

Steering Control Unit

SEF

Software Enabled Function - options which are Enabled by software (either entirely or in combination with additional hardware). For all SEFs, enabling the function requires a new CDF. An SEF may be Selectable, allowing it to be Activated or Deactivated by the technician once it has been enabled, or it may be non-selectable, such that it cannot be deactivated after being enabled.

Selectable

See Software Enabled Function (SEF)

Service Pack

Software update provided by a software manufacturer to fix an error and/or improve quality

SPED

Special Products Engineering Department - responsible for options not in the standard price book, but available by special order

SPI

Serial Peripheral Interface

SPN

Suspect Parameter Number

SRV

Secondary Relief Valve

STB

Short-To-Battery - indicates a short to a battery level voltage source

STG

Short-To-Ground - indicates a short to a ground or frame connection

STS

Short-To-Supply - indicates a short to a supply voltage source other than battery level

TBC

To Be Continued

TBD

To Be Determined

9080-50-4

Confidential/Proprietary - Do Not Copy or Duplicate

Supplementary Data

Abbreviations and Acronyms

Table 9080-50-1. Abbreviations and Acronyms (Continued) Term

Definition or Description

Truck Settings

The specific adjustments of the various parameters on a given truck. They may be saved to a data file through the Service PC software and copied to additional similar trucks.

TSP

Troubleshooting Procedure

USB

Universal Serial Bus - serial 4-wire connection that has advanced features over a serial port. Normally found on computers as a slotted connector configuration

YRM

Yale Reference Manual

Confidential/Proprietary - Do Not Copy or Duplicate

9080-50-5

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

9080-50-6

Supplementary Data

Fault Mode Indicator Reference

Group 70

Fault Mode Indicator Reference FAULT MODE INDICATOR (FMI) REFERENCE LIST

are not used in the lift truck systems. For a complete listing of these FMI codes, refer to SAE Specification J1939-73.

There are additional FMI codes that define characteristics of other failures but are not listed here because they Table 9080-70-1. FMI FMI #

Description

Data Valid but Above Normal Operational Range - Most Severe Level

Data Valid but Below Normal Operational Range - Most Severe Level

Data Erratic, Intermittent or Incorrect

Voltage Above Normal or Shorted to High Source (OORH)

Voltage Below Normal or Shorted to Low Source (OORL)

Current Below Normal or Open Circuit (OC)

Current Above Normal or Grounded Circuit

Mechanical System not Responding or Out of Adjustment

Abnormal Frequency or Pulse Width or Period

Abnormal Update Rate

Abnormal Rate of Change (AROC)

Root Cause Not Known

Bad Intelligent Device or Component

Out of Calibration

Special Instructions

Confidential/Proprietary - Do Not Copy or Duplicate

9080-70-1

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

9080-70-2

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

9000 YRM 1377

5/11 (2/11)(7/09)(3/09)(2/09)

Maintenance

DIAGRAMS ERP16-20VF (ERP30-40VF) [A955]; ERP15-20VT (ERP030-040VT) [G807]

PART NO. 524319503

8000 YRM 1341

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Diagrams

Table of Contents

TABLE OF CONTENTS Diagrams, Schematics, or Arrangements ............................................................................................................ Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) ............................................................................................................................... Figure 2. Manual Hydraulic Control Valve Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) ......................................................................................................... Figure 3. E-Hydraulic Control Valve Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) .........................................................................................................

1 1 23 24

This section is for the following models: ERP16-20VF (ERP30-40VF) [A955]; ERP15-20VT (ERP030-040VT) [G807]

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 1 of 22)

Diagrams, Schematics, or Arrangements

8000 YRM 1341

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 2 of 22)

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 3 of 22)

Diagrams, Schematics, or Arrangements

8000 YRM 1341

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 4 of 22)

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 5 of 22)

Diagrams, Schematics, or Arrangements

8000 YRM 1341

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 6 of 22)

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 7 of 22)

Diagrams, Schematics, or Arrangements

8000 YRM 1341

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 8 of 22)

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 9 of 22)

Diagrams, Schematics, or Arrangements

8000 YRM 1341

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 10 of 22)

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 11 of 22)

Diagrams, Schematics, or Arrangements

8000 YRM 1341

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 12 of 22)

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 13 of 22)

Diagrams, Schematics, or Arrangements

8000 YRM 1341

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 14 of 22)

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 15 of 22)

Diagrams, Schematics, or Arrangements

8000 YRM 1341

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 16 of 22)

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 17 of 22)

Diagrams, Schematics, or Arrangements

8000 YRM 1341

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 18 of 22)

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 19 of 22)

Diagrams, Schematics, or Arrangements

8000 YRM 1341

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 20 of 22)

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 21 of 22)

Diagrams, Schematics, or Arrangements

8000 YRM 1341

Figure 1. Wiring Diagram/Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 22 of 22)

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 2. Manual Hydraulic Control Valve Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955)

Diagrams, Schematics, or Arrangements

8000 YRM 1341

Figure 3. E-Hydraulic Control Valve Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 1 of 2)

8000 YRM 1341

Diagrams, Schematics, or Arrangements

Figure 3. E-Hydraulic Control Valve Schematic for ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) (Sheet 2 of 2)

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

8000 YRM 1341

12/09 (4/09)(2/09)(9/08) Printed in U.S.A.

Maintenance

ELECTRICAL SYSTEM ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

PART NO. 524320282

2200 YRM 1337

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Electrical System

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Discharging the Capacitors ............................................................................................................................. Display Panel and Key or Keyless Switch Replacement ..................................................................................... Display Panel, Replace ................................................................................................................................... Remove....................................................................................................................................................... Install .......................................................................................................................................................... Electronic and Manual Hydraulic Controls........................................................................................................... General ........................................................................................................................................................... Manual Hydraulic Controls .............................................................................................................................. Upper Front Cover ...................................................................................................................................... Direction Control Switch ............................................................................................................................. Remove .................................................................................................................................................. Install ...................................................................................................................................................... Clamp Button .............................................................................................................................................. Remove .................................................................................................................................................. Install ...................................................................................................................................................... Emergency Disconnect Switch ................................................................................................................... Remove .................................................................................................................................................. Install ...................................................................................................................................................... E-Hydraulic Controls - Test ............................................................................................................................. Mini-Levers ................................................................................................................................................. Full Stroke Test ........................................................................................................................................... Function Returns to Neutral Test ................................................................................................................ Push Button Switch..................................................................................................................................... E-Hydraulic Controls ....................................................................................................................................... Mini-levers, Remove and Install .................................................................................................................. Armrest Assembly....................................................................................................................................... Remove .................................................................................................................................................. Install ...................................................................................................................................................... Horn Button................................................................................................................................................. Remove .................................................................................................................................................. Install ...................................................................................................................................................... Direction Control Switch ............................................................................................................................. Remove .................................................................................................................................................. Install ...................................................................................................................................................... Emergency Disconnect Switch ................................................................................................................... Remove .................................................................................................................................................. Install ...................................................................................................................................................... Momentary Switches and Function Selection Button ................................................................................. Remove .................................................................................................................................................. Install ...................................................................................................................................................... Sensors and Switches ......................................................................................................................................... General ........................................................................................................................................................... Steering Axle Sensor ...................................................................................................................................... Lift Truck Models ERP15-20VT (ERP030-040VT) (G807) .......................................................................... Remove .................................................................................................................................................. Install ...................................................................................................................................................... Lift Truck Models ERP16-20VF (ERP30-40VF) (A955) .............................................................................. Remove .................................................................................................................................................. Install ...................................................................................................................................................... Hydraulic Motor Speed Sensor .......................................................................................................................

1 2 2 2 2 4 6 6 6 6 7 7 9 9 9 9 10 10 10 11 11 11 11 11 12 12 13 13 14 15 15 15 16 16 16 16 16 17 17 17 18 20 20 20 20 20 23 23 23 23 25

Table of Contents

Electrical System

TABLE OF CONTENTS (Continued) Remove....................................................................................................................................................... Install .......................................................................................................................................................... Hydraulic Motor Temperature Sensor.............................................................................................................. Transmission Speed Sensor ........................................................................................................................... Remove....................................................................................................................................................... Install .......................................................................................................................................................... Traction Motor Temperature Sensor ................................................................................................................ Tilt Position Sensor ......................................................................................................................................... Remove....................................................................................................................................................... Install .......................................................................................................................................................... Low Level Brake Fluid Switch.......................................................................................................................... Remove....................................................................................................................................................... Install .......................................................................................................................................................... Service Brake Pressure Sensor ...................................................................................................................... Remove....................................................................................................................................................... Install .......................................................................................................................................................... Accelerator Pedal Position Sensor .................................................................................................................. Remove....................................................................................................................................................... Install .......................................................................................................................................................... Seat Sensor (Operator Presence System)...................................................................................................... Non-Suspension Seat ................................................................................................................................. Remove .................................................................................................................................................. Install ...................................................................................................................................................... Full Suspension and Swivel Seats.............................................................................................................. Remove .................................................................................................................................................. Install ...................................................................................................................................................... Steering Wheel Position Sensor...................................................................................................................... Remove....................................................................................................................................................... Install .......................................................................................................................................................... Load Weight Sensor........................................................................................................................................ Remove....................................................................................................................................................... Install .......................................................................................................................................................... Battery Gate Switch ........................................................................................................................................ Remove....................................................................................................................................................... Install .......................................................................................................................................................... Horn Switch..................................................................................................................................................... Remove....................................................................................................................................................... Install .......................................................................................................................................................... Rear Horn Button Switch................................................................................................................................. Remove....................................................................................................................................................... Install .......................................................................................................................................................... Impact Sensor ................................................................................................................................................. Remove....................................................................................................................................................... Install .......................................................................................................................................................... Motor Controllers Replacement........................................................................................................................... General ........................................................................................................................................................... Hydraulic Pump and Motor Controller ............................................................................................................. Remove....................................................................................................................................................... Fan, Remove .......................................................................................................................................... Fan, Install .............................................................................................................................................. Install ..........................................................................................................................................................

25 25 25 25 25 27 28 28 28 28 28 28 29 30 30 30 30 30 32 32 32 32 32 33 33 33 33 33 35 35 35 35 36 36 36 37 37 39 39 39 40 40 40 41 42 42 42 42 44 44 44

Electrical System

Table of Contents

TABLE OF CONTENTS (Continued) Traction Motor Controllers ............................................................................................................................... Remove....................................................................................................................................................... Fan, Remove .......................................................................................................................................... Fan, Install .............................................................................................................................................. Install .......................................................................................................................................................... Line Contactor................................................................................................................................................. Remove....................................................................................................................................................... Install .......................................................................................................................................................... Vehicle Systems Manager ................................................................................................................................... General ........................................................................................................................................................... Remove ........................................................................................................................................................... Install............................................................................................................................................................... Programming a New VSM and/or Display Panel............................................................................................. General ....................................................................................................................................................... PC Service Tool Software ............................................................................................................................... Fuses................................................................................................................................................................... Audible Alarm ...................................................................................................................................................... Battery Connection.............................................................................................................................................. Inspect............................................................................................................................................................. Replacing Cables ............................................................................................................................................ Cab Heater .......................................................................................................................................................... Remove ........................................................................................................................................................... Clean............................................................................................................................................................... Inspect............................................................................................................................................................. Install............................................................................................................................................................... Lights ................................................................................................................................................................... General ........................................................................................................................................................... Work Lights (Front and Rear).......................................................................................................................... Halogen Bulb Lights.................................................................................................................................... Remove .................................................................................................................................................. Install ...................................................................................................................................................... LED Lights .................................................................................................................................................. Remove .................................................................................................................................................. Install ...................................................................................................................................................... Strobe Light..................................................................................................................................................... Remove....................................................................................................................................................... Install .......................................................................................................................................................... LED Tail, Backup, and Brake Lights ................................................................................................................ Remove....................................................................................................................................................... Install .......................................................................................................................................................... Front Marker/Turn Signal Lights ...................................................................................................................... Remove....................................................................................................................................................... Install .......................................................................................................................................................... Converter ........................................................................................................................................................ Remove....................................................................................................................................................... Install ..........................................................................................................................................................

44 44 48 49 49 49 49 51 52 52 52 52 54 54 54 55 57 58 58 58 60 60 60 60 60 62 62 63 63 63 63 64 64 64 64 64 64 65 65 65 66 66 67 67 68 68

iii

Table of Contents

Electrical System

TABLE OF CONTENTS (Continued) This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

2200 YRM 1337

General

General The removal and replacement procedures for the following electrical components are covered in this service manual: • Display panel • Electronic and manual hydraulic control components • Motor controllers • Sensors and switches • Lights • Fuses, alarm and horn • Battery • Vehicle System Manger (VSM) The adjustment of the switches on the linkage for the manual control valve are in the section Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334. If lift truck is equipped with an E-hydraulic control valve, see Main Control Valves, (Manual and E-Hydraulic Valves) 2000 YRM 1334 for the replacement procedures on the Electro-Hydraulic Valve Driver Module. See AC Motor Repair 620 YRM 1385 for information on servicing and maintaining the AC hydraulic pump motor and Industrial Battery 2240 YRM 1 for information on the battery. See Transaxle 1300 YRM 1330 for information on servicing and maintaining the transaxle motors.

make a connection. This prevents "cutting" new threads and damaging the existing thread in the plastic part. If any welding must be done, obtain proper authorization from a Resident Service Engineer. If authorization is given, be sure to follow the procedures in the WARNING and CAUTIONS below.

WARNING Forklift frames and components may be painted with a catalyzed paint such as polyurethane or a two-part primer. Welding, burning, or other heat sufficient to cause thermal decomposition of the paint may release isocyanates. These chemicals are allergic sensitizers to the skin and respiratory tract and overexposure may occur without odor warning. Should work be performed, utilize good industrial hygiene practices including removal of all paint (prime and finish coats) to the metal around the area to be welded, local ventilation, and/or supplied-air respiratory protection.

CAUTION When an arc welder is used, always disconnect the battery connector on the lift truck. This action will prevent damage to the motor controllers.

If any of the wire harnesses need to be repaired, see the section Wire Harness Repair 2200 YRM 1128 for repair procedures.

Connect the ground clamp for the arc welder as close as possible to the weld area. This action will prevent damage to a bearing from the large current from the welder.

Some of the components used are made of plastic. When using screws to replace and install plastic components, the screws should be rotated counterclockwise until the screw thread turns over the last thread in the plastic part. The screw can then be turned clockwise to

Before performing arc welding repairs, disconnect the motor controller and VSM connections to prevent damage to the motor controllers and VSM. See the sections Motor Controllers Replacement and Vehicle Systems Manager for the procedures.

Display Panel and Key or Keyless Switch Replacement

DISCHARGING THE CAPACITORS WARNING

2200 YRM 1337 the capacitor(s) before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected.

DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the battery.

DO NOT short across the motor controller terminals with a screwdriver or jumper wire.

Disconnect the battery and allow the capacitors to discharge before opening any compartment covers or inspecting or repairing the electrical system. DO NOT place tool on top of the battery. If a tool causes a short circuit, the high current flow from the battery can cause personal injury and property damage.

1. Ensure the capacitors are discharged by performing Step 2 through Step 6 below.

Some checks and adjustments are performed with the battery connected. DO NOT connect the battery until the procedure instructs you to do so. Never wear any metallic items on your fingers, arms, or neck. Metal items can accidentally make an electrical connection and cause injury

Make certain the Emergency-Disconnect switch has not been activated. This will isolate the controllers and prevent the capacitors from discharging properly. The proper way to disconnect the battery is by separating the battery connectors.

2. Turn key or keyless switch to OFF position. 3. Disconnect the battery by separating the connectors. 4. Block drive wheels to prevent lift truck from moving. 5. Make sure the Emergency-Disconnect switch HAS NOT been activated. If the Emergency-Disconnect switch is activated, rotate the switch to the right until it pops up.

Before performing any tests or adjustment, block the lift truck to prevent unexpected movement.

6. Wait at least 10 seconds to be sure that the capacitors are fully discharged.

The capacitor in the transistor controller(s) can hold an electrical charge for about 10 seconds after the battery is disconnected. To prevent an electrical shock and personal injury, discharge

If a torque value is not specified, go to Metric and Inch (SAE) Fasteners 8000 YRM 231 for torque values.

Display Panel and Key or Keyless Switch Replacement DISPLAY PANEL, REPLACE

Discharge capacitors as directed in Discharging the Capacitors in General section of this manual.

Remove WARNING Before replacing the display panel, fully lower all parts of the mast and tilt it forward until the tips of the forks touch the ground. This action will prevent the mast from lowering suddenly if the control lever is accidently moved.

WARNING Disconnect the battery before doing any work on the electrical system. Serious injury to personnel and/or damage to lift truck components can occur if battery is not disconnected.

CAUTION A short circuit and damage can occur if wires are not installed correctly. Make sure wire connectors do not touch the other meter terminals or wire connectors, metal brackets, or the bracket mounting nuts. Make sure the wires are not pulled tight and are not touching other parts to damage the insulation. NOTE: The display panel cannot be repaired and must be replaced as a unit, if it has a malfunction. See the Parts Manual for replacement part number. The key or keyless switch can be replaced without replacing the whole display panel.

2200 YRM 1337

Display Panel and Key or Keyless Switch Replacement the slot. When display panel is loose from the slot, pull display panel out of the display panel cover. See Figure 7. When the display panel is pulled from the display panel cover, the warning buzzer will disconnect from the rear of the display panel. See Figure 3.

The display panel is mounted inside of a display panel cover. The display panel cover is mounted to a bracket on the upper right corner of the overhead guard. See aFigure 1.

NOTE: STANDARD KEY SWITCH SHOWN. 1. 2. 3. 4.

OVERHEAD GUARD DISPLAY PANEL COVER DISPLAY PANEL KEY OR KEYLESS SWITCH Figure 1. Display Panel Arrangement

1. Read and follow the WARNING and CAUTION above. 2. Insert a flat head screwdriver in the slot on the bottom of the display panel (see Figure 2). Pull the screwdriver down to loosen the display panel from

NOTE: STANDARD KEY SWITCH SHOWN. 1. 2. 3. 4.

SLOT DISPLAY PANEL OVERHEAD GUARD SCREWDRIVER Figure 2. Display Panel Removal

3. Disconnect the display wire harness from pin connector on the back of the display panel. Remove display panel from lift truck. See Figure 4.

Display Panel and Key or Keyless Switch Replacement

2200 YRM 1337 4. Remove the key or keyless switch from display panel by pinching in on the pinch points and pulling key or keyless switch from display panel. See Figure 5.

NOTE: REAR OF DISPLAY PANEL AND DISPLAY PANEL COVER SHOWN. SOME ELECTRICAL COMPONENTS AND CONNECTIONS OMITTED FOR CLARITY. 1. WARNING BUZZER 2. DISPLAY PANEL 3. DISPLAY PANEL COVER

4. PIN CONNECTOR 5. WARNING BUZZER ELECTRICAL CONNECTION

Figure 3. Warning Buzzer

NOTE: BACK SIDE OF DISPLAY PANEL SHOWN. 1. PIN CONNECTOR 2. PINCH POINTS 3. KEY OR KEYLESS SWITCH COVER Figure 5. Key or Keyless Switch Removal

Install NOTE: If switch being installed uses a key, insert key into switch first. This will help install the switch into the display panel. If switch is keyless, use the knob to help install switch into display panel. 1. Take new key or keyless switch and install into display panel. Match the notches on the switch with the holes on the switch cover. See Figure 5 and Figure 6. Switch will snap into place.

1. PIN CONNECTOR

2. KEYSWITCH

Figure 4. Disconnecting Display Panel

2200 YRM 1337

Display Panel and Key or Keyless Switch Replacement Legend for Figure 6 NOTE: KEY SWITCH SHOWN. 1. KEY SWITCH 2. DISPLAY PANEL

3. NOTCH

2. Connect the display wire harness to the pin connector on the back of the display panel. See Figure 4. 3. Connect the warning buzzer to the back of the display panel. See Figure 3. 4. Insert the notches on the top of the display panel into the slots on the top of the display panel cover. See Figure 7. 5. Push in the bottom of the display panel until the notch on the bottom slides into the slot on the bottom and the display panel locks into place inside the cover. See Figure 7.

Figure 6. Key or Keyless Switch Installation

1. TOP NOTCHES 2. TOP SLOTS 3. DISPLAY PANEL COVER

4. BOTTOM NOTCH 5. BOTTOM SLOT 6. DISPLAY PANEL Figure 7. Display Panel Installation

Electronic and Manual Hydraulic Controls

2200 YRM 1337

Electronic and Manual Hydraulic Controls GENERAL WARNING Before replacing any part of the electronic or manual hydraulic control assembly, fully lower all parts of the mast and tilt it forward until the tips of the forks touch the ground. This action will prevent the mast from lowering suddenly if the control lever is accidently moved.

WARNING Discharge capacitors as directed in Discharging the Capacitors in General section of this manual. Disconnect the battery before doing any work on the electrical system. Serious injury to personnel and/or damage to lift truck components can occur if battery is not disconnected.

WARNING Never wear any metallic items on your fingers, arms, or neck. Metal items can accidently make an electrical connection and cause an injury.

CAUTION A short circuit and damage can occur if wires are not installed correctly. Make sure wire connectors do not touch the other metal terminals or wire connectors, metal brackets, or the bracket mounting nuts. Make sure the wires are not pulled tight and are not touching other parts to damage the insulation. The lift trucks covered in this service manual come standard with manual hydraulic control levers, but have the option of using electronic-hydraulic (E-Hydraulic) mini-lever controls. In each hydraulic control arrangement, there are several electronic component parts that can be replaced if they are no longer working properly. These components are:

• Direction Control Switch - The direction control switch is an optional feature and is used to select the direction of travel when the lift truck is equipped with a standard accelerator pedal. • Emergency Disconnect Switch - The emergency disconnect switch is used to disconnect all electrical power to the lift truck. The switch is operated by pushing the button down until it clicks. To reset (re-connect) the emergency disconnect switch and energize the electrical circuits, turn the switch clockwise until button pops up. • Clamp Button - The lift trucks covered in this service manual may be equipped with a clamp function. On lift trucks equipped with manual hydraulic control levers, If lift truck is equipped with three levers, the button for the clamp function is located on the top of the third lever. If lift truck has four levers, the clamp button is on the top of the fourth lever. For lift trucks equipped with E-Hydraulic mini-levers, If lift truck is equipped with three mini-levers, the momentary switch for the clamp function is located behind the third lever on the palm rest. If lift truck has four levers, the momentary switch is located behind the fourth lever on the palm rest. When removing and replacing sensors or switches, be sure to tag connectors to aid in correct installation.

MANUAL HYDRAULIC CONTROLS Upper Front Cover NOTE: To replace the direction control switch, emergency disconnect switch, and the clamp button, the upper front cover must be removed first from the manual hydraulic control lever assembly as described below. 1. Read and follow the WARNING and CAUTION section in the General section above. 2. Remove four capscrews and front cover from hydraulic lever assembly. See Figure 8.

2200 YRM 1337

Electronic and Manual Hydraulic Controls manual control valve wire harness from direction control switch. See Figure 9. 3. Remove two outer capscrews and lift/lower with direction control switch handle from manual lift/lower lever. See Figure 10. 4. Remove one inner capscrew and palm side grip handle from manual lift lever. See Figure 10. 5. Remove direction control switch cable from cable track. See Figure 10. 6. Remove two screws, direction control switch retainer, direction control switch cup, and direction control switch from lift/lower with direction control switch handle. See Figure 10 and Figure 11.

NOTE: OPTIONAL DIRECTION CONTROL SWITCH AND CLAMP BUTTON SHOWN. FOUR LEVERS SHOWN. IF LIFT TRUCK IS EQUIPPED WITH THREE LEVERS, THE CLAMP BUTTON IS ON THE TOP OF THE THIRD LEVER. 1. 2. 3. 4. 5. 6. 7.

UPPER FRONT COVER CAPSCREWS LOWER COVER UPPER REAR COVER DIRECTION CONTROL SWITCH CLAMP BUTTON EMERGENCY DISCONNECT SWITCH Figure 8. Manual Hydraulic Control Lever Assembly

3. Using four capscrews, install front cover on hydraulic lever assembly. See Figure 8.

Direction Control Switch Remove 1. Read and follow the WARNING and CAUTION section in the General section above.

1. CLAMP BUTTON CONNECTOR 2. EMERGENCY DISCONNECT SWITCH CONNECTOR 3. DIRECTION CONTROL SWITCH CONNECTOR 4. MANUAL CONTROL VALVE WIRE HARNESS Figure 9. Manual Control Levers Assembly Electrical Components

2. Remove the upper front cover. See the section Upper Front Cover for procedures. Disconnect the

Electronic and Manual Hydraulic Controls

2200 YRM 1337

A. AUX HANDLE WITH DUAL FUNCTION B. LIFT/LOWER WITH DIRECTION CONTROL SWITCH 1. PALM SIDE GRIP HANDLE 2. CLAMP SWITCH HANDLE 3. LIFT/LOWER WITH DIRECTION CONTROL SWITCH HANDLE 4. MANUAL AUX 2 LEVER 5. MANUAL LIFT LEVER 6. DIRECTION CONTROL SWITCH 7. CLAMPING PUSH-BUTTON

8. 9. 10. 11. 12. 13. 14. 15.

INNER CAPSCREW OUTER CAPSCREW CABLE TRACK SCREW DIRECTION CONTROL SWITCH RETAINER DIRECTION CONTROL SWITCH CUP PUSH-BUTTON CABLE DIRECTION CONTROL SWITCH CABLE

Figure 10. Manual Hydraulic Control Handles

2200 YRM 1337

Electronic and Manual Hydraulic Controls 5. Route direction control switch cable through cable track on manual lift/lower lever. See Figure 10. 6. Install palm side handle and one capscrew on manual lift/lower lever. See Figure 10 7. Install lift/lower with direction control switch handle and two outer capscrews on manual lift/lower lever. See Figure 10. Tighten outer capscrews to 1.35 to 1.65 N•m (11.9 to 14.6 lbf in). 8. Install upper front cover. See the section Upper Front Cover for procedures.

Clamp Button Remove 1. Read and follow the WARNING and CAUTION section in the General section above. 2. Remove the upper front cover. See the section Upper Front Cover for procedures. Disconnect the manual control valve wire harness from the clamp button. See Figure 9. 3. Remove two outer capscrews and clamp switch handle from manual aux 2 lever. See Figure 10. 4. Remove one inner capscrew and palm side grip handle from manual aux 2 lever. See Figure 10.

1. 2. 3. 4.

SCREW DIRECTION CONTROL SWITCH RETAINER DIRECTION CONTROL SWITCH CUP DIRECTION CONTROL SWITCH CABLE Figure 11. Direction Control Switch

Install 1. Install direction control switch into direction control switch cup. See Figure 10. 2. Install direction control switch cup and direction control switch into lift/lower direction control switch handle. See Figure 10 and Figure 11. 3. Install direction control switch retainer onto back side of direction control switch cup, inside lift/lower with direction control switch handle. See Figure 10 and Figure 11.

5. Remove push-button cable from cable track. See Figure 10. Install 1. Route push-button cable through cable track on manual aux 2 lever. See Figure 10. 2. Install palm side handle and one inner capscrew on manual aux 2 lever. See Figure 10. NOTE: Ensure clamping push-button is in correct position on clamp switch handle during assembly. 3. Install clamp switch handle and two outer capscrews on manual aux 2 lever. See Figure 10. Tighten outer capscrews to 1.35 to 1.65 N•m (11.9 to 14.6 lbf in). 4. Install upper front cover. See the section Upper Front Cover for procedures.

4. Install two screws through retainer and direction control switch cup into direction control switch. See Figure 10 and Figure 11.

Electronic and Manual Hydraulic Controls

2200 YRM 1337

Emergency Disconnect Switch Remove 1. Read and follow the WARNING and CAUTION section in the General section above. 2. Remove the upper front cover. See the section Upper Front Cover above for procedures. 3. Remove the five socket head capscrews from upper rear cover. See Figure 12. Pull cover forward to generate enough space to disconnect the emergency disconnect switch wires. See Figure 9.

NOTE: THE EMERGENCY DISCONNECT SWITCH SHOWN IN FIGURE 13 IS ALSO USED ON LIFT TRUCKS EQUIPPED WITH E-HYDRAULIC CONTROLS. A. INSERT SCREWDRIVER HERE 1. 2. 3. 4. 5. 6. 7. 8.

EMERGENCY DISCONNECT SWITCH SWITCH ADAPTER LOCK NUT EMERGENCY DISCONNECT BUTTON BUSHING UPPER REAR COVER HOLE Figure 13. Emergency Disconnect Switch Replacement

Install 1. 2. 3. 4.

SOCKET HEAD SCREWS UPPER REAR COVER LEVER LINKAGE MANUAL HYDRAULICS WIRE HARNESS Figure 12. Upper Rear Cover Removal

1. Insert the emergency disconnect button and bushing into hole in upper rear cover. See Figure 13. Place nut on button and turn it clockwise to secure emergency disconnect button and bushing in hole. Tighten nut to 2 N•m (18 lbf in).

4. Disconnect the clamp function and direction control switch if lift truck is equipped with these features. See Figure 9.

2. Connect wires to emergency disconnect switch. Tighten screws to 0.8 N•m (8.55 lbf in) typical; 1.2 N•m (10.7 lbf in) maximum.

5. Insert screwdriver or other flat tipped tool into the slot on the side of the switch. Pull tool up to remove the emergency disconnect switch, switch adapter, and lock from upper rear cover. See Figure 13.

3. Install switch adapter and lock onto emergency disconnect button assembly. Install switches, by pushing switches onto switch adapter until switches clicks into place. Connect the main wire harness to the emergency disconnect switch. See Figure 9.

6. Remove the nut from upper rear cover. Remove the emergency disconnect button and bushing from hole in upper rear cover. See Figure 13.

4. Connect the clamp function and direction control switch if lift truck is equipped with these functions. See Figure 9.

2200 YRM 1337 5. Install and tighten the five socket head capscrews to secure upper rear cover to manual lever assembly. See Figure 13. 6. Install upper front cover. See the section Upper Front Cover for procedures.

E-HYDRAULIC CONTROLS - TEST Mini-Levers Perform all of the following test procedures to be sure mini-levers operate properly. See User Interface, Service Technician 2200 YRM 1336 instructions to view Lever output Value. With Service Password, view Diagnostics – Hydraulic Data Display – Hydraulic Input.

Full Stroke Test Check for full stroke of mini-lever. Use DSC or install the Service Tool to monitor functions. 1. Stroke each lever to full stroke, forward and backward, and allow lever to snap back to center. 2. (Do not start.) Turn key switch to ON position. 3. Display the electro-hydraulic diagnostics menu on the dash display panel. Operate each lever to full stroke forward and read input. • Is lever output ≥ -92%? • YES: Go to Step 4. • NO: Mini-lever not working properly. See procedures for each generation of MLM for repair or replacement. Upon completion, rerun the test. 4. Operate each lever to full stroke backward and read input. • Is lever output ≥ +92%? • YES: Mini-lever is supplying full stroke. • NO: Mini-lever not working properly. See procedures for each generation of MLM for repair or replacement. Upon completion, rerun the test. 5. If mini-lever continues to not function properly, contact your local Yale dealer or see Yale Axcess Online.

Electronic and Manual Hydraulic Controls

Function Returns to Neutral Test Check to confirm function returns to neutral (0%). Use DSC or install the Service Tool to monitor functions. 1. Stroke each lever to full stroke, forward and backward, and allow lever to snap back to center. 2. (Do not start.) Turn key switch to ON position. 3. Display the electro-hydraulic diagnostics menu on the dash display panel. • Is each lever output = 0%? • YES: Go to Step 4. • NO: Mini-lever is not working properly. See procedures for each generation of MLM for repair or replacement. Upon completion, rerun the test. 4. Operate each lever to full stroke forward and slowly release (1-2 seconds from full stroke). Read output when fully released. • Is each lever output = 0%? • YES: Go to Step 5. • NO: Mini-lever is not working properly. See procedures for each generation of MLM for repair or replacement. Upon completion, rerun the test. 5. Operate each lever to full stroke back and slowly release (1-2 seconds from full stroke). Read output when fully released. • Is each lever output = 0%? • YES: Mini-lever function is returning to neutral. • NO: Mini-lever is not working properly. See procedures for each generation of MLM for repair or replacement. Upon completion, rerun the test. 6. If mini-lever continues to not function, contact your local Yale dealer or see Yale Axcess Online.

Push Button Switch 1. Validate push button switch operates properly by operating applicable function. 2. If system does not function; see procedures for each generation of MLM for repair or replacement. Upon completion, rerun the test. 3. If push button switch continues to not function properly, contact your local Yale dealer or see Yale Axcess Online.

Electronic and Manual Hydraulic Controls

E-HYDRAULIC CONTROLS The lift trucks covered in this service manual may be equipped with optional E-Hydraulic control mini-levers. See Figure 14. Each mini-lever can be replaced separately if one malfunctions. Like manual control levers, E-Hydraulic control mini-levers can be equipped with an optional clamp function (either the third or fourth mini-lever). There is a momentary switch behind the mini-lever (either the third or fourth mini-lever) that engages and disengages the clamp function. If the clamping function quits working, the mini-lever and momentary switch may need to be replaced. See the sections Mini-levers, Remove and Install and Momentary Switches and Function Selection Button for replacement procedures.

1. 2. 3. 4. 5. 6. 7.

2200 YRM 1337 1. Read and follow the WARNING and CAUTION section in the General section above. 2. Remove the two capscrews that secure the minilever to the armrest. Remove mini-lever from armrest. See Figure 15.

ARMREST EMERGENCY DISCONNECT SWITCH HORN BUTTON DIRECTION CONTROL SWITCH MINI-LEVERS TO WIRE HARNESS MOMENTARY SWITCHES Figure 14. E-Hydraulic Controls Arrangement

Mini-levers, Remove and Install CAUTION The following procedure should only be performed by trained certified technicians. The removal and replacement of the mini-levers should be done in a clean environment whenever possible and on an electrically grounded surface. Do not touch any printed circuit board (PCB) surface to prevent damage from electrostatic voltage.

1. 2. 3. 4.

CAPSCREWS MINI-LEVER ARMREST MOMENTARY SWITCH Figure 15. Mini-Lever Removal

NOTE: Before installing new mini-lever, check the Parts Manual for the correct part number to be sure the correct mini-lever is being installed. 3. Install new mini-lever onto armrest using two capscrews.

2200 YRM 1337

Electronic and Manual Hydraulic Controls

Armrest Assembly Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove two capscrews from seat box cover and remove cover from seat box. Disconnect the main E-Hydraulic control wire harness from E-Hydraulic armrest harness. See Figure 16.

1. 2. 3. 4. 5.

E-HYDRAULIC CONTROL WIRE HARNESS FLANGE CAPSCREWS ARMREST ARMREST MOUNTING BRACKET HOLES FOR FLANGE CAPSCREWS Figure 17. E-Hydraulic Armrest and Mounting Bracket

4. Remove armrest from armrest mounting bracket.

NOTE: COMPONENTS PARTS AND ELECTRICAL CONNECTIONS OMITTED OR MOVED FOR CLARITY. 1. 2. 3. 4.

SEAT BOX COVER CAPSCREWS SEAT BOX E-HYDRAULIC ARMREST HARNESS

5. OPERATOR PRESENCE SYSTEM HARNESS 6. ARMREST

Figure 16. Seat Box Cover Removal 3. Pull up on handle (see Figure 18) and slide armrest all the way forward and remove the flange capscrew from under the armrest mounting bracket that attaches the armrest to the mounting bracket. Pull up on handle and slide armrest all the way back and remove the other flange capscrew. See Figure 17.

A. HANDLE MOVES ARMREST FORWARD OR BACKWARD B. HANDLE MOVES ARMREST UP OR DOWN Figure 18. Armrest Adjustment Handles

Electronic and Manual Hydraulic Controls

2200 YRM 1337

5. Remove the six socket head screws that fasten the bottom and top armrest covers together. See Figure 19. Remove the bottom armrest cover from armrest.

1. 2. 3. 4.

TO E-HYDRAULIC CONTROL WIRE HARNESS SOCKET HEAD SCREWS PCB CASSETTE MOMENTARY SWITCHES/FUNCTION SELECTION BUTTON CONNECTOR Figure 20. PCB Cassette Removal

Install 1. Install PCB cassette to armrest with three socket head screws. See Figure 20. 1. SOCKET HEAD SCREWS 2. BOTTOM ARMREST COVER Figure 19. Bottom Armrest Cover Removal NOTE: The momentary switches and function selection button are optional features. If lift truck is not equipped with these features, there will be a plug covering the electrical connector on the PCB cassette. 6. Disconnect the momentary switches/function selection button connector from PCB cassette. See Figure 20. 7. Remove the three socket screws from PCB cassette and remove PCB cassette from the armrest. See Figure 20.

2. If lift truck is equipped, connect the momentary switches/function selection button connector to PCB cassette. See Figure 20. 3. Install bottom armrest cover to armrest with six socket head screws. See Figure 19. 4. Install new armrest onto mounting bracket with flange capscrews. Tighten flange capscrews to 13 to 15 N•m (115 to 132 lbf in). 5. Connect the E-hydraulic wire harness to armrest. See Figure 17. Install seat box cover to seat box with two capscrews. See Figure 16. Tighten capscrews to 1.2 N•m (10.6 lbf in). 6. Connect the battery.

2200 YRM 1337

Electronic and Manual Hydraulic Controls

Horn Button

Install

Remove

1. Insert new horn switch into armrest and secure switch to armrest with two Phillips head screws. See Figure 21.

1. Read and follow the WARNING and CAUTION section in the General section above. 2. Remove the armrest from armrest mounting bracket. Remove bottom armrest and PCB cassette. See the section Armrest Assembly for removal procedures. 3. Disconnect the horn button from the E-Hydraulic control wire harness. Remove two Phillips head screws that attach horn button to armrest. See Figure 21. Remove horn button from armrest.

2. Connect the horn button to the E-Hydraulic control wire harness. 3. Install armrest and PCB cassette to armrest and install armrest to armrest mounting bracket. See the section Armrest Assembly for installation procedures.

NOTE: MOMENTARY SWITCHES AND FUNCTION SELECTION BUTTON CONNECTIONS NOT SHOWN FOR CLARITY. SEE FIGURE 25 FOR MOMENTARY SWITCHES AND FUNCTION SELECTION BUTTON CONNECTIONS. 1. 2. 3. 4. 5.

PHILLIPS HEAD SCREWS DIRECTION CONTROL SWITCH ADAPTER EMERGENCY DISCONNECT SWITCH EMERGENCY DISCONNECT SWITCH ADAPTER NUT

6. 7. 8. 9.

LOCK HORN BUTTON CONNECTOR ARMREST DIRECTION CONTROL SWITCH CONNECTOR

Figure 21. Switch Arrangement and Connections, E-Hydraulic Mini-Levers

Electronic and Manual Hydraulic Controls

Direction Control Switch Remove 1. Read and follow the WARNING and CAUTION section in the General section above. 2. Remove the armrest from armrest mounting bracket. Remove bottom armrest cover. See the section Armrest Assembly for removal procedures.

2200 YRM 1337 3. Install armrest cover to armrest, and install armrest to armrest mounting bracket. See the section Armrest Assembly for installation procedures.

Emergency Disconnect Switch Both E-Hydraulic controls and manual hydraulic controls use the same emergency disconnect switch. See Figure 23.

3. Remove the direction control switch assembly from the armrest by compressing the clips on either side of the bezel and carefully pulling the assembly out. Disconnect the E-Hydraulic control wiring harness from the direction control switch. See Figure 22.

1. 2. 3. 4.

DIRECTION CONTROL SWITCH BEZEL ARMREST E-HYDRAULIC CONTROL VALVE WIRING HARNESS

Figure 22. Direction Control Switch Replacement 4. Remove the direction control switch from the bezel. See Figure 22. Install 1. Insert new direction control switch into bezel. See Figure 22. 2. Connect the E-Hydraulic control valve wiring harness to the direction control switch. Install the direction control switch assembly into the armrest by compressing the clips on either side of the bezel and pushing the assembly into the armrest until the clips latch. See Figure 22.

1. HORN BUTTON 2. EMERGENCY DISCONNECT SWITCH 3. DIRECTION CONTROL SWITCH Figure 23. Emergency Disconnect Switch Location, E-Hydraulic Controls Remove 1. Read and follow the WARNING and CAUTION section in the General section above. 2. Remove the armrest from armrest mounting bracket. Remove bottom armrest and PCB cassette. See the section Armrest Assembly for removal procedures.

2200 YRM 1337 3. Disconnect the wires from the emergency disconnect switch. 4. Insert screwdriver or other flat tipped tool into the slot on the side of the switch. See Figure 13. Pull tool up to remove the emergency disconnect switch, switch adapter, and lock from underneath armrest. 5. Remove the nut from underneath armrest. See Figure 21. Remove the emergency disconnect button and bushing from top part of armrest. Install 1. Insert the emergency disconnect button and bushing into hole in top part of armrest.

Electronic and Manual Hydraulic Controls the function selection button will be located behind the fourth mini-lever. Pressing the button allows the fourth mini-lever to switch between the fourth and fifth functions. If the lift truck is equipped with a clamp attachment, the last mini-lever on the right controls the clamp function. Behind this lever will be a momentary switch. To engage the clamp, move the mini-lever backward. To disengage the clamp, push the momentary switch behind the minilever and move mini-lever forward. The different configurations of switches and buttons discussed in this section may not be found on your lift truck.

2. Place nut on button and turn it clockwise to secure emergency disconnect button and bushing to armrest. Tighten nut to 2 N•m (18 lbf in). See Figure 13 or Figure 21. 3. Install switch adapter and lock onto emergency disconnect button assembly. Install switches, by pushing switches onto switch adapter until switches clicks into place. 4. Connect wires to emergency disconnect switch. Tighten screws to 0.8 N•m (8.55 lbf in) typical; 1.2 N•m (10.7 lbf in) maximum. 5. Install armrest and PCB cassette to armrest and install armrest to armrest mounting bracket. See the section Armrest Assembly for installation procedures.

Momentary Switches and Function Selection Button On lift trucks equipped with E-Hydraulic controls, there may be two optional momentary switches (green buttons) and a function selection button (yellow button) located behind the second, third, or fourth mini-lever. See Figure 24. The momentary switch located behind the second mini-lever is used to override the Return To Set Tilt (RTST) function. By pressing this switch, the RTST parameters are overridden and the mast is allowed to tilt unrestricted. If the lift truck is equipped with three mini-levers and a four function control valve, there will be a function selection button behind the third mini-lever. Pressing this button allows the third mini-lever to switch between the third and fourth functions. If the lift truck is equipped with four mini-levers and a five function control valve,

NOTE: ALL POSSIBLE MOMENTARY SWITCHES AND FUNCTION SELECTION BUTTON CONFIGURATIONS SHOWN. NOT ALL LIFT TRUCK MAY HAVE ALL SWITCHES AND BUTTONS SHOWN. 1. MINI-LEVERS 2. MOMENTARY SWITCH (RTST) 3. FUNCTION SELECTION BUTTON

4. MOMENTARY SWITCH (CLAMP) 5. ARMREST HOUSING

Figure 24. Momentary Switches and Function Selection Button Location Remove 1. Read and follow the WARNING and CAUTION section in the General section above. 2. Remove the armrest from armrest mounting bracket. Remove bottom armrest and PCB cassette. See procedures in Armrest Assembly section above.

Electronic and Manual Hydraulic Controls NOTE: Tag wires prior to disconnecting them to aid in reconnecting.

2200 YRM 1337 c. Rotate red screw to right stop.

3. Pull the momentary switches or function selection button connectors apart to disconnect them from wire harness. See Figure 25.

d. Adjust position of yellow, rectangular function selection button. See Figure 24. Install and tighten knurl nut to secure function selection button to armrest.

4. If momentary switch is being replaced, remove lock nut from back of green, round, push button. Remove push button switch from armrest. See Figure 25.

e. Apply Nye 760G grease (supplied in kit) to function selection button switch connector. Push function selection button connector to wire harness. See Figure 25.

NOTE: Note the position of the yellow, rectangular, function button before removal to aid in installation. See Figure 24. 5. If function selection button is being replaced: a. Remove knurl nut. See Figure 25. b. Rotate red screw to left stop. Remove blue connector by sliding it from black cylinder. See Figure 25. c. Remove function button from armrest. Install 1. If installing a new function selection button: a. Insert black cylinder portion of function selection button through armrest housing. b. Slide blue connector onto cylinder. See Figure 25.

2. If installing a momentary switch: a. Install new green, round momentary switch assembly through armrest housing. b. Install and tighten lock nut to secure momentary switch to armrest. See Figure 25. c. Push momentary switch connector to wire harness. See Figure 25. 3. Install armrest and PCB cassette to armrest and install armrest to armrest mounting bracket. See the section Armrest Assembly for installation procedures. 4. Connect the E-hydraulic wire harness to armrest. See Figure 17.

2200 YRM 1337

1. 2. 3. 4.

CLAMP BUTTON CONNECTION RTST CONNECTION FUNCTION SELECTION BUTTON CONNECTION RED SCREW

Electronic and Manual Hydraulic Controls

5. 6. 7. 8.

LOCK NUT BLUE CONNECTOR KNURL NUT BLACK CYLINDER

Figure 25. Momentary Switches and Function Selection Button Replacement

Sensors and Switches

2200 YRM 1337

Sensors and Switches GENERAL WARNING Before replacing any sensor or switch, fully lower all parts of the mast and tilt it forward until the tips of the forks touch the ground. This action will prevent the mast from lowering suddenly if the control lever is accidently moved. Never have any metal on your fingers, arms, or neck. These metal items can accidentally create an electrical connection and cause an injury.

WARNING Discharge capacitors as directed in Discharging the Capacitors in General section of this manual.

CAUTION A short circuit and damage can occur if wires are not installed correctly. Make sure wire connectors do not touch the other metal terminals or wire connectors, metal brackets, or the bracket mounting nuts. Make sure the wires are not pulled tight and are not touching other parts to damage the insulation. All sensors and switches used on these trucks are nonrepairable parts. Replace with new sensors or switches whenever a sensor or switch malfunctions and is not operating correctly. See the Parts Manual for replacement part numbers. Before installing new sensors or switches, use a clean cloth and make sure the area around the sensor or switch is clean and free of oils and contaminates. When removing and replacing sensors or switches, be sure to tag connectors to aid in correct reconnecting.

STEERING AXLE SENSOR Lift Truck Models ERP15-20VT (ERP030-040VT) (G807) The steering axle sensor is located on top of the steering axle. To access the sensor, the hydraulic pump and motor and hydraulic system components need to be removed from the counterweight. Remove 1. Read and follow the WARNING and CAUTION in the General section above. NOTE: Be sure to tag connectors and hoses to aid in installation. 2. Disconnect the power cables, electrical connections, and hydraulic hoses from the hydraulic pump, motor, and hydraulic tank. NOTE: Before removing the hydraulic motor, pump and system components, attach a strap with a lifting device around the hydraulic motor. Lifting device must be able to lift 91 kg (200 lb). 3. Remove the three capscrews and washers that secure hydraulic motor to motor mounting bracket. Remove motor, pump and system components from counterweight using lifting device. See Figure 26. 4. Disconnect steering axle sensor from steering wire harness. Remove two socket head screws from steering axle cover. Remove cover and sensor from steering axle. See Figure 27. 5. The steering axle sensor is attached to underside of cover. Remove two socket head screws, and steering axle sensor from cover. See Figure 27.

2200 YRM 1337

1. 2. 3. 4. 5.

Sensors and Switches

HYDRAULIC TANK HYDRAULIC RETURN HOSE HYDRAULIC OIL FILTER HYDRAULIC TANK BREATHER HYDRAULIC MOTOR POWER CABLES

6. HYDRAULIC MOTOR ELECTRICAL CONNECTORS 7. HYDRAULIC MOTOR MOUNTING CAPSCREWS AND WASHERS 8. HYDRAULIC MOTOR

9. HYDRAULIC MOTOR MOUNTING BRACKET 10. HYDRAULIC SUPPLY HOSE

Figure 26. Hydraulic System Mounting Bracket and Components

Sensors and Switches

2200 YRM 1337

Figure 27. Steering Axle Sensor Removal

2200 YRM 1337

Sensors and Switches Legend for Figure 27

NOTE: SOME COMPONENTS OMITTED FOR CLARITY. LEFT SIDE SHOWN. 1. STEERING AXLE 2. STEERING AXLE COVER SOCKET HEAD SCREWS 3. COUNTERWEIGHT

4. SENSOR SOCKET HEAD SCREWS 5. STEERING AXLE SENSOR 6. STEERING AXLE COVER

Install

Remove

1. Install new steering axle sensor on steering axle cover using two socket head screws.

1. Read and follow the WARNING and CAUTION in the General section above.

2. Install cover to the top of the steering axle. Secure cover to steering axle with two socket head screws. Connect steering axle sensor to steering wire harness. See Figure 27.

2. Put the lift truck on jacks or blocks and remove the right steer tire and wheel. See Periodic Maintenance 8000 YRM 1373 section for the procedures.

3. Use lifting device and place hydraulic system components and hydraulic motor and pump back into counterweight cavity. 4. Attach hydraulic pump and motor to mounting bracket using three capscrews and washers. Tighten capscrews to 26 N•m (230 lbf in). 5. Connect the hydraulic hoses. Connect the power cables and electrical connections. 6. Remove strap from hydraulic motor. Install counterweight cover on counterweight. Connect the battery.

Lift Truck Models ERP16-20VF (ERP30-40VF) (A955) The steering axle sensor is located on the right side of the steering axle. See Figure 28.

3. Disconnect the battery and disconnect sensor from steering wire harness. 4. Remove the flange capscrew and protective cover from steering axle. 5. Remove two socket head screws and sensor from steering axle. See Figure 28. Install 1. Using two socket head screws, install new sensor onto steering axle. See Figure 28. 2. Connect sensor to steering wire harness. Install protective cover to steering axle with flange capscrew. 3. Install wheel and tire to steering axle and remove lift truck from blocks. See Periodic Maintenance 8000 YRM 1373 section for the procedures. 4. Connect the battery.

Sensors and Switches

2200 YRM 1337

NOTE: RIGHT SIDE SHOWN. 1. FLANGE CAPSCREW 2. PROTECTIVE COVER 3. SOCKET HEAD SCREWS

4. STEERING AXLE SENSOR 5. STEERING WIRE HARNESS CONNECTOR 6. MAGNET Figure 28. Steering Axle Sensor Replacement

2200 YRM 1337

Sensors and Switches

HYDRAULIC MOTOR SPEED SENSOR

Install

Remove

1. Install new sensor and connector into hydraulic motor. See Figure 29.

1. Read and follow the WARNING and CAUTION in the General section above.

2. Attach sensor to hydraulic motor with socket head screw.

2. Remove the cover from the counterweight. 3. Disconnect hydraulic speed sensor wire harness. 4. Remove the socket head screw, speed sensor, and connector from hydraulic motor. See Figure 29.

3. Connect hydraulic speed sensor to hydraulic wire main harness. 4. Install counterweight cover and connect the battery.

HYDRAULIC MOTOR TEMPERATURE SENSOR The hydraulic motor temperature sensor is heat welded and sealed onto the winding coils in the stator housing in the hydraulic motor. It is a non-replaceable part and cannot be replaced separately from the hydraulic motor. See Figure 29.

TRANSMISSION SPEED SENSOR NOTE: There are two transmission speed sensors. The procedures below describe how to replace one sensor. The procedures are the same for both sensors.

Remove NOTE: LIFT TRUCK MODEL ERP15-20VT (ERP030040VT) (G807) SHOWN. HYDRAULIC MOTOR SPEED SENSOR IN SAME LOCATION ON LIFT TRUCK MODELS ERP16-20VF (ERP30-40VF) (A955). 1. 2. 3. 4.

HYDRAULIC MOTOR SPEED SENSOR SOCKET HEAD SCREW HYDRAULIC MOTOR TEMPERATURE SENSOR SPEED SENSOR CONNECTOR

1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove the floor mat. Lift the floor plate up enough to disconnect the accelerator pedal or Foot Directional Control pedal, (see Figure 30 or Figure 35). Remove floor plate with the accelerator pedal or Foot Directional Control pedal still attached.

Figure 29. Hydraulic Motor Speed Sensor

Sensors and Switches

2200 YRM 1337

A. FOOT DIRECTIONAL CONTROL PEDAL

B. STANDARD ACCELERATOR PEDAL

1. PEDAL BASE 2. ACCELERATOR PEDAL POSITION SWITCH

3. FOOT DIRECTIONAL CONTROL PEDAL CONNECTOR

Figure 30. Disconnecting Accelerator and Foot Directional Control Pedal

2200 YRM 1337

Sensors and Switches

3. The transmission speed sensors are located on the top of each transmission. Disconnect the transmission speed sensor from transmission wire harness. 4. Remove the socket head screw securing the transmission speed sensor to transmission. Remove transmission speed sensor and sensor connector from transmission. See Figure 31.

Install 1. Install new transmission speed sensor and sensor connector onto transmission. Secure transmission speed sensor to transmission with socket head screws. See Figure 31. 2. Connect transmission speed sensor to transmission wire harness. 3. Connect the accelerator pedal or Foot Directional Control pedal and install floor plate. Install floor mat and connect the battery.

NOTE: SOME COMPONENT PARTS OMITTED FOR CLARITY. 1. SOCKET HEAD SCREW 2. SENSOR CONNECTOR

3. TRANSMISSION SPEED SENSOR 4. TRANSMISSION Figure 31. Transmission Speed Sensor Removal

Sensors and Switches

2200 YRM 1337

TRACTION MOTOR TEMPERATURE SENSOR The traction motor temperature sensor is heat welded and sealed onto the winding coils in the stator housing in the traction motor. It is a non-replaceable part and cannot be replaced separately from the traction motor.

TILT POSITION SENSOR WARNING Before replacing any components installed on the mast, fully lower all parts of the mast and tilt it forward until the tips of the forks touch the ground. This action will prevent the mast from lowering suddenly if the control lever is accidently moved. NOTE: Tilt position sensor only on lift trucks equipped with e-hydraulics. The tilt position sensor is located on the right side of the mast. It is mounted on a bracket on the right tilt cylinder anchor. See Figure 32.

Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Disconnect the tilt position sensor from the cowl wire harness connector. 3. Remove two socket head capscrews, washer, external tooth lockwasher, and capscrews from tilt position sensor mounting bracket. Remove tilt position sensor mounting bracket and tilt position sensor from mast. See Figure 32.

Install 1. Connect new tilt position sensor to cowl wire harness connector. See Figure 32. 2. Install tilt position sensor to tilt position sensor mounting bracket using washer, external tooth washer, capscrew, and socket head capscrews. 3. Connect the battery. 4. Tilt the mast completely forward and backward to ensure that the tilt position sensor is correctly installed and connected.

NOTE: SOME TRUCK COMPONENTS OMITTED FOR CLARITY. 1. 2. 3. 4. 5. 6. 7. 8. 9.

RIGHT TILT CYLINDER WASHER EXTERNAL TOOTH LOCKWASHER TILT POSITION SENSOR MOUNTING BRACKET CAPSCREW SOCKET HEAD CAPSCREW TILT POSITION SENSOR CONNECTOR COWL WIRE HARNESS CONNECTOR TILT POSITION SENSOR Figure 32. Tilt Position Sensor Replacement

LOW LEVEL BRAKE FLUID SWITCH NOTE: The low level brake fluid switch is a component of the master brake cylinder reservoir and is located on the bottom of the reservoir.

2200 YRM 1337

Sensors and Switches

NOTE: SOME COMPONENTS OMITTED FOR CLARITY 1. 2. 3. 4.

BRAKE MASTER CYLINDER BRAKE PRESSURE SENSOR COWL HARNESS CONNECTOR BRAKE FLUID RESERVOIR

5. LOW LEVEL BRAKE FLUID SWITCH CONNECTOR 6. BRAKE PEDAL

Figure 33. Brake System Switches and Sensors 4. Press the retaining clip on the low level brake fluid switch and pop low level brake fluid switch out and remove it from the brake fluid reservoir. See Figure 34.

Install

2. Connect the low brake fluid level switch connector to the cowl harness. 3. Connect the accelerator pedal or Foot Directional Control pedal and install floor plate. Install floor mat and connect the battery.

1. Install new low level brake fluid switch into brake fluid reservoir. Switch will snap into position. See Figure 34.

Sensors and Switches

2200 YRM 1337

Install 1. Install a new brake pressure sensor on master cylinder. Tighten brake pressure sensor to 23 to 28 N•m (204 to 248 lbf in). 2. Connect new brake pressure sensor to cowl wire harness. See Figure 33. 3. Connect the accelerator pedal or Foot Directional Control pedal, if lift truck is equipped with one, and install floor plate. Install floor mat and connect the battery. 1. 2. 3. 4. 5.

4. Bleed the brake system as described in the section Brake System 1800 YRM 1332.

RETAINING CLIP BRAKE MASTER CYLINDER BRAKE PRESSURE SENSOR BRAKE FLUID RESERVOIR LOW LEVEL BRAKE FLUID SWITCH

ACCELERATOR PEDAL POSITION SENSOR

Figure 34. Low Level Brake Fluid Switch Replacement

SERVICE BRAKE PRESSURE SENSOR Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove the floor mat. Lift the floor plate up enough to disconnect the accelerator pedal or Foot Directional Control pedal (see Figure 30 or Figure 35). Remove floor plate with the accelerator pedal or Foot Directional Control pedal still attached, for access to the brake master cylinder. 3. Disconnect brake pressure sensor from cowl wire harness and remove it from master cylinder. See Figure 33.

Remove NOTE: The accelerator pedal position sensor can not be replaced separately from the accelerator pedal. If the accelerator pedal position sensor malfunctions, the accelerator pedal assembly must be replaced. NOTE: In the steps and illustrations below, the standard accelerator pedal is used. The procedures to replace a Foot Directional Control pedal are the same as the standard accelerator pedal. 1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove the floor mat. Lift the floor plate up enough to disconnect the electrical connectors from the accelerator pedal or Foot Directional Control pedal (see Figure 35).

Legend for Figure 35 NOTE: FLOOR MAT REMOVED FOR CLARITY. A. TOP VIEW

B. BOTTOM VIEW

1. 2. 3. 4.

5. 6. 7. 8.

CAPSCREW ACCELERATOR PEDAL FLOOR PLATE PEDAL BASE

ACCELERATOR PEDAL MOUNTING PLATE ACCELERATOR PEDAL POSITION SENSOR ELECTRICAL CONNECTORS NUTS

2200 YRM 1337

Sensors and Switches

Figure 35. Accelerator Pedal Replacement

Sensors and Switches 3. Remove three capscrews and nuts that attach the accelerator pedal and pedal base to accelerator pedal mounting plate. Remove accelerator pedal mounting plate

Install 1. Install new accelerator pedal, pedal base and accelerator pedal mounting plate to floor plate with capscrews and nuts. See Figure 35.

2200 YRM 1337 2. Connect seat sensor to seat harness. 3. Install seat onto hood using four capscrews and washers in the correct holes as marked during removal. Tighten capscrews to 18 N•m (156 lbf in). See Figure 36. 4. Connect seat harness to chassis harness. 5. Connect the battery and close the hood.

2. Connect the accelerator pedal electrical connectors. 3. Install the floor mat and connect the battery.

SEAT SENSOR (OPERATOR PRESENCE SYSTEM) Non-Suspension Seat Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Tilt the steering column all the way up. NOTE: Before removing seat from hood, tag or mark the holes that mount the seat to the hood. This will aid in correctly installing seat to hood. 3. Disconnect seat harness from chassis harness. Remove four capscrews and washers holding the seat to the hood. Remove seat from hood. See Figure 36. 4. Disconnect seat sensor. See Figure 37. 5. Remove two capscrews, washers, and seat sensor from seat. Install 1. Using two capscrews and washers, install sensor to seat. See Figure 37.

NOTE: BOTTOM VIEW OF HOOD SHOWN. 1. 2. 3. 4. 5.

HOOD LATCH ASSEMBLY CAPSCREWS AND WASHERS GAS SPRING HOOD HINGE ASSEMBLY SEAT HARNESS

Figure 36. Seat Removal, Non-Suspension Seat

2200 YRM 1337

Sensors and Switches 3. Place bottom seat cushion onto seat base and attach cushion to base with pins. 4. Connect the battery.

1. 2. 3. 4. 5.

CAPSCREWS SEAT SENSOR SEAT SENSOR ELECTRICAL CONNECTOR SEAT GROUND WIRE SEAT HARNESS Figure 37. Seat Sensor, Non-Suspension Seat

Full Suspension and Swivel Seats Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Pull out two pins that secure the bottom seat cushion to seat base. 3. Lift bottom seat cushion up and disconnect the seat sensor from harness. 4. Use a small, flat-bladed screwdriver and remove the seat sensor from seat base. Install 1. Install new seat sensor into seat base.

1. SEAT SENSOR 2. CUSHION PINS 3. SEAT HARNESS

4. SEAT BASE 5. TO CHASSIS HARNESS

Figure 38. Seat Sensor, Full Suspension Seat

STEERING WHEEL POSITION SENSOR Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Tilt steering column as far up as it will go. 3. Remove steering column upper cover by pressing from both sides and pulling steering column upper cover up. See Figure 39.

2. Connect seat sensor to seat harness. See Figure 38.

Sensors and Switches

2200 YRM 1337

Figure 39. Steering Column Upper Cover Removal

2200 YRM 1337

Sensors and Switches Legend for Figure 39

1. 2. 3. 4.

STEERING WHEEL STEERING COLUMN UPPER COVER STEERING CONTROL UNIT TILT MEMORY LEVER

4. Disconnect the steering wire harness from the Remove two steering wheel position sensor. socket head screws and disconnect spring from steering wheel position sensor. Remove steering wheel position sensor from steering column. Figure 40.

5. 6. 7. 8.

SPRING STEERING COLUMN LOWER COVER STEERING WHEEL POSITION SENSOR UPPER COVER MOUNTING NOTCHES

4. Connect battery. Adjust steering column for operator comfort.

LOAD WEIGHT SENSOR The lift trucks covered in this manual may be equipped with an optional load weight sensor. See Operating Manual for a more detailed description on how the load weight sensor works.

Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove the floor mat. Lift the floor plate up enough to disconnect the accelerator pedal or Foot Directional Control pedal (see Figure 30 or Figure 35). Remove floor plate with the accelerator pedal or Foot Directional Control pedal still attached. 3. Disconnect the harness connector from the load weight sensor. 4. Remove load weight sensor from T-Fitting on hydraulic control valve. See Figure 41.

Install 1. SOCKET HEAD SCREW HOLE 2. STEERING WHEEL POSITION SENSOR 3. SPRING Figure 40. Steering Wheel Position Sensor

Install 1. Install new steering wheel position sensor to steering column with two socket head screws. Connect the spring to steering wheel position sensor. See Figure 40. 2. Connect the sensor to the steering wire harness.

1. Insert new load weight sensor into T-Fitting. Tighten sensor by hand, and then torque sensor to 37 N•m (27 lbf ft). 2. Connect the harness connector to the load weight sensor. See Figure 41. 3. Connect the accelerator pedal or Foot Directional Control pedal and install floor plate. Install floor mat and connect the battery. 4. Re-calibrate the load weight sensor. See the section User Interface, Service Technician 2200 YRM 1336 for calibration procedures.

3. Install steering column upper cover by pressing from both sides and pushing against lower cover until upper cover snaps into place.

Sensors and Switches

2200 YRM 1337

BATTERY GATE SWITCH The lift trucks covered in this manual may be equipped with an optional battery restraint system that includes rollers and a side battery gate for horizontal removal of the battery. There is a switch for the side battery gate, located on the right side of the lift truck, under the floor plate and floor mat. See Figure 42.

Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove the floor mat. Lift the floor plate up enough to disconnect the accelerator pedal or Foot Directional Control pedal (see Figure 30 or Figure 35). Remove floor plate with the accelerator pedal or Foot Directional Control pedal still attached. 3. Disconnect the switch from main harness. NOTE: E-HYDRAULIC CONTROL VALVE SHOWN. LOAD WEIGHT SENSOR IS IN SAME POSITION ON MANUAL HYDRAULIC CONTROL VALVE. 1. 2. 3. 4. 5.

HYDRAULIC CONTROL VALVE SPECIAL FITTING T-FITTING LOAD WEIGHT SENSOR HARNESS CONNECTOR Figure 41. Load Weight Sensor

4. Remove two capscrews and washers and remove switch from plate. See Figure 42.

Install 1. Install new switch onto plate using two washers and capscrews. See Figure 42. 2. Connect switch to main harness. 3. Connect the accelerator pedal or Foot Directional Control pedal and install floor plate. Install floor mat and connect the battery.

2200 YRM 1337

1. 2. 3. 4.

Sensors and Switches

5. ACTUATOR MAGNET SWITCH 6. BATTERY GATE SWITCH 7. CAPSCREW/WASHER

SIDE BATTERY GATE GATE LEVER PLATE SWITCH CONNECTOR

Figure 42. Battery Gate Switch

HORN SWITCH NOTE: The procedures below are for replacing the horn switch located on the steering column. If your lift truck is equipped with E-Hydraulic mini-levers, there is a horn button on the armrest. See the section Electronic and Manual Hydraulic Controls for procedures to replace horn sensor on the E-Hydraulic armrest.

Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove horn button, nut, and rod from steering wheel. See Figure 43. 1. HORN BUTTON 2. NUT

3. ROD 4. STEERING WHEEL

Figure 43. Horn Button Assembly and Electrical Connections

Sensors and Switches

2200 YRM 1337

CAUTION Horn wires could be damaged using a steering wheel puller. 3. remove hex nut and steering wheel from steering column. If necessary, use a puller tool to remove steering wheel. See Figure 44.

1. HEX NUT 2. STEERING WHEEL

3. STEERING COLUMN

Figure 44. Steering Wheel 4. Remove steering column upper cover by pressing from both sides and pulling cover up. See Figure 39. 5. Disconnect horn switch from steering wire harness. Remove capscrews, washers, and tapped plate from horn switch. Remove horn switch from horn switch plate. See Figure 45.

NOTE: FIXED STEERING COLUMN SHOWN. HORN SWITCH ON OPTIONAL TELESCOPIC STEERING COLUMN IS THE SAME. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

FIXED STEERING COLUMN HORN SWITCH PLATE PIN RETAINING RING SPRING SWITCH CONTACT WASHER SNAP RING CAPSCREW WASHER HORN SWITCH TAPPED PLATE Figure 45. Horn Switch

2200 YRM 1337

Sensors and Switches

Install 1. Install new horn switch, tapped plate, washers, and capscrews to horn switch plate. See Figure 45. Connect horn switch to steering wire harness. 2. Install steering column upper cover by pressing from both sides and pushing against steering column lower cover until steering column upper cover snaps into place. See Figure 39. 3. Install steering wheel and hex nut on steering column. Tighten nut to 40 to 54 N•m (30 to 40 lbf ft). See Figure 44. 4. Install rod, nut, and horn button in steering wheel. See Figure 43. 5. Connect the battery.

REAR HORN BUTTON SWITCH NOTE: The procedures below are for replacing the optional horn switch located in the rear handle on the rear right overhead guard leg. If your lift truck is equipped with E-Hydraulic mini-levers, there is a horn button on the armrest. See the section Electronic and Manual Hydraulic Controls for procedures to replace horn sensor on the E-Hydraulic armrest.

Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove the counterweight cover and disconnect rear horn switch from main wire harness. See Figure 46.

1. 2. 3. 4.

REAR HORN BUTTON REAR HANDLE OVERHEAD GUARD LEGS REAR HORN SWITCH CONNECTOR

Figure 46. Rear Horn Button Switch Arrangement 3. Remove the two capscrews from rear horn cover. Remove rear horn cover from rear handle. See Figure 47. 4. Remove rear horn switch and horn harness from rear handle and overhead guard leg.

Sensors and Switches

2200 YRM 1337

Install 1. Install new rear horn switch and horn harness into rear handle. Connect rear horn switch to main wire harness. See Figure 46. 2. Attach rear horn cover to hear handle with two capscrews. See Figure 47. 3. Install cover onto counterweight.

IMPACT SENSOR The impact sensor is located below floor mats and floor plates, above the VSM.

Remove 1. 2. 3. 4.

CAPSCREW REAR HORN COVER REAR HORN SWITCH AND HORN HARNESS REAR HANDLE

1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove floor mats and floor plates from lift truck.

Figure 47. Rear Horn Button Switch Disassembly NOTE: Tag sensor cable connection on main wiring harness before disconnecting to aid in reconnecting. 3. Disconnect sensor cable from main wiring harness. NOTE: Note placement and orientation of impact sensor prior to removal to aid in installation. 4. Remove two nuts, two capscrews, and impact sensor from sensor bracket. See Figure 48.

2200 YRM 1337

1. 2. 3. 4.

Sensors and Switches

IMPACT SENSOR SENSOR BRACKET CAPSCREW NUT Figure 48. Impact Sensor

Install 1. Install impact sensor, two capscrews, and two nuts onto sensor bracket as noted during removal. See Figure 48.

2. Connect sensor cable to main wiring harness as tagged during removal. 3. Install floor plates and floor mats in lift truck.

NOTE: Remove tag after connection is made.

Motor Controllers Replacement

2200 YRM 1337

Motor Controllers Replacement GENERAL WARNING Before replacing any of the motor controllers, fully lower all parts of the mast and tilt it forward until the tips of the forks touch the ground. This action will prevent the mast from lowering suddenly if the control lever is accidently moved.

HYDRAULIC PUMP AND MOTOR CONTROLLER Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove the counterweight cover for access to the hydraulic motor controller. See Figure 49.

WARNING Discharge capacitors as directed in in General section of this manual.

CAUTION Do not remove the small screws that fasten the cover of the motor controller. Make sure there is no dirt between the plate of the motor controller and the mount surface of the lift truck frame. The hydraulic pump and motor controller and traction motor controller, control and monitor the electrical function for their respective components. Before replacing any motor controllers, follow capacitor discharge procedure outlined above. Attach a tag to truck battery connector stating DO NOT CONNECT BATTERY. Remove the key or turn the keyless switch OFF. Make an identification for correct connection of the power cables on the power terminals of the motor controller and all electrical connections that are disconnected prior to removing the controller. This will aid in reconnecting during installation.

NOTE: LIFT TRUCK MODEL ERP15-20VT (ERP030040VT) (G807) SHOWN. COUNTERWEIGHT COVER FOR LIFT TRUCK MODELS ERP16-20VF (ERP30-40VF) (A955) IS THE SAME. 1. COUNTERWEIGHT COVER 2. CAPSCREW 3. COUNTERWEIGHT Figure 49. Counterweight Cover Removal NOTE: Make sure all power cables and electrical connections are clearly marked before disconnecting them to help aid in reconnecting. 3. Disconnect the power cables and all electrical connections from motor controller. 4. Remove two motor controller mounting bracket bolts that attach the motor controller assembly to the counterweight. Remove motor controller assembly and motor controller mounting bracket from lift truck counterweight frame. See Figure 50.

2200 YRM 1337

Motor Controllers Replacement

A. TOP VIEW OF CONTROLLER ARRANGEMENT

B. FRONT VIEW OF CONTROLLER

1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15.

AIR GUIDE SOCKET HEAD CAPSCREW HYDRAULIC PUMP AND MOTOR CONTROLLER HYDRAULIC MOTOR POWER CABLE W POWER CABLE V POWER CABLE U MOTOR CONTROLLER MOUNTING BRACKET

FAN CAPSCREW FAN MOUNTING BRACKET FAN FAN CONNECTOR CONTROLLER MOUNTING BRACKET BOLTS POWER CABLE GROMMET

Figure 50. Hydraulic Pump and Motor Controller

Motor Controllers Replacement 5. Remove four socket head capscrews and motor controller from motor controller mounting bracket. See Figure 50. Fan, Remove

2200 YRM 1337 NOTE: Perform Step 4 for lift truck models ERP15-20VT (G807). 4. After install complete, perform ground test. See Frame 100 YRM 1329, Ground Test.

1. Remove bolts and fan air duct housing from motor controller mounting bracket. See Figure 51.

TRACTION MOTOR CONTROLLERS

2. Remove four nuts, washers, capscrews, and fans from air duct housing.

NOTE: The lift truck models covered in this service manual are equipped with two traction motor controllers. The procedures below are the same for both traction motor controllers.

Fan, Install 1. Insert new fan into air duct housing. Make sure fan labels are visible and facing downward. See Figure 51. Secure fan to air duct housing with four capscrews, washers and nuts. 2. Install fan air duct housing to controller mounting bracket with two bolts. See Figure 51.

Install NOTE: Before installing new hydraulic pump and motor controller, inspect and replace fans if necessary. See Fan, Remove and Fan, Install for procedures. 1. Using four socket head screws, install new motor controller to motor controller mounting bracket. 2. Using two bolts, install motor controller bracket and motor controller assembly to counterweight. See Figure 50. 3. Connect the fans and other electrical connections as noted during removal. Connect power cables at the power terminals of the motor controller as identified during removal. Tighten power cables to 13 to 15 N•m (115 to 133 lbf in). Connect the battery.

Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove the floor mat. Lift the floor plate up enough to disconnect the accelerator pedal or Foot Directional Control pedal. See Figure 30 or Figure 35. Remove floor plate with the accelerator pedal or Foot Directional Control pedal still attached. NOTE: Make sure all power cables and electrical connections are clearly marked before disconnecting them to aid in reconnecting. 3. Disconnect the electrical connector plug for the control wires. Disconnect the fan from cowl harness. See Figure 52. 4. Disconnect the power cables from traction motor controller. See Figure 53.

2200 YRM 1337

1. 2. 3. 4. 5.

Motor Controllers Replacement

BOLT FAN ELECTRICAL CONNECTORS MOTOR CONTROLLER MOUNTING BRACKET NUT FAN AIR DUCT HOUSING

6. 7. 8. 9.

FAN* WASHER CAPSCREW GROMMET

*LABELS ON THIS SIDE. Figure 51. Fans

Motor Controllers Replacement

2200 YRM 1337

NOTE: SOME COMPONENTS OMITTED FOR CLARITY 1. 2. 3. 4. 5.

FRONT BULKHEAD CONTROLLER MOUNTING PLATE CONTROLLER MOUNTING HOOK FAN TRACTION MOTOR CONTROLLER

6. 7. 8. 9.

POWER CABLES ELECTRICAL CONNECTOR PLUG VEHICLE SYSTEMS MANAGER LINE CONTACTOR

Figure 52. Traction Motor Controller Removal

2200 YRM 1337

Motor Controllers Replacement

NOTE: RIGHT TRACTION MOTOR CONTROLLER SHOWN. ARRANGEMENT FOR LEFT TRACTION MOTOR CONTROLLER IS THE SAME. 1. 2. 3. 4. 5.

CONTROLLER MOUNTING PLATE FAN FAN CONNECTOR POWER CABLE U POWER CABLE V

6. POWER CABLE W 7. POWER CABLE CONNECTIONS TO LEFT TRACTION MOTOR CONTROLLER 8. TRACTION MOTOR CONTROLLER

Figure 53. Traction Motor Controller Arrangement 5. Lift traction motor controller, fan, and controller mounting plate off of controller mounting hook and remove from lift truck. SeeFigure 52.

6. Remove four socket head screws and nuts and remove traction motor controller from controller mounting plate. See Figure 54.

Motor Controllers Replacement

1. 2. 3. 4.

2200 YRM 1337

SOCKET HEAD SCREW TRACTION MOTOR CONTROLLER FAN CONNECTOR FAN CAPSCREW

5. CONTROLLER MOUNTING PLATE 6. NUTS 7. FAN AIR DUCT

Figure 54. Controller Replacement Fan, Remove 1. Remove fan connector and wire harness from fan assembly. See Figure 54. 2. Remove two fan capscrews and remove fan air duct and fan from controller mounting plate. See Figure 54. 3. Remove four capscrews, washers and nuts and remove fan from fan air duct. See Figure 55.

1. 2. 3. 4.

FAN CONNECTOR CAPSCREWS FAN AIR DUCT FAN

5. 6. 7. 8.

WASHER NUT FINGER GUARD LABEL SIDE OF FAN

Figure 55. Fan Replacement

2200 YRM 1337 Fan, Install NOTE: Make sure fan label is facing towards finger guard. See Figure 55. 1. Install new fan into fan air duct using four capscrews, washers, and nut to attach fan to finger guard. See Figure 55. 2. Install fan assembly to controller mounting plate with two fan capscrews. See Figure 54. 3. Connect the fan connector and wire harness to fan.

Install 1. On the back plate of new traction motor controllers, apply an even coat of silicone compound (Yale Part No. 504223239) or equivalent grease. The motor controller must make full contact with the lift truck heatsink. 2. Install new traction motor controller to controller mounting plate with four socket head screws, washers, and nuts. See Figure 54. 3. Install traction motor controller and fan assembly onto hooks on front bulkhead. See Figure 52. 4. Connect the power cables to motor controller. Tighten cables to 13 to 15 N•m (115 to 133 lbf in). 5. Connect electrical connector plug for the control wires. Connect fan to cowl wire harness.

Motor Controllers Replacement 6. Connect the accelerator pedal or Foot Directional Control pedal and install floor plate. Install floor mat and connect the battery. See Figure 30 or Figure 35. NOTE: Perform Step 7 for lift truck models ERP15-20VT (G807). 7. After install complete, perform ground test. See Frame 100 YRM 1329, Ground Test.

LINE CONTACTOR Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove the floor mat. Lift the floor plate up enough to disconnect the accelerator pedal or Foot Directional Control pedal (see Figure 30 or Figure 35). Remove floor plate with the accelerator pedal or Foot Directional Control pedal still attached. NOTE: Tag or mark line contactor power cables before disconnecting them to aid in connecting them during installation. 3. Disconnect the power cables. Remove capscrews that attach line contactor to line contactor mounting bracket. Remove line contactor from line contactor mounting bracket. Line contactor mounting bracket is mounted to brake pedal bracket with two capscrews and inserts. See Figure 56.

Motor Controllers Replacement

1. 2. 3. 4. 5.

LINE CONTACTOR MOUNTING BRACKET CAPSCREWS BRAKE PEDAL BRAKE PEDAL BRACKET LINE CONTACTOR

2200 YRM 1337

6. 7. 8. 9.

POWER CABLES VEHICLE SYSTEMS MANAGER TRACTION MOTOR CONTROLLER CAPSCREW AND INSERT*

*HARDWARE ATTACHES LINE CONTACTOR MOUNTING BRACKET TO BRAKE PEDAL BRACKET. Figure 56. Line Contactor Location and Removal

2200 YRM 1337

Motor Controllers Replacement

Install 1. Check new line contactor to ensure the PTC thermistor assembly is on contactor posts. See Figure 57. 2. Install new line contactor onto line contactor mounting bracket using two capscrews. See Figure 56. 3. Connect power cables to line contactor in same positions as noted during removal. 4. Connect the accelerator pedal or Foot Directional Control pedal and install floor plate. Install floor mat and connect the battery. See Figure 30 or Figure 35.

1. CAPSCREWS 2. PTC THERMISTOR ASSEMBLY 3. LINE CONTACTOR Figure 57. Line Contactor

Vehicle Systems Manager

2200 YRM 1337

Vehicle Systems Manager GENERAL WARNING Before replacing the Vehicle Systems Manager (VSM), fully lower all parts of the mast and tilt it forward until the tips of the forks touch the ground. This action will prevent the mast from lowering suddenly if the control lever is accidently moved. Never have any metal on your fingers, arms, or neck. These metal items can accidentally create an electrical connection and cause an injury.

WARNING Discharge capacitors as directed in Discharging the Capacitors in General section of this manual.

CAUTION Make sure there is no dirt between the plate of the motor controller and the mount surface of the lift truck frame. The Vehicle Systems Manager (VSM) is a micorprocessor-powered controller which controls or monitors directly or indirectly, every electrical device on the lift truck.

REMOVE NOTE: The VSM is not a serviceable part. If it malfunctions, replace with a new VSM. See the Parts Manual for replacement part number. 1. Read and follow the WARNING and CAUTION above in the General section. 2. Remove the floor mat. Lift the floor plate up enough to disconnect the accelerator pedal or Foot Directional Control pedal (see Figure 30or Figure 35). Remove floor plate with the accelerator pedal or Foot Directional Control pedal still attached. NOTE: Be sure to tag all connectors to aid correct installation 3. Disconnect the two main harness electrical connectors from VSM. 4. Remove three bolts securing the VSM and harness bracket to mounting bracket. Remove VSM from lift truck. See Figure 58.

INSTALL 1. Install new VSM onto mounting bracket. Tighten bolts to 19 N•m (168 lbf in). 2. Connect all electrical connections, as noted, to the VSM. See Figure 58. 3. Connect power cables to line contactor in same positions as noted during removal. 4. Connect the accelerator pedal or Foot Directional Control pedal and install floor plate. Install floor mat and connect the battery. See Figure 30 or Figure 35.

2200 YRM 1337

Vehicle Systems Manager

1. BOLTS 2. MOUNTING BRACKET 3. MAIN HARNESS ELECTRICAL CONNECTORS

4. VEHICLE SYSTEMS MANAGER 5. FUSE PANEL 6. LINE CONTACTOR

Figure 58. Vehicle Systems Manager Removal

Vehicle Systems Manager

PROGRAMMING A NEW VSM AND/OR DISPLAY PANEL NOTE: See the section Diagnostic Troubleshooting Manual 9000 YRM 1377 for information on how delete and reset fault codes to the VSM, how to use the PC Service Tool software, and for the procedures to troubleshoot the VSM, display panel, and other electrical components used on these trucks.

General Whenever a new VSM or display panel is installed (see Display Panel and Key or Keyless Switch Replacement for procedures to remove and install the display panel) on a lift truck, the data that controls all functions and features unique to that lift truck will be automatically transferred to the new VSM or display panel. There are two types of data files to be transferred when a new VSM or display panel is installed: • Configuration Data File (CDF). This data file has the configuration and optional details specific to a given truck. For example, configuration information may include data that shows the truck’s lifting capacity and base type (e.g., 2-3 Ton lifting capacity). Optional information may include data describing if the lift truck has any Software Enabled Features (SEF) installed (e.g., operator passwords). Adding new SEF will require that new CDF be downloaded. This data information is directly linked to the truck’s serial number. An example of a lift truck serial number is G807V12345A001. The first 11 characters (G807V12345A001) represent the truck’s serial number and the last 3 digits (001) represent the CDF revision loaded on the truck. The serial number of a lift truck is stored in the display panel. See the section User Interface, Service Technician 2200 YRM 1336 for the procedures to find the serial number. The CDF can be found online at Axcess Online® using the serial number. The CDF revision will change every time a new version is ordered and transferred to Axcess Online®. The CDF cannot be modified by a service technician. However, a replacement file (with alternate options [SEF]) can be loaded into a truck’s controller by a service technician.

2200 YRM 1337 • Truck Settings File (TSF). This data file includes information on the specific adjustments done to the various parameters on a given lift truck. The parameters on a given truck are those items that can be adjusted by a service technician. For example, auto-deceleration, which may be set on a scale from 1 to 10. Each parameter will also have a default value. Truck Setting Files also include the ability to activate and deactivate features. For example, a truck which has a CDF that enables the operator password feature, would have a selection in the TSF indicating whether the option has been activated or deactivated. A copy of the TSF is stored in both the VSM and display panel. Truck Settings Files can be copied across trucks within a fleet.

PC SERVICE TOOL SOFTWARE The PC Service Tool software is not used to transfer backup copies whenever a new VSM or display panel is installed on a lift truck. Backup copies are generated automatically when the system detects that a blank (new) VSM or display panel has been installed. A non-blank VSM or display panel is one that has been used previously. A non-blank VSM or display panel is not usable outside of the system it was originally connected to. In other words, a VSM or display panel cannot be removed from one lift truck and installed onto another lift truck. If a VSM or display panel must be replaced, a new part (blank) must be used. See the Parts Manual for part numbers for replacement parts. To perform diagnostic service, the PC Service Tool software can be used. To connect the PC Service Tool, remove the dust cover that covers the PC service tool diagnostic connector on the right side of the steering column and connect the interface cable (Yale Part No. 580039670) to the PC service tool diagnostic connector. See Figure 59. All transfers will create a transfer log on the PC’s hard drive and can be accessed by service personnel. The file transfer log will include all serial number transfers and other configuration information related to a specific truck. For minimum PC requirements to run the software, refer to the PC Service Tool Installation and Use Guide, Systems Requirements section.

2200 YRM 1337

Fuses Legend for Figure 59 1. DUST COVER 2. TILT MEMORY LEVER

Figure 59. Connecting PC Service Tool

Fuses WARNING Disconnect the battery and separate the connector before opening the compartment cover or inspecting/repairing the electrical system. If a tool causes a short circuit, the high-current flow from the battery can cause an injury or parts damage.

WARNING Use only fuses rated as specified in Figure 61. Replacing fuses with higher or lower amperage ratings than specified may cause injury or parts damage.

WARNING Discharge capacitors as directed in Discharging the Capacitors in General section of this manual.

Remove the floor mat. Lift the floor plate up enough to disconnect the accelerator pedal or Foot Directional Control pedal. See Figure 30 or Figure 35. Remove floor plate with the accelerator pedal or Foot Directional Control pedal still attached for access to fuse panel and relays. The condition of the fuses can normally be checked by looking at them. Some fuses do not change in appearance and must be checked with an ohmmeter. See Figure 61. Discharge capacitors as specified in Discharging the Capacitors in General section of this manual. Replace all bad fuses. Check to see what caused the fuse to open before connecting the battery. Make certain to replace any failed fuse with one of the same amperage.

The fuse panel and relay is located under the floor mat and floor plate, in front of left traction motor controller. See Figure 60.

Fuses

1. 2. 3. 4. 5.

2200 YRM 1337

FUSE PANEL AND RELAYS CAPSCREW AND INSERT TRACTION MOTOR CONTROLLERS VEHICLE SYSTEMS MANAGER LINE CONTACTOR Figure 60. Fuse Panel and Relay Location

2200 YRM 1337

Audible Alarm Legend for Figure 61 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

FU4 - (5 AMP) AUXILIARY DC CONVERTER FU3 - (10 AMP) SPARE FU2 - (10 AMP) STANDARD DC CONVERTER FU1 - (10 AMP) EMERGENCY DISCONNECT FUSE AND RELAY MOUNTING BRACKET RELAY - BRAKE LIGHTS RELAY - BACK UP LIGHTS RELAY - E-HYDRAULIC RELAY - KEY OR KEYLESS SWITCH FUSE WIRES

Figure 61. Fuse Panel Arrangement

Audible Alarm WARNING DO NOT operate a truck if the audible alarm does not function properly. Injury to personnel may occur.

Connect the connector as removed and test for proper operation. Replace the compartment covers, remove the truck from blocks, and return to service.

An audible alarm is used to indicate backwards travel. When backing up, the operator may be preoccupied with the position of the mast or carriage or have a restricted range of visibility. The audible alarm sounds when the lift truck is moved backwards to alert nearby traffic to pay close attention when near the lift truck. The alarm is located in the upper right corner on the rear overhead guard crossmember. See Figure 62. If the audible alarm is not functioning properly, raise the drive wheels of the lift truck. Refer to Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15-20VT (ERP030-040VT) (G807) or Periodic Maintenance 8000 YRM 1373 for lift truck models ERP16-20VF (ERP30-40VF) (A955) for procedures. Test the voltage to the audible alarm when the control handle is moved to the reverse position. When proper voltage (12 to 48 volts) is reaching the assembly yet no sound is produced, the assembly must be replaced. Disconnect the unit connector from the overhead guard wiring harness. Remove the hardware attaching the alarm to the overhead guard. Position the new unit as removed and secure using the hardware.

1. CAPSCREW 2. AUDIBLE ALARM 3. REAR OVERHEAD GUARD CROSSMEMBER Figure 62. Audible Alarm

Battery Connection

2200 YRM 1337

Battery Connection The battery cables supply power from the battery terminals through the battery cable connectors and then to the connections of the motor controllers and main contactor in the truck.

INSPECT Inspect the battery cables for cuts or damage to the insulation. Inspect for abrasions of the insulation or burned insulation or connector ends. Inspect the battery connectors for worn or damaged cable ends or cracked housings. Overheated cables or heat affected terminal lug ends are signs of cable damage, loose connections, or improper battery charging or maintenance. Replace any damaged cables and repair or replace damaged battery connectors.

REPLACING CABLES WARNING Making repairs with the battery connected can cause a short circuit. Disconnect the battery by separating the connectors before inspecting or repairing the electrical system. Be careful using tools near the battery terminals. Contact between terminals can cause a short circuit. High current flow during a short circuit can result in injury or parts damage. 1. Move the lift truck to a safe, level area and completely lower the mast. Turn the key switch to the OFF position and attach a DO NOT OPERATE tag to the control handle. Block the drive wheel to prevent unexpected movement. 2. Pull the connector (battery side) from the fixed connector (truck side) to separate the battery cable connectors. See Figure 63. 3. If the power cables or connector (battery side) are damaged, replace the cables: a. Remove the battery from the lift truck. See the Operating Manual or Periodic Maintenance for procedures to remove battery from lift truck.

d. Reinstall the battery to the lift truck. See the Operating Manual or Periodic Maintenance for procedures to install battery in lift truck. e. Connect the battery connectors. 4. If the power cables or connector (truck side) are damaged, replace the cables: a. Remove the floor mat. Lift the floor plate up enough to disconnect the accelerator pedal or Foot Directional Control pedal. See Figure 30 or Figure 35. Remove floor plate with the accelerator pedal or Foot Directional Control pedal still attached for access to the main contactor. b. Discharge capacitors as follows: Turn lift truck OFF Unplug battery connector If emergency disconnect switch is applied, release it Wait 10 seconds, capacitors will discharge themselves. NOTE: Make note of position of cables for proper reinstallation. c. Remove the nuts securing the cables to the terminals of the main contactor. Remove the cables from the terminals. d. Remove the two clamps securing cables to the frame inside the electrical compartment. One cable is on top of hydraulic filter and the other is under hydraulic motor. e. Remove the hardware securing the connector (truck side) to the mounting bracket. f.

g. Route new cables into the electrical compartment. h. Secure the connector to the mounting bracket using capscrews and attaching hardware. i.

Position the power cables onto the terminals as removed. Secure the cables to the terminals of the main contactor and hoist controller using the attaching hardware.

Install the two clamps securing power cables to the frame inside the electrical compartment as removed.

b. Disconnect the cables from the battery terminals. c. Install new cables.

Remove the power cables from the lift truck.

2200 YRM 1337

Battery Connection

k. Connect the accelerator pedal or Foot Directional Control pedal (see Figure 30 or Figure 35) and install floor plate. Install floor mat and connect the battery.

Figure 63. Battery Connector and Cables

Cab Heater

2200 YRM 1337

Cab Heater REMOVE NOTE: Cab heater applicable to lift truck models ERP15-20VT (G807) 1. Remove two nuts, two washers and two capscrews from heater harness and plate located on hydraulic tank. See Figure 64. 2. Remove two nuts, two washers and two capscrews from cantactor and plate located on hydraulic tank. See Figure 64. 3. Disconnect contactor from wire harness and remove from lift truck. See Figure 64. 4. Remove heater control and cab heater from door assembly as outlined in cab heater See Operator’s Cab 100 YRM 1446,Remove. 5. Remove heater wiring harness from lift truck. See Figure 64. NOTE: Perform Step 6 only if heater fan motor inoperative prior to removing from lift truck. 6. Remove 25 amp fuse from in line fuse holder and inspect for broken element. Replace as necessary. See Figure 64.

CLEAN WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

1. Using compressed air, blow dirt and debris from all components and hardware as necessary. 2. Using a lint free cloth, wipe down components as needed.

INSPECT 1. Inspect all components for cracks and damage. Replace as necessary. 2. Inspect wiring harness for damage and exposed wires. Replace as necessary.

INSTALL NOTE: Perform Step 1 only if Remove Step 6 was performed. 1. Install new 25 amp fuse into in line fuse holder. See Figure 64. 2. Install heater wiring harness onto lift truck. See Figure 64. 3. Install cab heater and heater control onto door assembly as outlined in cab heater section. See Operator’s Cab 100 YRM 1446,Install. 4. Install two capscrews, two washers and two nuts onto contactor and plate located on hydraulic tank. See Figure 64. 5. Connect wiring harness onto contactor. See Figure 64. 6. Install two capscrews, two washers and twu nuts onto heater harness and plate located on hydraulic tank. See Figure 64.

2200 YRM 1337

1. 2. 3. 4.

CAB HEATER WIRE HARNESS CONTACTOR BOOT

Cab Heater

5. 6. 7. 8.

SCREW WASHER NUT CAPSCREW

9. PLATE WELDMENT 10. HEATER CONTROL 11. FUSE HOLDER AND FUSE

Figure 64. Cab Heater Electrical

Lights

2200 YRM 1337

Lights GENERAL

and/or damage to lift truck components can occur if battery is not disconnected.

WARNING Before replacing any of the lights, fully lower all parts of the mast and tilt it forward until the tips of the forks touch the ground. This action will prevent the mast from lowering suddenly if the control lever is accidently moved. Never have any metal on your fingers, arms, or neck. These metal items can accidentally create an electrical connection and cause an injury.

WARNING Discharge capacitors as directed in Discharging the Capacitors in General section of this manual.

Disconnect the battery before doing any work on the electrical system. Serious injury to personnel

Figure 65. Lights Arrangement

2200 YRM 1337

Lights Legend for Figure 65

NOTE: LIFT TRUCK MODELS ERP15-20VT (ERP030-040VT) (G807) SHOWN. LIGHTS ARRANGEMENT FOR LIFT TRUCK MODELS ERP16-20VF (ERP30-40VF) (A955) IS THE SAME. A. FRONT VIEW 1. 2. 3. 4. 5.

B. REAR VIEW

FRONT WORK LIGHTS FRONT MARKER/TURN SIGNAL LIGHTS* STROBE LIGHT LED TAIL, BACKUP, AND BRAKE LIGHTS REAR WORK LIGHTS

* FRONT MARKER/TURN SIGNAL LIGHTS USED ONLY ON ERP16-20VF (A955) AND ERP15-20VT (G807) LIFT TRUCK MODELS.

WORK LIGHTS (FRONT AND REAR)

Install

Halogen Bulb Lights

1. Install work light on overhead guard using the capscrew, washer, and nut. See Figure 66. Tighten nut to 20 N•m (177 lbf in). Connect overhead guard harness to work light.

Remove 1. Read and follow the WARNING and CAUTION section in the General section above.

2. Connect the battery.

CAUTION Do not touch the Halogen bulb surface or inside reflectors with your bare hands. Oils from skin can lead to breakage or shorten the life of the lamp. Use clean gloves or lint free cloth for installation and removal. Clean any dirt or oil, from the lamp surface with alcohol and a lint free cloth or tissue. Any foreign particles or materials on the bulb surface can cause hot spots on the bulb and result in lamp failure. 2. To replace the bulb, remove the lens assembly by removing the four capscrews. See Figure 66. Replace the bulb and reinstall the lens assembly. 3. To replace the work light assembly, disconnect the overhead guard harness from the light and remove the capscrew, washer, and nut attaching the work light to the overhead guard for front work lights, or to the mounting bracket for rear work lights.

NOTE: REAR WORK LIGHT SHOWN, FRONT WORK LIGHT IS SIMILAR. 1. CAPSCREWS (LENS ASSEMBLY) 2. LENS ASSEMBLY 3. NUT (ATTACHES LIGHT TO OVERHEAD GUARD) Figure 66. Halogen Bulb Work Lights

Lights

2200 YRM 1337

LED Lights

Install

NOTE: LED work lights are an optional feature on the lift trucks covered in this service manual. If the LED work light malfunctions, the whole LED work light assembly must be replaced.

1. Install new LED work light assembly by using capscrew, washer, and locknut. Tighten nut to 20 N•m (177 lbf in). See Figure 67.

Remove

2. Connect overhead guard harness to work light. 3. Connect the battery.

1. Read and follow the WARNING and CAUTION section in the General section above. 2. Disconnect overhead guard harness from work light. 3. Remove the locknut, washer, and capscrew and remove LED work light from overhead guard. See Figure 67

STROBE LIGHT NOTE: The strobe light may either be mounted above the top of the overhead guard (high-mounted) or below the top of the overhead guard (low-mounted). The removal and installation procedures are the same for both options.

Remove 1. Read and follow the WARNING and CAUTION section in the General section above. 2. Disconnect the overhead guard harness from strobe light electrical connector. 3. Remove the capscrews, washers, lockwasher, and nuts securing the strobe light and light guard to strobe light mounting bracket. See Figure 68. Remove strobe light and guard from lift truck. NOTE: If strobe light on your lift truck is equipped with a replaceable halogen bulb, go to Step 4. If strobe light is equipped with LED lights, the whole light assembly must be replaced. Go to Step 2 in the Install section. 4. If the strobe light bulb needs to be replaced, remove the strobe light lens from base and remove bulb.

Install 1. LOCKNUT 2. WASHER 3. CAPSCREW

4. MOUNTING BRACKET 5. LED LIGHT ASSEMBLY

Figure 67. LED Work Lights

1. If bulb is being replaced, install new bulb into strobe light base. Install strobe light lens onto base. 2. Place strobe light assembly and strobe light guard onto mounting bracket. Secure the assembly to mounting bracket with capscrews, washers, lockwasher, and nuts. See Figure 68. 3. Connect overhead guard harness to strobe light electrical connector. 4. Connect the battery.

2200 YRM 1337

Lights 3. Remove torx head screw securing the LED light assembly to LED light housing. See Figure 69. 4. Disconnect the chassis light harness from LED light assembly. 5. If the LED light housing must be removed from the overhead guard leg, remove two capscrews and remove the LED light housing from the overhead guard leg. The inserts should remain attached to housing. See Figure 69.

1. 2. 3. 4. 5. 6. 7.

CAPSCREW MOUNTING BRACKET STROBE LIGHT BULB STROBE LIGHT GUARD NUT STROBE LIGHT LENS LIGHT BASE

1. 2. 3. 4. 5.

Figure 68. Strobe Light Assembly

Figure 69. LED Tail, Backup, and Brake Lights Replacement

LED TAIL, BACKUP, AND BRAKE LIGHTS NOTE: These light assemblies are nonrepairable and must be replaced as an assembly. See the Parts Manual for replacement LED lights.

Remove

TORX HEAD SCREW LED LIGHT ASSEMBLY CAPSCREW LED LIGHT HOUSING INSERT

Install 1. If the LED light housing was removed, install housing on overhead guard leg with two capscrews and inserts.

1. Read and follow the WARNING and CAUTION section in the General section above.

Connect the chassis light harness to LED light assembly.

2. Remove the key, or turn the keyless switch OFF, if truck is equipped with this switch.

3. Insert the torx head screw and install the LED light assembly to LED light housing. See Figure 69. 4. Connect the battery.

Lights

2200 YRM 1337

FRONT MARKER/TURN SIGNAL LIGHTS NOTE: Front marker/turn signal lights are used only on ERP16-20VF (A955) and ERP15-20VT (G807) lift truck models.

Remove 1. Read and follow the WARNING and CAUTION in the General section above. 2. Remove the bolt and clip from light cover and trim. 3. Remove capscrew that attaches light cover to front work light mounting bracket. See Figure 70. 4. Disconnect connector on back of LED light mounting bracket from overhead guard wire harness. 5. Remove light assembly from overhead guard leg. 6. Remove two capscrews that secure the LED front marker/turn signal light and LED light mounting bracket to the light cover and remove components from light cover. See Figure 71.

NOTE: LEFT FRONT MARKER/TURN SIGNAL LIGHT SHOWN. PROCEDURES AND COMPONENTS ARE THE SAME FOR RIGHT LIGHT. 1. 2. 3. 4. 5. 6. 7.

TRIM LIGHT COVER LED FRONT MARKER/TURN SIGNAL LIGHT CAPSCREW LED LIGHT MOUNTING BRACKET BOLT CLIP

Figure 70. Front Marker/Turn Signal Light Removal

2200 YRM 1337

Lights

Install 1. Install new LED front marker/turn signal light onto LED mounting bracket. See Figure 72.

1. LED LIGHT MOUNTING BRACKET 2. ELECTRICAL CONNECTOR 3. LED FRONT MARKER/TURN SIGNAL LIGHT Figure 72. LED Light Installation 2. Attach LED front marker/turn signal light and LED mounting bracket to light cover with two capscrews. See Figure 71. 3. Assemble the light cover to trim. Attach both items to overhead guard with clip nut and bolt. Secure light cover to front work light mounting bracket with capscrew. See Figure 70. 4. Connect LED front marker/turn signal light to overhead guard wire harness. 5. Connect the battery. 1. LED FRONT MARKER/TURN SIGNAL LIGHT 2. LED LIGHT MOUNTING BRACKET 3. LIGHT COVER

4. CAPSCREW HOLE 5. ELECTRICAL CONNECTOR

Figure 71. Front Marker/Turn Signal Light Arrangement

CONVERTER The LED tail, backup, and brake Lights operate at 12 volts with a DC/DC converter. The converter is mounted to the front bulkhead, behind the right traction motor controller (see Figure 73). The converter is a nonrepairable component and must be replaced if it malfunctions. See the Parts Manual for part number.

Lights

2200 YRM 1337

Remove

Install

1. Read and follow the WARNING and CAUTION section in the General section above.

1. Install new converter to front bulkhead using four capscrews. See Figure 73.

2. Disconnect main wire harness from electrical connector. See Figure 73.

2. Connect main wire harness to electrical connector. Connect the battery.

3. Remove four capscrews from converter and remove converter from front bulkhead. See Figure 73.

NOTE: RIGHT TRACTION MOTOR CONTROLLER OMITTED FOR CLARITY. 1. CAPSCREW 2. CONVERTER

3. ELECTRICAL CONNECTOR 4. FRONT BULKHEAD Figure 73. Converter

5. LEFT TRACTION MOTOR CONTROLLER

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 1337

7/10 (4/10)(3/10)(2/10)(7/09)(1/09)(8/08) Printed in U.S.A.

Maintenance

FRAME ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

PART NO. 524295629

100 YRM 1329

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Frame

Table of Contents

1 1 2 3 3 5 5 7 9 11 11 13 13 14 17 19 23 24 24 24 25 26

This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

100 YRM 1329

Introduction

Introduction GENERAL This section contains a description and the service procedures for the parts of the frame. These parts include the frame, counterweight assembly, overhead guard, hood and seat assembly, side panels, and labels. Throughout this section, forward will refer to travel in the direction of the forks and left and right will be determined by an operator sitting in the seat facing forward. See Figure 1 and Figure 2.

A. LEFT SIDE B. RIGHT SIDE C. FORWARD TRAVEL Figure 2. Truck Orientation for Lift Truck ERP16-20VF (ERP30-40VF) (A955)

Figure 1. Truck Orientation for Lift Truck ERP15-20VT (ERP030-040VT) (G807)

Introduction

100 YRM 1329

DESCRIPTION OF OPERATION The frame is a welded assembly with mounts for the counterweight, overhead guard, mast, steering system, side panels, hydraulic system and transaxles. See Figure 3. The hood opens on hinges to give access to the battery compartment. The weight of the battery is a major part of the counterweight system on this truck. A slot in the overhead guard permits removal of the battery without removing the overhead guard. Spacers may be added around the battery as required on some models.

The hydraulic pump and motor assembly and hydraulic tank are in the counterweight. The counterweight cover is removed for access. The AC drive motors and transaxles are located under the floor plates in the operator compartment. The floor plates are held in position by tabs and are to be removed to give access to components underneath. The hydraulic control valve is fastened to the front of the battery compartment and has covers to protect the control valve and control linkages.

Each lift truck has a cast-iron counterweight appropriately weighted for the indicated capacity on the nameplate.

NOTE: FRAME SHOWN FROM RIGHT SIDE AND REAR. Figure 3. Frame

100 YRM 1329

Covers and Floor Plates

after the battery is disconnected. To prevent an electrical shock and personal injury, discharge the capacitor(s) before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Make certain the Emergency-Disconnect switch has not been activated. This will isolate the controller and prevent the capacitors from discharging properly. The proper way to disconnect the battery is by separating the battery connectors. 1. Ensure the capacitors are discharged by performing Step 2 through Step 6 below. 2. Turn the key or keyless switch to the OFF position. 3. Disconnect the battery by separating the connectors. 4. Block the drive wheels to prevent the lift truck from moving. 5. Make sure the Emergency-Disconnect switch HAS NOT been activated. If the Emergency-Disconnect switch is activated, rotate the switch to the right until it pops up. 6. Wait at least 10 seconds to be sure that the capacitors are fully discharged.

A cover on the top of the counterweight provides access to the hydraulic tank, hydraulic pump and motor assembly, and the hoist controller. See Figure 4.

Covers and Floor Plates

100 YRM 1329

Figure 4. Covers and Floor Plates

100 YRM 1329

Overhead Guard Replacement Legend for Figure 4

NOTE: COUNTERWEIGHT FOR ERP15-20VT (ERP030-040VT) (G807) LIFT TRUCK SHOWN AS AN EXAMPLE ONLY. 1. FLOOR PLATE MANUAL HYDRAULIC 2. FLOOR PLATE BRAKE PEDAL 3. FLOOR PLATE E-HYDRAULIC 4. FLOOR MAT MANUAL HYDRAULIC

5. FLOOR MAT E-HYDRAULIC 6. MANUAL HYDRAULIC COVERS 7. HOSE COVER 8. COUNTERWEIGHT COVER

Overhead Guard Replacement WARNING The overhead guard is part of the operator protection system. DO NOT operate the lift truck without the overhead guard correctly fastened to the lift truck. The overhead guard is designed to provide protection to the operator from falling objects and in the event of a tip over. A high visibility design allows for an unobstructed view while maintaining structural integrity. Removal of the battery is simplified by the slot in the overhead guard. This provides access to the battery with an overhead lifting device without removing the overhead guard.

REMOVE WARNING The overhead guard is heavy. Make sure the sling, chain, eyebolts, and crane or lifting device have the capacity to lift the overhead guard. 1. Remove hood and seat. See Hood and Seat Assembly Repair section in this manual.

7. Repeat Step 6 for opposite front leg. 8. Use a lifting device to lift overhead guard until it is just higher than the counterweight. NOTE: Tag electrical wiring and note routing during removal to aid in installation. 9. Tag and disconnect electrical wiring for display. Remove display from display cover. NOTE: Note routing of electrical wires into, out of, or on the overhead guard during removal to aid in installation. NOTE: Tag electrical connectors during removal to aid in installation. 10. Tag and disconnect electrical wires that go through the legs of overhead guard. Carefully remove the wiring if necessary. 11. Completely remove overhead guard from lift truck. 12. Remove two vibration mount bottoms from counterweight; remove two vibration mount bottoms and two retaining washers from frame. See Figure 5 and Figure 6.

2. Remove rear capscrew, washers, and vibration mount top from rear leg and counterweight. See Figure 5 and Figure 6.

13. Remove two capscrews and grab handle from front leg. See Figure 5 and Figure 6.

3. Repeat Step 2 for opposite rear leg.

NOTE: Perform following step if grab handle is mounted onto rear leg.

4. Remove three capscrews from cowl and front leg. See Figure 5 and Figure 6.

14. Remove two capscrews and grab handle from rear leg. See Figure 5 and Figure 6.

5. Repeat Step 4 for opposite front leg.

15. Remove two capscrews, display cover, and two clip nuts from overhead guard. See Figure 5 and Figure 6.

6. Remove nut, washers, front capscrew, and vibration mount top from front leg and frame. See Figure 5 and Figure 6.

Overhead Guard Replacement

Figure 5. Overhead Guard for Lift Truck ERP15-20VT (ERP030-040VT) (G807)

100 YRM 1329

Overhead Guard Replacement Legend for Figure 5

1. 2. 3. 4. 5. 6.

REAR CAPSCREW WASHER REAR LEG VIBRATION MOUNT TOP VIBRATION MOUNT BOTTOM COUNTERWEIGHT

7. 8. 9. 10. 11. 12.

NUT FRONT CAPSCREW FRONT LEG FRAME CAPSCREW OVERHEAD GUARD

INSTALL 1. Install grab handle and capscrews onto front leg. See Figure 5 and Figure 6. NOTE: Perform the following step if grab handle is mounted onto rear leg. 2. Install grab handle and two capscrews onto rear leg. See Figure 5 and Figure 6. 3. Install two retaining washers and two vibration mount bottoms onto frame; install two vibration mount bottoms onto counterweight. See Figure 5 and Figure 6. 4. Using a lifting device, position overhead guard just above mounting holes on counterweight and frame. 5. Route electrical wires through overhead guard legs as noted during removal. NOTE: Make sure electrical wires do not get pinched when overhead guard is lowered onto mounts. 6. Carefully lower overhead guard onto vibration mount bottoms on counterweight and frame.

13. 14. 15. 16. 17.

GRAB HANDLE COWL DISPLAY COVER RETAINING WASHER CLIP NUT

7. Install front capscrew, vibration mount top, washers, and nut into front leg and frame. See Figure 5 and Figure 6. 8. Repeat Step 7 for opposite front leg. 9. Install vibration mount top, washers and rear capscrew into rear leg and counterweight. See Figure 5 and Figure 6. 10. Repeat Step 9 for opposite rear leg. 11. Install three capscrews into cowl and front leg. See Figure 5 and Figure 6. 12. Repeat Step 11 for opposite front leg. 13. Install two clip nuts, display cover and two capscrews onto overhead guard. See Figure 5 and Figure 6. 14. Install display into display cover. Connect electrical wiring to display as noted during removal. 15. Install hood and seat. See Hood and Seat Assembly Repair section in this manual.

Overhead Guard Replacement

Figure 6. Overhead Guard for Lift Truck ERP16-20VF (ERP30-40VF) (A955)

100 YRM 1329

Hood and Seat Assembly Legend for Figure 6

1. 2. 3. 4. 5. 6.

REAR CAPSCREW WASHER REAR LEG VIBRATION MOUNT TOP COUNTERWEIGHT NUT

7. 8. 9. 10. 11. 12.

FRONT CAPSCREW FRONT LEG FRAME CAPSCREW GRAB HANDLE OVERHEAD GUARD

13. 14. 15. 16. 17.

COWL DISPLAY COVER VIBRATION MOUNT BOTTOM RETAINING WASHER CLIP NUT

Hood and Seat Assembly The hood is the platform for the seat assembly and is located above the battery. It functions as a battery restraint that completely covers the battery compartment. See Figure 7. When correctly locked to the frame, it will hold the battery in the battery compartment if an accident causes the lift truck to tip over. The hood is a stamped steel cover. Two hinges at the back attach to the overhead guard. A rotor lock latch assembly on the front of the hood locks the hood closed during operation. A gas-controlled strut holds the hood in the open position. Opening the latch assembly unlocks the hood from the frame so the hood can be raised to access the battery. See Figure 8. The latch assembly must be in good condition and properly secured before the lift truck can be operated. To raise the hood on a lift truck with manual hydraulics, the manual hydraulic lever and linkage assembly must be moved. Pull latch handle under manual hydraulic cover toward the seat, allowing the lever and linkage assembly to drop forward out of the way. If the sliding latch assembly does not lock the hood in the closed position, the lever and linkage assembly will not lock into position and the lift truck will not operate. A large, red push-button switch is mounted on the lever and linkage assembly for manual hydraulics and in the armrest console for the electro-hydraulics. This switch is an emergency battery disconnect that allows the operator to quickly disconnect the battery while seated on the lift truck in case of an emergency.

side of the base controls the adjustment of the seat to the forward and backward positions. Optional seats are available in cloth or vinyl with features such as non-suspension, full suspension, and limited swivel. All seats have a seat switch installed in the bottom cushion that senses operator presence. When the operator is not on the seat, the seat switch opens and interrupts the controller stopping operation of the lift truck as follows: • After 1.5 seconds, hydraulic functions will cease to operate. • The lift truck, through regenerative braking, will slowly come to a complete stop. The hood, seat belt, hip restraint brackets, seat, and seat mount are all parts of the operator restraint system. Checks and adjustments for the operator restraint system are described in the Operating Manual and Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15-20VT (ERP030-040VT) (G807) or Periodic Maintenance 8000 YRM 1373 for lift truck models ERP16-20VF (ERP30-40VF) (A955) To raise the hood and seat assembly, move the seat to the rear of the hood. Move the steering column to the most forward position. If lift truck is equipped with manual hydraulics, release and move the hydraulic lever and linkage assembly forward. Open the latch mechanism and raise the hood.

The seat assembly slides on seat rails that are fastened to the hood by four capscrews. A lever at the left front

Hood and Seat Assembly

1. SEAT

100 YRM 1329

2. HOOD Figure 7. Hood and Seat Assembly

3. SEAT SWITCH CONNECTOR

100 YRM 1329

Hood and Seat Assembly 3. Disconnect seat harness and remove from hood. NOTE: The seat assembly does not have to be removed from the hood for the hood to be removed from the lift truck. Perform Step 4 if removing seat assembly. 4. To remove seat assembly, disconnect electrical connectors if not already done, remove four screws, washers, spacers if required, and seat assembly from hood. 5. Raise hood. 6. Remove gas spring. See Figure 9. 7. Lower hood. 8. Remove two captive screws, tow pin, and counterweight cover from counterweight. 9. Remove two nuts securing hood mounting bolts. See Figure 9. 10. Remove washers and hood mounting bolts from hood hinges and hood mounting brackets. See Figure 9. 11. Release latch and lift hood out of lift truck. 12. If necessary, hood mounting brackets can be removed from overhead guard rear legs by removing the nuts and capscrews. See Figure 9.

INSTALL

A. MOUNTING PLACEMENT B. MOUNTING HARDWARE 1. 2. 3. 4. 5. 6. 7.

HOOD LATCH HOOD FRONT BULKHEAD CAPSCREW NUT OPEN POSITION CLOSED POSITION Figure 8. Latch Mechanism

REMOVE 1. Disconnect battery connector.

1. Install hood mounting brackets, capscrews, and nuts onto overhead guard rear legs, if removed. Do not fully tighten capscrews at this time. See Figure 9. 2. Lower hood into position. 3. Install hood mounting bolts and washers onto hood hinges and hood mounting brackets. See Figure 9. 4. Install nuts onto hood mounting bolts. See Figure 9. 5. Allow hood to engage latch and adjust hood for adequate latch engagement with the hood striker. Adequate engagement is when the latch completely clears the 90 degree bend of the hood striker.

NOTE: Tag electrical connectors during removal to aid in installation.

6. Tighten capscrews on hood mounting brackets.

2. Tag and disconnect the electrical connectors to the emergency battery disconnect and the seat switch.

8. Install gas spring. See Figure 9.

7. Raise hood.

Hood and Seat Assembly

100 YRM 1329

9. Reinstall seat, if removed, and route seat harness through hood and connect to seat.

12. Install counterweight cover, captive screws, and tow pin onto counterweight.

10. Connect the electrical wiring harness to the seat switch.

13. Move manual hydraulic lever and linkage assembly back to upright position and lock in place.

11. Close the hood. Make certain that the latch is properly engaged.

14. Connect the battery connector.

1. 2. 3. 4. 5.

HOOD GAS SPRING NUT WASHER HOOD MOUNTING BOLT

6. HOOD HINGE 7. OVERHEAD GUARD REAR LEG 8. HOOD MOUNTING BRACKET 9. CAPSCREW Figure 9. Hood Mounting

100 YRM 1329

Counterweight Replacement

GROUND TEST NOTE: If the static discharge ground connection is not secured properly it could lead to the possible failure of the traction and/or pump motor controllers. 1. To ensure proper installation of seat assembly and associated bracketing, perform continuity test. 2. Using an ohm meter, place a test lead at the armrest mounting bolt and another at the truck frame. The resistance needs to read 5 Ohms or less. See Figure 10. 3. If the resistance is greater than 5 Ohms, double check installation of seat assembly, both ends of seat wiring harness, and wiring harness ground strap. 1. ARMREST BOLT 2. FRAME Figure 10. Ground Test

Counterweight Replacement WARNING DO NOT operate the lift truck if the capscrews for the counterweight are not installed. The counterweight is a structural member of the truck chassis. The counterweight cannot be removed without first supporting the frame. If the capscrews are not properly installed the counterweight will not support the lift truck. A one-piece, cast iron counterweight is used to offset the weight of the load and support the rear suspension of the lift truck. See Figure 11 and Figure 12. The weight of the counterweight is shown in Table 1 and Table 2.

Figure 11. Counterweight for Lift Truck ERP15-20VT (ERP030-040VT) (G807)

Counterweight Replacement

100 YRM 1329 Table 2. Counterweights for Lift Truck ERP16-20VF (ERP30-40VF) (A955) Model

mm (in)*

Weight

+ 20 kg (44 lb) 0 kg (0 lb)

ERP16-20VF (ERP30-40VF)

546 mm (21.5 in.)

670 kg (1477 lb)

ERP16-20VF (ERP30-40VF)

642 mm (25.3 in.)

670 kg (1477 lb)

ERP16-20VF (ERP30-40VF)

750 mm (29.5 in.)

670 kg (1477 lb)

*Approximate battery compartment lengths. A compartment space, accessed by removal of the counterweight cover, has been designed to house the hydraulic tank, hydraulic pump and motor, hoist controller, and electrical connections. Figure 12. Counterweight for Lift Truck ERP16-20VF (ERP30-40VF) (A955) Table 1. Counterweights for Lift Truck ERP15-20VT (ERP030-040VT) (G807) Model

mm (in)*

Weight

+ 13.8 kg (30 lb) 13.8 kg (30 lb)

ERP15-20VT (ERP030-04VT)

546 mm (21.5 in.)

690 kg (1521 lb)

ERP15-20VT (ERP030-04VT)

642 mm (25.3 in.)

690 kg (1521 lb)

ERP15-20VT (ERP030-04VT)

750 mm (29.5 in.)

690 kg (1521 lb)

*Approximate battery compartment lengths.

A battery platform is used to support the battery on the lift truck frame. The battery platform also serves as part of the counterweight system and requires the use of an overhead lifting device for removal or installation. Be sure to replace the same battery platform, or one of equal weight, if the platform must be removed.

REMOVE See Periodic Maintenance 1. Remove battery. 8000 YRM 1339 for lift truck ERP15-20VT (ERP030-040VT) (G807) or Periodic Maintenance 8000 YRM 1373 for lift truck ERP16-20VF (ERP30-40VF) (A955). 2. Remove overhead guard. See Overhead Guard Replacement section in this manual. 3. Remove hydraulic pump and motor and hydraulic tank from counterweight. See Hydraulic System 1900 YRM 1333. 4. Remove controller from counterweight. See Electrical System 2200 YRM 1337. 5. Remove steer axle, including wheels and tires. See Steering System 1600 YRM 1331 for lift truck ERP15-20VT (ERP030-040VT) (G807) and Steering System 1600 YRM 1363 for lift truck ERP16-20VF (ERP30-40VF) (A955).

100 YRM 1329

Counterweight Replacement

NOTE: Perform Step 6 through Step 10 for lift truck ERP15-20VT (ERP030-040VT) (G807).

NOTE: Ensure frame is supported, as specified in Steering System 1600 YRM 1363 prior to removal.

6. Remove nuts, capscrews, washers, and steer plate from counterweight. See Figure 13.

11. Remove two capscrews from top of rear bulkhead and counterweight. See Figure 15.

WARNING The counterweight is very heavy. Make sure the chains, eyebolts, and overhead lifting device have the capacity to lift the counterweight.

12. Remove two capscrews from rear bulkhead and spacer plates. Remove rear bulkhead. See Figure 15.

WARNING

7. Insert eye bolts into counterweight. See Figure 14. Attach lifting device to eye bolts to hold counterweight.

The counterweight is very heavy. Make sure the slings and overhead lifting device have the capacity to lift the counterweight.

NOTE: Ensure frame is supported, as specified in Steering System 1600 YRM 1331 prior to removal.

13. Wrap two slings through slots in top of counterweight. Attach slings to lifting device. See Figure 16.

8. Remove upper capscrews and washers from frame and counterweight. See Figure 13. 9. Remove lower capscrews and washers from frame and counterweight. See Figure 13. 10. Using lifting device, lift counterweight away from lift truck frame.

14. Remove lower capscrews, nuts, and washers from frame and counterweight. See Figure 15. 15. Remove upper capscrews and washers from frame and counterweight. See Figure 15. Using lifting device, lift counterweight away from frame.

NOTE: Perform Step 11 through Step 15 for lift truck ERP16-20VF (ERP30-40VF) (A955).

Counterweight Replacement

1. 2. 3. 4.

STEER PLATE COUNTERWEIGHT CAPSCREW NUT

100 YRM 1329

5. 6. 7. 8.

WASHER UPPER CAPSCREW LOWER CAPSCREW FRAME

Figure 13. Frame and Counterweight for Lift Truck ERP15-20VT (ERP030-040VT) (G807)

100 YRM 1329

Counterweight Replacement 5. Install steer plate, washers, capscrews, and nuts onto counterweight. Tighten capscrews to 300 N•m (221 lbf ft). See Figure 13. NOTE: Perform Step 6 through Step 11 for lift truck ERP16-20VF (ERP30-40VF) (A955). 6. Using a lifting device, lower counterweight into position on lift truck frame. 7. Install washers and upper capscrews into frame and counterweight. See Figure 15. Tighten capscrews to 755 N•m (557 lbf ft). 8. Install washers, lower capscrews, and nuts into frame and counterweight. See Figure 15. Tighten capscrews to 250 N•m (184 lbf ft). 9. Detach both slings and remove from counterweight. See Figure 16.

1. COUNTERWEIGHT 2. EYE BOLT Figure 14. Counterweight Lift for Lift Truck ERP15-20VT (ERP030-040VT) (G807)

INSTALL WARNING The counterweight is very heavy. Make sure the chains, eyebolts, and overhead lifting device have the capacity to lift the counterweight. NOTE: Perform Step 1 through Step 5 for lift truck ERP15-20VT (ERP030-040VT) (G807). 1. Using a lifting device, lower counterweight into position on lift truck.

10. Place rear bulkhead in position and install two capscrews into rear bulkhead and spacer plates. See Figure 15. 11. Install two capscrews into top of rear bulkhead and counterweight. See Figure 15. 12. Install steer axle, with wheels and tires, onto counterweight. See Steering System 1600 YRM 1331 for lift truck ERP15-20VT (ERP030-040VT) (G807) and Steering System 1600 YRM 1363 for lift truck ERP16-20VF (ERP30-40VF) (A955). 13. Install controller into counterweight. See Electrical System 2200 YRM 1337. 14. Install hydraulic tank and hydraulic pump and motor into counterweight. See Hydraulic System 1900 YRM 1333. 15.

2. Install washers and lower capscrews into frame and counterweight. See Figure 13. Tighten capscrews to 250 N•m (184 lbf ft). 3. Install washers and upper capscrews into frame and counterweight. See Figure 13. Tighten capscrews to 755 N•m (557 lbf ft).

Install overhead guard. See Overhead Guard Replacement section in this manual.

16. Install battery. See Periodic Maintenance 8000 YRM 1339 for lift truck ERP15-20VT (ERP030-040VT) (G807) or Periodic Maintenance 8000 YRM 1373 for lift truck ERP16-20VF (ERP30-40VF) (A955).

4. Remove lifting device and eye bolts from counterweight. See Figure 14.

Counterweight Replacement

100 YRM 1329

NOTE: MAJOR COMPONENTS NOT SHOWN FOR CLARITY. 1. REAR BULKHEAD 2. CAPSCREW 3. SPACER PLATE

4. FRAME 5. COUNTERWEIGHT 6. LOWER CAPSCREW

7. NUT 8. WASHER 9. UPPER CAPSCREW

Figure 15. Frame and Counterweight for Lift Truck ERP16-20VF (ERP30-40VF) (A955)

100 YRM 1329

Safety Labels Legend for Figure 16 1. COUNTERWEIGHT 2. SLING

Figure 16. Counterweight Lift for Lift Truck ERP16-20VF (ERP30-40VF) (A955)

Safety Labels WARNING Safety labels are installed on the lift truck to give information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read. DO NOT add to or modify the lift truck. Any change to the lift truck, the tires, or its equipment can change the lifting capacity. The lift truck must be rated as equipped and the nameplate must show the new capacity rating. Contact your Yale lift truck dealer for a replacement nameplate. If a label must be replaced, use the following procedure to install a new label. See Figure 17 and Figure 18.

WARNING Always use solvents and paints in an area with adequate ventilation. DO NOT use solvents or paints near heat, fire, or electrical equipment that can create sparks. Follow the manufacturer’s instructions and cautions.

1. Clean the painted surface. Use household cleaning products to clean new paint and clean old paint with cleaning solvent. DO NOT use solvent on new paint. Make sure the surface is dry and is clean of dirt, oil, and grease. 2. Remove the paper from the back of the label and hold the label by the edges. Do not touch the adhesive surface.

CAUTION The label cannot be moved after it touches the surface. 3. Carefully hold the label in the correct position above the surface and carefully apply to the correct location. Make sure that all air is removed from under the label by smoothing any wrinkles or bubbles with your fingers working from the center out. Check that the corners and edges are tight against the surface.

Safety Labels

100 YRM 1329

Figure 17. Label Locations for Lift Truck ERP15-20VT (ERP030-040VT) (G807)

100 YRM 1329

Safety Labels Legend for Figure 17

NOTE: NOT ALL LABELS USED ON ERP15-20VT (ERP030-040VT) (G807) LIFT TRUCK MODELS ARE SHOWN IN FIGURE 17. SEE PARTS MANUAL FOR A COMPLETE LISTING OF ALL LABELS USED ON ERP15-20VT (ERP030-040VT) (G807) LIFT TRUCKS. 1. OVERHEAD GUARD IMPACT WARNING (INNER LEFT SIDE) 2. BATTERY SPACER 3. MAST WARNING 4. TILT COLUMN 5. PINCH POINT 6. OPERATOR WARNING 7. PINCH POINT 8. OPERATOR RESTRAINT 9. MAST WARNING

10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

YALE CAPACITY PLATE AC LABEL COUNTERWEIGHT LABEL PATENTS AND TRADEMARKS "EE" UL LABEL (OPTIONAL) FREEZER (OPTIONAL) CAPACITY LABEL UL LABEL NO RIDER LABEL

Safety Labels

100 YRM 1329

Figure 18. Label Locations for Lift Truck ERP16-20VF (ERP30-40VF) (A955)

100 YRM 1329

Painting Instructions Legend for Figure 18

NOTE: NOT ALL LABELS USED ON ERP16-20VF (ERP30-40VF) (A955) LIFT TRUCK MODELS ARE SHOWN IN FIGURE 18. SEE PARTS MANUAL FOR A COMPLETE LISTING OF ALL LABELS USED ON ERP16-20VF (ERP30-40VF) (A955) LIFT TRUCKS. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

FREEZER "EE" UL LABEL (OPTIONAL) YALE - AC TECHNOLOGY PATENTS AND TRADEMARKS UL LABELS UL LABEL LIFTING EYE PINCH POINT BATTERY DISCONNECT OPERATOR WARNING LOCK/UNLOCK LABEL NO RIDER

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

BATTERY SPACER MAST WARNING YALE DECAL MAST WARNING PINCH POINT OPERATOR RESTRAINT TILT COLUMN BRAND LABEL NAMEPLATE CAPACITY PLATE COUNTERWEIGHT LABEL

Painting Instructions WARNING Always use solvents and paints in an area with ventilation. DO NOT use solvents or paints near heat, fire, or electrical equipment that can make sparks. Follow the manufacturer’s instructions and cautions. 1. Remove all dirt from the surface to be painted. Clean the area to be painted. Use a solvent for painted surfaces to remove grease and oil before sanding. DO NOT use solvent on new paint. Make sure all oil and grease is removed. 2. Use sandpaper to remove the top surface of paint and rust from the metal. All metal surfaces where the paint is completely removed, must be primed. Apply primer before applying the paint.

CAUTION DO NOT put tape on cylinder rods to protect from paint. Use a thick layer of multipurpose grease to protect cylinder rods. Cylinders can be damaged if operated with tape on the cylinder rod. 3. Protect all surfaces that will not be painted. DO NOT paint: Pedal Pads Lever Knobs Instrument Panel Steering Wheel Labels and Information Plates

Seat Assembly and Rails Information Case Tires Mast Chains and Hoses Battery Connector Key Switch Cylinder Rods All Plastic Covers

CAUTION DO NOT paint the pads, plastic covers or knobs, cables, labels, information plates, or controls. Paint can make some assemblies not operate correctly. 4. Paint the surfaces. Use the correct paint from your dealer for Yale® lift trucks. Follow the directions on the container.

WARNING Make sure all labels are installed after painting is complete. Safety labels are installed on the lift truck to give information about possible hazards. It is important that all safety labels are installed on the lift truck and can be read. 5. Check that all labels are installed in the correct locations on the lift truck. See Safety Labels. NOTE: Use colors approved by Yale Material Handling Corporation.

Battery Specifications

100 YRM 1329

Battery Specifications ERP15-20VT (G807) EUROPEAN MODEL TRUCKS Minimum Compartment Size Length × Width

Length

Width

Minimum

Maximum

ERP1.5-1.6VT

546 x 991 mm (21.5 x 39 in.)

508 mm (20 in.)

970 mm (38.2 in.)

800 kg (1764 lb)

1100 kg (2425 lb)

ERP1.8VT

640 x 9914 mm (25.2 x 39 in.)

597/635 mm (23.5/25 in.)

975/986 mm (38.4/38.8 in.)

1225 kg (2700 lb)

1300 kg (2865 lb)

ERP2.0VT

750 x 991 mm (29.5 x 39 in.)

700/737 mm (25.5/29 in.)

830 mm (36.7 in.)

1000 kg (2200 lb)

1300 kg (2865 lb)

Model

Weight

Battery Size Min/Max

NOTE: Tolerances of the battery compartment are +3 and 0 mm (+0.12 and 0 in.). The battery size column shows the size range that will permit the battery to still fit into a battery compartment. NOTE: Battery compartment length is front to back. Width is side to side. The "length" dimension of the battery must fit within the battery compartment front-to-back dimension with a clearance of 0 to 13 mm (0 to 0.5 in.) maximum. Battery width must fit within the battery compartment side-to-side dimension.

WARNING The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use only batteries with the correct length shown in this table. Adjust the spacer plate to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.

ERP030-040VT (G807) US MODEL TRUCKS Minimum Compartment Size Length × Width

Length

Width

Minimum

Maximum

ERP30VT

546 x 991 mm (21.5 x 39 in.)

508 mm (20 in.)

970 mm (38.2 in.)

800 kg (1765 lb)

1100 kg (2425 lb)

ERP35VT

640 x 991 mm (25.2 x 39 in.)

597/635 mm (23.5/25 in.)

975/986 mm (38.4/38.8 in.)

1225 kg (2700 lb)

1300 kg (2865 lb)

ERP40VT

750 x 991 mm (29.5 x 39 in.)

700/737 mm (25.5/29 in.)

830 mm (36.7 in.)

1000 kg (2200 lb)

1300 kg (2865 lb)

Model

Battery Size Min/Max

Weight

100 YRM 1329

Battery Specifications

ERP16-20VF (A955) EUROPEAN MODEL TRUCKS Minimum Compartment Size Length × Width

Length

Width

Minimum

Maximum

ERP16VF

546 x 991 mm (21.5 x 39 in.)

508 mm (20 in.)

970 mm (38.2 in.)

800 kg (1765 lb)

1100 kg (2425 lb)

ERP18VF

640 x 991 mm (25.2 x 39 in.)

597/635 mm (23.5/25 in.)

975/986 mm (35.4/38.8 in.)

1225 kg (2700 lb)

1300 kg (2865 lb)

ERP20VF

750 x 991 mm (29.5 x 39 in.)

700/737 mm (25.5/29 in.)

830 mm (36.7 in.)

1000 kg (2200 lb)

1300 kg (2865 lb)

Model

Battery Size Min/Max

Weight

Battery Specifications

100 YRM 1329

ERP30-40VF (A955) US MODEL TRUCKS Minimum Compartment Size Length × Width

Length

Width

Minimum

Maximum

ERP30VF

546 x 991 mm (21.5 x 39 in.)

508 mm (20 in.)

970 mm (38.2 in.)

800 kg (1765 lb)

1100 kg (2425 lb)

ERP35VF

640 x 991 mm (25.2 x 39 in.)

597/635 mm (23.5/25 in.)

975/986 mm (35.4/38.8 in.)

1225 kg (2700 lb)

1300 kg (2865 lb)

ERP40VF

750 x 991 mm (29.5 x 39 in.)

700/737 mm (25.5/29 in.)

830 mm (36.7 in.)

1000 kg (2200 lb)

1300 kg (2865 lb)

Model

Battery Size Min/Max

Weight

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

100 YRM 1329

7/10 (2/10)(1/09)(7/08) Printed in U.S.A.

Maintenance

HYDRAULIC SYSTEM ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

PART NO. 524295633

1900 YRM 1333

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Hydraulic System

Table of Contents

1 1 1 4 4 4 4 5 6 6 8 8 8 8 9 9 9 10 11 11 11

This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

1900 YRM 1333

Hydraulic Pump Repair

General This section describes the repairs, checks, and adjustments for the hydraulic pump and motor assembly and hydraulic tank, including the hydraulic filter and breather replacement. Repair procedures for related systems can be found in the following sections: Lift Truck electrical systems, see Electrical System 2200 YRM 1337 for lift truck models: • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) Steering system components and functions, see Steering System 1600 YRM 1331 for lift truck models: • ERP15-20VT (ERP030-040VT) (G807) Steering System 1600 YRM 1363 for lift truck models: • ERP16-20VF (ERP30-40VF) (A955) Mast repair, see Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 for European lift truck models: • ERP15-20VT (G807)

• ERP16-20VF (A955) Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405 for European and Americas lift truck models: • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) Proper torque values, fluid capacities, pressure settings, and other specifications, see Capacities and Specifications 8000 YRM 1340 for lift truck models: • ERP15-20VT (ERP030-040VT) (G807) Capacities and Specifications 8000 YRM 1376 for lift truck models: • ERP16-20VF (ERP30-40VF) (A955) Hydraulic lift and tilt cylinders, see Cylinder Repair 2100 YRM 1382 for lift truck models: • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955)

Hydraulic Pump Repair REMOVE CAUTION DO NOT permit dirt to enter the hydraulic system during the steps of this procedure. Dirt can cause damage to the components of the hydraulic system.

Periodic Maintenance 8000 YRM 1373 for lift trucks: • ERP16-20VF (ERP30-40VF) (A955) NOTE: Make sure crane and sling have the lifting capacity of 54 kg (119 lb) or more. 2. Place the hood in fully open position.

Never operate the hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump. NOTE: To service the hydraulic pump, it is necessary to remove the pump/motor assembly from the lift truck. 1. Remove battery from lift truck. See How to Change Battery in Operating Manual or one of the following service manuals: Periodic Maintenance 8000 YRM 1339 for lift trucks: • ERP15-20VT (ERP030-040VT) (G807)

3. Attach sling to hood to support the hood when gas spring is disconnected.

CAUTION The hood must be in the fully open position and supported by an overhead lifting device before the gas spring can be disconnected. DO NOT discharge the gas spring when the hood is in the closed position. 4. Remove retainer clip from gas spring. See Figure 1.

Hydraulic Pump Repair

1900 YRM 1333 5. Remove gas spring from ball stud. 6. Remove nut and washer from hood mounting bolt on each side of lift truck. 7. Using crane and sling, remove hood from lift truck. 8. Locate hydraulic tank drain hose. Cut strap clamps holding drain hose and extend hose to its full length. See Figure 2.

1. HOOD MOUNTING BOLT 2. WASHER 3. NUT (NOT SHOWN)

4. HOOD 5. GAS SPRING 6. RETAINER CLIP

Figure 1. Hood Mounting

NOTE: LIFT TRUCK ERP15-20VT (ERP030-040VT) (G807) COUNTERWEIGHT SHOWN. 1. HYDRAULIC TANK DRAIN HOSE 2. FRAME BULKHEAD PLATE 3. HYDRAULIC TANK

4. PUMP AND MOTOR ASSEMBLY 5. CAPSCREWS 6. MOTOR MOUNTING CAPSCREWS

Figure 2. Hydraulic Module

1900 YRM 1333

Hydraulic Pump Repair NOTE: Make sure crane and sling have the lifting capacity of 54 kg (119 lb) or more.

WARNING The hydraulic oil is HOT at normal operating temperature. Prevent burns from hydraulic oil by using protective clothing and gloves suitable for chemicals and temperatures.

15. Remove three mounting capscrews holding pump and motor assembly in hydraulics module bracket. See Figure 4.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 9. Install a container with a capacity of 17.9 liter (19 qt) under lift truck. 10. Remove plug from end of the hydraulic tank drain hose, and drain hydraulic oil into container. 11. Remove four capscrews and frame bulkhead plate from truck frame and counterweight. See Figure 2. NOTE: Plug hoses and pump fittings to prevent foreign material from entering hydraulic system. 12. Disconnect pressure hose from outlet fitting. See Figure 3. Cap hose and outlet fitting.

1. MOUNTING CAPSCREWS

Figure 4. Hydraulic Pump and Motor Mounts 16. Using a crane and sling, connect the sling to hydraulic pump and motor assembly. Raise the crane to support and remove pump and motor assembly. NOTE: DO NOT damage hoses, electrical connectors, or cables during the removal process. 17. Move pump and motor assembly to a workbench or other suitable area for disassembly, inspections, and cleaning.

1. 2. 3. 4.

MOTOR PUMP CAPSCREW OUTLET FITTING

5. INLET FITTING 6. NUT 7. POWER CABLE

Figure 3. Pump/Motor Assembly 13. Disconnect inlet hose from inlet fitting. See Figure 3. Cap hose and inlet fitting. NOTE: Tag electrical connections during removal to aid in installation.

NOTE: Note the position of the inlet and outlet fittings on the pump prior to removal for correct alignment during installation. 18. Remove outlet and inlet fittings from pump. See Figure 3. NOTE: Note orientation of coupling to pump and motor drive tangs. Coupling must be reinstalled with the same orientation as removed. 19. Remove two capscrews, pump, and coupling from motor.

14. Remove three nuts and disconnect three power cables from motor. Lay power cables aside to prevent damage. See Figure 3.

Hydraulic Pump Repair

DISASSEMBLE CAUTION

1900 YRM 1333

CLEAN WARNING

If the pump is held in a vise for disassembly, use a soft jaw vise. Make sure the vise does not hold the pump too tightly and cause distortion of the housing or O-ring surface of the outlet port.

Cleaning solvents can be flammable and toxic, can cause skin irritation. When using cleaning solvent, always follow the recommendations of the manufacturer.

NOTE: Make careful notes of the location and orientation of parts and seals during disassembly. Some of the parts are similar but not exactly the same. It can be difficult to make an identification if parts are mixed.

Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

NOTE: Place an alignment mark on each section of the housing to aid in assembly. 1. Remove four flange-head screws holding housing together. See Figure 5.

1. Clean all parts in solvent. Dry parts with compressed air. Do not dry the parts with a lint-free cloth. Make sure all surfaces are free of scratches and sharp edges.

2. Carefully remove mounting flange. See Figure 5.

ASSEMBLE

3. Remove seal plate and backup seal from mounting flange or housing. See Figure 5. Discard seal plate and backup seal.

NOTE: Install new seals during assembly.

4. Carefully remove housing. See Figure 5. 5. Remove drive gear and driven gear. See Figure 5. 6. Remove side plate from cover plate. See Figure 5.

NOTE: Make sure internal parts of pump are clean. Lubricate parts with clean hydraulic oil as they are installed in the pump. 1. Install new backup seal and new seal plate onto cover plate. See Figure 5.

7. Remove seal plate and backup seal from housing or cover plate. See Figure 5. Discard seal plate and backup ring.

NOTE: Make sure backup seal and seal plate do not move out of the correct position.

8. Remove and discard O-ring seal from mounting flange. See Figure 5.

3. Install housing onto cover plate. See Figure 5.

INSPECT

4. Install driven gear and drive gear into housing. See Figure 5.

2. Install side plate onto cover plate. See Figure 5.

NOTE: Some pump bodies will show gear marks where the gears rotate because of the small clearances between the parts. These gear marks do not indicate a worn or damaged pump unless the pump will not supply the volume and pressure shown on the specifications.

5. Install new backup seal and new seal plate onto housing. See Figure 5.

1. Check parts for wear and damage. Remove and discard all seals, replace with new seals. If pump gears or shaft are worn or damaged, replace the pump.

6. Carefully install mounting flange onto housing. See Figure 5.

2. Inspect coupling. If the coupling shows signs of excessive wear, replace coupling.

NOTE: Make sure backup seal and seal plate do not move out of the correct position.

NOTE: Make sure marks made during disassembly are aligned prior to installing flange-head screws. 7. Install four flange-head screws into cover plate to hold housing together. Tighten screws to 46 to 49 N•m (34 to 36 lbf ft). See Figure 5.

1900 YRM 1333

1. 2. 3. 4.

HOUSING MOUNTING FLANGE SEAL PLATE BACKUP SEAL

Hydraulic Pump Repair

5. 6. 7. 8.

DRIVE GEAR SIDE PLATE COVER PLATE DRIVEN GEAR

9. 10. 11. 12.

FLANGE-HEAD SCREW DOWEL PIN COUPLING O-RING

Figure 5. Pump Assembly 8. Lubricate O-ring seal with clean hydraulic oil. Install O-ring seal in groove in mounting flange.

INSTALL 1. Install coupling on hydraulic motor shaft. 2. Rotate pump shaft to align with coupling.

3. Lubricate pump O-ring seal with clean hydraulic oil. 4. Carefully assemble pump to hydraulic motor to ensure O-ring is not damaged during installation. 5. Install two capscrews that fasten the pump to the motor. Tighten capscrews to 25 N•m (18 lbf ft). See Figure 3.

Hydraulic Tank Assembly

1900 YRM 1333

NOTE: Remove any plugs from pump openings and install plugs into fittings after installation. 6. Install inlet fitting into pump. Orient fitting as shown in Figure 6. Tighten fitting to 151 to 166 N•m (114 to 122 lbf ft).

13. Connect three power cables and install three nuts to motor. Tighten nuts to 24 N•m (17 lbf ft). See Figure 3. Power cables terminals must not rotate when installed or torqued. 14. Connect pressure hose to the outlet fitting. 15. Install the frame bulkhead plate and four capscrews onto truck frame and counterweight. 16. Fill hydraulic tank. Refer to Add Hydraulic Oil, in this section. 17. Using slings and an overhead lifting device, carefully install the hood/seat assembly to the lift truck. 18. Install the two hood mounting bolts on each side of the hood. Install nuts and washers to hood mounting bolts. See Figure 1. 19. Install gas spring to ball stud. 20. Install retainer clip to gas spring. See Figure 1.

Figure 6. Inlet Fitting Orientation 7. Install outlet fitting into pump. Tighten fitting to 98 to 110 N•m (72 to 81 lbf ft). See Figure 3. 8. Install plug and clamp to end of hydraulic tank drain hose. Tighten clamp. 9. Using a crane and sling carefully install hydraulic pump and motor assembly onto the three isolators in the hydraulics module bracket. 10. Remove crane and sling after ensuring pump and motor assembly is secure. 11. Install three mounting capscrews. See Figure 4.

21. Install battery. See How to Change Battery in Operating Manual or one of the following service manuals: Periodic Maintenance 8000 YRM 1339 for lift trucks: • ERP15-20VT (ERP030-040VT) (G807) Periodic Maintenance 8000 YRM 1373 for lift trucks: • ERP16-20VF (ERP30-40VF) (A955) 22. Turn lift truck ON, operate hydraulic system, and check all hydraulic lines and connections for leaks.

12. Connect pump suction hose and clamp to inlet fitting. Tighten clamp.

Hydraulic Tank Assembly REMOVE 1. Remove battery from lift truck. See How to Change Battery in Operating Manual or one of the following service manuals: Periodic Maintenance 8000 YRM 1339 for lift trucks: • ERP15-20VT (ERP030-040VT) (G807)

Periodic Maintenance 8000 YRM 1373 for lift trucks: • ERP16-20VF (ERP30-40VF) (A955) NOTE: Make sure crane and sling have the lifting capacity of 54 N•m (119 lbf ft) or more. 2. Place hood in fully open position. 3. Attach sling to hood to support hood when gas spring is disconnected.

1900 YRM 1333

Hydraulic Tank Assembly NOTE: Make sure crane and sling have the lifting capacity of 54 kg (119 lb) or more. 15. Remove three mounting capscrews holding pump and motor assembly to hydraulics module bracket. See Figure 4.

5. Remove gas spring from ball stud. See Figure 1.

16. Using a crane and sling, connect the sling to hydraulic pump and motor assembly. Raise the crane to support and remove pump and motor assembly from hydraulic module bracket.

6. Remove nut and washer from hood mounting bolt on each side of lift truck. See Figure 1.

NOTE: DO NOT damage hoses, electrical connectors, or cables during the removal process.

7. Using crane and sling, remove hood from lift truck.

17. Move hydraulic pump and motor assembly to a workbench or other suitable area.

4. Remove retainer clip from gas spring. See Figure 1.

8. Remove four capscrews and frame bulkhead plate from truck frame and counterweight. See Figure 2. 9. Locate hydraulic tank drain hose. Cut strap clamps holding drain hose, and extend hose to its full length.

18. Loosen clamp and disconnect return hose from filter assembly. Cap hose and filter assembly. See Figure 7. 19. Remove capscrew attaching ground wire assembly to hydraulics module bracket and counterweight.

WARNING The hydraulic oil is HOT at normal operating temperature. Prevent burns from hydraulic oil by using protective clothing and gloves suitable for chemicals and temperatures.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 10. Install a container with a capacity of 20 liter (21 qt) under lift truck. 11. Remove plug from end of hydraulic tank drain hose and drain the hydraulic oil into container. NOTE: Plug hoses and pump fittings to prevent foreign material from entering hydraulic system. 12. Disconnect pressure hose from outlet fitting. See Figure 3. Cap pressure hose and outlet fitting. 13. Disconnect inlet hose from inlet fitting. See Figure 3. Cap inlet hose and inlet fitting. NOTE: Tag electrical connections during removal to aid in installation. 14. Remove three nuts and disconnect three power cables from motor. Lay power cables aside to prevent damage. See Figure 3.

1. 2. 3. 4. 5. 6.

TANK FILTER ASSEMBLY CAPSCREWS BREATHER FILTER FITTING GROUND WIRE ASSEMBLY

7. 8. 9. 10. 11.

PUMP INLET HOSE CLAMP RETURN HOSE WASHER SCREW

Figure 7. Hydraulic Tank (Top View)

Hydraulic Tank Assembly 20. Remove hydraulic tank from counterweight. 21. Move hydraulic tank to a workbench for disassembly and inspection.

DISASSEMBLE NOTE: Note placement of ground wire assembly prior to removal to aid in assembly.

1900 YRM 1333

Steam Method

1. Remove one capscrew and ground wire assembly from filter assembly and hydraulic tank. See Figure 7.

Use the following procedure to clean the tank with steam:

2. Remove three remaining capscrews from filter assembly and hydraulic tank. See Figure 7.

When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in.). Control the pressure of the steam by a valve installed at the nozzle of the hose.

3. Remove filter assembly. See Hydraulic Filter Replacement.

NOTE: Insert plugs in tank openings.

4. Remove breather filter from tank. See Figure 7.

1. Fill tank 1/4 full with solution of water and sodium bicarbonate (baking soda) or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water.

NOTE: Perform Step 5 only if gaskets or strainer basket are damaged. 5. Remove three capscrews and two gaskets from tank. Remove strainer basket from inside tank. 6. Remove fitting from tank. See Figure 7. 7. Loosen clamp and disconnect inlet hose from tank. See Figure 7. Tighten clamp on hose to keep clamp and hose together.

CLEAN WARNING When cleaning the tank, do not use solutions that make dangerous gasses at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns using protective clothing and gloves suitable for chemicals and temperatures.

WARNING The hydraulic oil is HOT at normal operating temperature. Prevent burns from hydraulic oil by using protective clothing and gloves suitable for chemicals and temperatures.

WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion.

2. Mix solution in tank using air pressure. Make sure all surfaces of the tank are flushed with solution. Drain tank. 3. Remove tank plugs. Put steam into tank until tank does not have odors and is hot. Steam vapors must come from all openings. 4. Flush inside of tank with boiling water. Make sure all loose material is removed from inside of tank. 5. Inspect inside of tank, if it is not clean, repeat Step 3 and Step 4, then make another inspection. When making inspections, us a light that is approved for locations with flammable vapors. 6. Put plugs in all openings of tank. Wait 15 minutes, then remove the inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat cleaning procedures. 7. When procedure is complete, remove plugs from tank openings.

Chemical Method If tank cannot be cleaned with steam, use the following procedure: 1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkali base. Follow instructions given by manufacturer.

1900 YRM 1333 NOTE: Insert plugs in tank openings.

Hydraulic Tank Assembly 7. Install remaining capscrews holding filter assembly onto hydraulic tank.

2. Fill tank with cleaning solution. Use compressed air to mix solution in tank.

INSTALL

3. Drain tank. Flush inside of tank with boiling water. Make sure all cleaning compound is removed.

1. Install hydraulic tank into counterweight. See Figure 2.

4. Inspect inside of tank, if it is not clean, repeat Step 1 through Step 3, then make another inspection. When making inspections, use a light that is approved for locations with flammable vapors.

2. Install capscrew attaching ground wire assembly onto hydraulic module bracket and steer plate assembly. See Figure 7.

5. Put plugs in all openings of tank. Wait 15 minutes, then remove the inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat cleaning procedures. 6. When procedure is complete, remove plugs from tank openings.

INSPECT WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion. 1. Make a visual inspection of all sides of the tank. Inspect for cracks and leakage, check for wet areas or accumulation of dirt caused by leakage. Areas not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors. If the tank is damaged, replace tank. 2. Inspect all tank components, replace components if damaged.

ASSEMBLE 1. Install fitting into tank. See Figure 7. 2. If removed, install strainer basket inside tank. 3. Install two gaskets and three capscrews into tank.

NOTE: Remove plugs from hoses and fittings as connections are made. 3. Loosen clamp and connect pump inlet hose onto hydraulic tank. Tighten clamp. See Figure 7. 4. Loose clamp and connect return hose onto filter assembly. Tighten clamp. See Figure 7. 5. If removed, install tank drain hose assembly and clamp on end of drain fitting. Tighten clamp. See Figure 2. 6. Install plug and clamp in opposite end of drain hose. Tighten clamp. 7. Using a crane and sling, carefully install hydraulic pump and motor assembly onto three isolators in hydraulic module bracket. 8. Remove crane and sling after ensuring pump and motor assembly is secure. 9. Install three motor mounting capscrews. See Hydraulic Pump and Motor Mounts. 10. Connect pump inlet hose and clamp on inlet fitting. Tighten hose clamp. See Figure 7. NOTE: Remove tags from electrical connections as they are made. 11. Connect three power cables and install three nuts to motor. Tighten nuts to 24 N•m (17 lbf ft). Power cable terminals must not rotate when tightened. See Figure 3.

4. Install breather filter onto tank. See Figure 7.

12. Install outlet hose on pump outlet fitting. See Figure 3.

5. Install filter assembly into hydraulic tank. See Hydraulic Filter Replacement. See Figure 7.

13. Install frame bulkhead plate and four capscrews onto counterweight and truck frame. See Figure 2.

6. Install ground wire assembly under one of four capscrews used to hold filter assembly on tank as noted during disassembly. See Figure 7.

14. Fill hydraulic tank using instructions found in Add Hydraulic Oil section.

Hydraulic Tank Assembly

1900 YRM 1333

15. Using slings and an overhead lifting device, carefully install hood and seat assembly onto lift truck. 16. Install two hood mounting bolts on each side of hood. See Figure 1. 17. Install battery. See How to Change Battery in Operating Manual or one of the following service manuals: Periodic Maintenance 8000 YRM 1339 for lift trucks: • ERP15-20VT (ERP030-040VT) (G807)

CAUTION Filter element must be installed with the debris cup to the bottom and the check valve to the top. Installing the filter element upside down could result in severe damage to the hydraulic system. 7. Install new hydraulic filter element into hydraulic filter housing. 8. Lubricate new O-ring with clean hydraulic oil and install on head. See Figure 8.

Periodic Maintenance 8000 YRM 1373 for lift trucks: • ERP16-20VF (ERP30-40VF) (A955) 18. Turn lift truck ON, operate hydraulic system, and check all hydraulic lines and connections for leaks.

HYDRAULIC FILTER REPLACEMENT NOTE: Ensure head is protected to prevent foreign material from entering hydraulic system. 1. Remove lid, O-ring, and spring from head. Use socket or wrench if unable to remove lid by hand. Discard O-ring. See Figure 8. NOTE: Have container large enough to hold the filter assembly and allow for final hydraulic oil draining. 2. Remove hydraulic filter element from hydraulic filter housing and place into container. See Figure 8. NOTE: Perform Step 3 through Step 5 only if head is damaged. 3. Inspect head, if damaged remove four capscrews and hydraulic filter housing from hydraulic tank. Discard quad seal. See Figure 8. Plug hole to prevent dirt from entering hydraulic tank. 4. Lubricate new quad seal with clean hydraulic oil and install on new hydraulic filter housing. 5. Install new hydraulic filter housing and four capscrews into hydraulic tank.

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local dealer. 6. Fill hydraulic tank with hydraulic oil to replenish oil lost with filter element. See Add Hydraulic Oil for your lift truck for procedure.

1. 2. 3. 4. 5.

LID O-RING SPRING HEAD HYDRAULIC FILTER HOUSING

6. QUAD SEAL 7. HYDRAULIC FILTER ELEMENT 8. PLUG 9. CHECK VALVE 10. DEBRIS CUP

Figure 8. Hydraulic Filter 9. Inspect spring and lid; if worn or damaged, replace with new parts. See Parts Manual if new parts are required. 10. Install spring and lid onto head. See Figure 8. 11. Operate hydraulic system and check hydraulic lines and connections for leaks. With lift truck hydraulic

1900 YRM 1333

Specifications

system in neutral check hydraulic oil level in hydraulic tank. Add oil, if necessary. See Add Hydraulic Oil for your lift truck for procedure.

BREATHER CLEAN AND INSPECT

7. Install counterweight cover and two thumbscrews onto counterweight. 8. Install tow pin into counterweight cover.

ADD HYDRAULIC OIL

1. Remove tow pin from counterweight cover.

2. Remove two thumbscrews and counterweight cover from counterweight. 3. Remove breather filter from hydraulic tank. See Figure 7.

2. Remove two thumbscrews and counterweight cover from counterweight. 3. Remove hydraulic breather from hydraulic tank.

CAUTION

WARNING Cleaning solvents can be flammable and toxic and may cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 4. Wash breather in solvent and use compressed air to dry. 5. Inspect breather for damage. Replace if damaged. Refer to Parts Manual if replacement is required.

DO NOT fill tank above the FULL mark on dipstick. If tank is too full, oil will come out the breather during operation. 4. Fill tank with hydraulic oil. NOTE: To find specified hydraulic oil, refer to one of the following service manuals: Capacities and Specifications 8000 YRM 1340 for lift trucks: • ERP15-20VT (ERP030-040VT) (G807) Capacities and Specifications 8000 YRM 1376 for lift trucks: • ERP16-20VF (ERP30-40VF) (A955)

6. Install breather on hydraulic tank.

Specifications Hydraulic System Capacities Tank

Dipstick FULL Mark 17.9 liter (19.0 qt)

Torques Pump to Motor Capscrews

25 N•m (18 lbf ft)

Motor Power Cable Nuts

24 N•m (17 lbf ft)

Suction Hose Fitting to Hydraulic Pump

151 to 166 N•m (111 to 122 lbf ft)

Pressure Line Hose Fitting to Hydraulic Pump

98 to 110 N•m (72 to 81 lbf ft)

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

1900 YRM 1333

11/10 (2/10)(8/08)(7/08) Printed in U.S.A.

Maintenance

INDUSTRIAL BATTERY ALL ELECTRIC LIFT TRUCKS

PART NO. 524158040

2240 YRM 1

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Industrial Battery

Table of Contents

1 1 2 2 3 4 5 5 6 6 6 6 7 7 7 9 10 10 11 12 13 14 14 14 14 15 15

This section is for the following models: All Electric Lift Trucks

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Lead-Acid Batteries

General This section describes how to select and do the maintenance for large batteries used in electric lift trucks. This information is for service personnel that must do the maintenance on large lead-acid batteries. Battery repair requires special training and equipment. Do not try to repair a battery unless you have the correct tools, equipment, and experience. Most battery repairs are done by a special repair service. Some batteries have

a nameplate attached to the face of the battery cover. This nameplate communicates specific information about the battery including the name of the battery manufacturer, battery type, serial number, nominal voltage, capacity in amperes at the five-hour rate, and service mass (with ballast if used to compensate for lack of battery mass).

Lead-Acid Batteries A lead-acid battery converts chemical energy into electrical energy. See Figure 1. Chemical changes within the battery give the electrical energy. When the chemical reaction has occurred so the battery will not give its rated voltage and current, the battery is discharged. A reverse chemical action must occur so the battery can be used again. The batteries described in this section can be charged again by an electric voltage and current from an outside source so there is a reverse chemical action. The lead-acid chemicals store the electric energy until the electric energy is needed to operate an electric device.

Figure 1. Lead-Acid Industrial Battery A lead-acid battery is made from several lead-acid batteries called cells. Each cell has positive and negative plates with dielectric spacers between each plate. All of the plates are within a solution of electrolyte. See Figure 2.

1. VENT AND FILL CAP 2. POST 3. POST SEAL 4. PLATE PROTECTOR (SHIELD)

5. 6. 7. 8. 9. 10.

POSITIVE PLATE EXPANSION MATS RETAINER SEPARATOR NEGATIVE PLATE BATTERY JAR

Figure 2. Battery Cell

Chemical Reaction in a Cell

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Specific Gravity The strength of the electrolyte is measured in points of specific gravity. For example, a solution of sulfuric acid has a specific gravity of 1.835. Water has a specific gravity of 1.000. Electrolyte is 27 percent acid and 73 percent water and has a specific gravity of 1.275.

Chemical Reaction in a Cell WARNING NEVER pour water into concentrated acid. Combining these liquids creates the rapid production of heat which can cause the water to boil and the acid to erupt and splash out of the container. ALWAYS pour concentrated acid into water when making a dilute solution of acid. In a fully-charged cell, the electrolyte has a specific gravity of 1.270 to 1.130. NEVER discharge a battery below a specific gravity of 1.130. The battery can have permanent damage if discharged below 1.130. The cell generates a voltage (potential difference) when two different types of metal are in the electrolyte. The two metals in a lead-acid cell are lead peroxide (PbO 3) for positive plates, and sponge lead (Pb) for negative plates. See Figure 3. A potential difference of approximately 2 volts per cell is generated. The potential difference does not vary according to the size of the cell.

During the discharge of the cell, lead peroxide and sponge lead mix with sulfuric acid to make lead sulfate (PbSO 4) on both plates. See Figure 4. This action decreases the voltage in the cell. When the sulfuric acid is removed from the electrolyte, the specific gravity of the electrolyte decreases. See Figure 5. The potential difference of a discharged cell is approximately 1.75 volts. When a direct current is applied to a discharged cell, the lead sulfate is changed into lead and sulfuric acid. The lead goes to the positive plate and stays as lead and to the negative plate and stays as lead peroxide. See Figure 6. The concentration of sulfuric acid in the electrolyte increases. The specific gravity of the electrolyte increases as the concentration of sulfuric acid increases. In a fully charged cell, the positive plate again contains the lead peroxide and the negative plate contains the sponge lead.

Figure 4. Discharging Cell Figure 3. Fully Charged Cell

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Electrical Terms

Figure 5. Discharged Cell

Figure 6. Charging Cell

Electrical Terms Voltage: Is an electromotive force (EMF) (also called "potential difference") caused by the difference in electric charge between two points. See Figure 7. Ampere: Is a measurement of electric current. Watt: Is a measure of electric power. The number of watts is equal to the number of volts multiplied by the number of amperes. A kilowatt-hour is 1000 watts of electric power used in 1 hour. Ohms: Is the measurement of electrical resistance. Polarity: In a battery, the electric current is shown to flow from the positive terminal to the negative terminal. Maintenance-Free Battery: The electrolyte level in the battery does not need to be checked during the life of the battery. Maintenance-free batteries use a calcium alloy of lead instead of an antimony alloy, which reduces

the amount of electrolysis. In a maintenance-free battery, the amount of free-standing electrolyte above the plates is much higher, ensuring enough electrolytes to keep the plates covered during extended periods of use. Therefore, there is no need to add water to a maintenance-free battery during the course of its life. Flooded Cell: This is a lead acid battery that has free flowing electrolyte fluid in each cell of the battery. The electrolyte is a mixture of sulfuric acid and water. Direct Current (DC): When the voltage between the two terminals is always the same polarity, the current flow and voltage are called Direct Current. Alternating Current (AC): When the polarity of voltage between two terminals is changing between positive and negative at a quick and constant rate, the voltage is called Alternating Current.

Battery Selection

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Figure 7. Electrical Terms

Battery Selection NOTE: The capacity of the battery can be found on the lift truck’s Nameplate. See the Frame section or Operating Manual for your lift truck for the location of the Nameplate. The battery needed to operate a period of 8 hours depends on many conditions. Operations that require the lift truck to go up ramps or require the use of additional attachments increase the use of power from the battery. Some work conditions require that more than one battery must be used during a work period. The number of 8-hour work periods per day is normally equal to the number of batteries needed. For example, for three work periods, you need three batteries. The capacity of the battery you need is found as follows: • The size of the lift truck and the attachments. • The type of work. Heavy-duty operation or normal operation for one 8-hour work period. Lift trucks are available in various voltage ranges. See Figure 8. The small "walkie" lift trucks are normally 12 or 24 volts. The larger sit-down rider lift trucks are normally 24, 36, 48, 72, or 80 volts. The number of cells in a lead-acid battery gives the battery voltage. See Figure 9. A fully charged cell has a potential difference of approximately 2 volts. See Figure 8. This potential difference does not change with size of the cell.

Figure 8. Cell Voltage

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Battery as a Counterweight

Figure 9. Multicell Battery for Electric Lift Truck

Battery Voltage NOTE: The voltage of the battery can be found on the lift truck’s Nameplate. See the Frame section or Operating Manual for your lift truck for the location of the Nameplate. The battery voltage you need is found as follows: • Will your lift truck operate on more than one voltage? • If you have more than one lift truck in operation, do the battery voltages need to be the same?

To reach the necessary battery voltage, the cells are connected in series. For example: 24 volts = 12-cell battery 36 volts = 18-cell battery 48 volts = 24-cell battery 72 volts = 36-cell battery 80 volts = 40-cell battery

Battery as a Counterweight On electric lift trucks that use the battery as part of the counterweight, the battery is part of the capacity of the lift truck to lift loads. The minimum weight of the battery is shown on the nameplate. If the battery is not the minimum weight, the capacity of the lift truck is reduced. If the battery used in the lift truck is less than the size of

the battery compartment, blocks and spacers must be installed to hold the battery in position. See the Frame or Periodic Maintenance service manual or Operating Manual for your lift truck model for the correct measurements for installing battery spacers.

Battery Maintenance

2240 YRM 1

Battery Ratings The ratings of batteries are measured in ampere-hours and kilowatt-hours at a constant rate of discharge. A rating of 6 hours is the standard. Ampere-hours is the measurement of battery capacity. To calculate amperehours, multiply amperes by hours. See Table 1. For example, 5 amperes times 5 hours is 25 ampere-hours. You cannot change the potential difference of a cell. You can increase the ampere-hour rating by increasing the number of plates in a cell, or by installation of larger plates. The constant rate of discharging can be compared to a measurement of the battery capacity and ampere-hours. For example, a battery with a rating of 600 ampere-hours during a work period of 6 hours will generate 100 amperes per hour for 6 hours. The same battery cannot generate 300 amperes for 2 hours. The heat generated within the battery will damage the battery.

KILOWATT-HOURS A kilowatt is 1000 watts. A watt is a measure of electric power. The capacity in kilowatt-hours is the total power generated by the battery. Watt-hours are measured by multiplying the voltage by ampere-hours. To measure the kilowatt-hours, divide the watt-hours by 1000. volts × amperes × hours 1000

= kilowatt-hours or kWh

To calculate the kilowatt-hours for a battery that has a rating of 600 ampere-hours and a 48-volt system, use this formula: 48 volts × 600 amperes × hours 1000

= 28.8 kWh

Table 1. Battery Capacity Terms Amperes × Hours = Ampere-Hours 600 Ampere Hours = 100 Amperes for 6 Hours Volts × Amperes × Hours/1000 = Kilowatt-Hours (KWH)

The watt-hours can be converted to kilowatt-hours to indicate the battery needed for the operation. Always select the correct type of battery. Remember, a battery that has a rating of 300 ampere-hours will not do the same job as a battery that has a rating of 600 amperehours. Do not permit the specific gravity to go below the limits shown in the manual.

Battery Maintenance Battery maintenance must include the following items: • A good battery charger • A clean battery • Keep the electrolyte at the correct level (see Figure 13) • Keep a record of the battery • An Equalization Charge once a month

with a lift truck or a conveyor or rollers designed for that purpose. If the battery does not have a cover, a rubber mat or insulating material must be put over the top of the battery to prevent a short circuit with other equipment. Make sure the lifting equipment has enough capacity for the job. Do not use chain or wire rope slings.

SAFETY PROCEDURES

4. Never put metal materials or tools on a battery.

1. Wear a rubber apron, gloves, boots, and goggles or a face shield when doing maintenance on batteries.

5. Disconnect battery from lift truck before doing maintenance or repairs.

2. Batteries generate hydrogen gas when they are being charged. Keep open fire away from batteries. Do not check the electrolyte level with a match or a lighter. Do not smoke and do not create sparks.

6. When maintenance on the battery or the battery charger is required, disconnect both the AC and DC power. If the battery connectors must be replaced, make sure the positive and negative terminals and cables are kept separate and insulated from each other. Even a momentary short circuit can cause an explosion and damage the battery.

3. Lift batteries correctly with a crane or equipment designed for the job. Always use a spreader bar designed and adjusted for the battery. Move batteries

2240 YRM 1 7. Keep water readily available to flush spilled electrolyte. Electrolyte in the eyes must be flushed with water immediately, and then quickly get medical attention. Special showers and eye wash systems are required in areas where battery maintenance is done. 8. If electrolyte is spilled on a work surface or the floor, flush area with water, use a solution of soda (sodium bicarbonate) to make the acid neutral. 9. Only trained persons are permitted to do maintenance on batteries and battery chargers. Make sure the regulations by government safety agencies, government insurers, private insurers, and private organizations are followed when doing maintenance on batteries.

MAINTENANCE RECORDS NOTE: Follow the same sequence when you record the cell number. Always begin the record with a positive cell. Follow a sequence so the last cell is always the cell for the negative cable. Record the beginning ampere reading of the charger each time the battery is charged. Any difference in the daily ampere reading can indicate a problem with the battery or the charger.

NEW BATTERY CAUTION Always use a spreader bar and slings that lift vertically on the lifting eyes of the battery. DO NOT use a chain or sling without a spreader bar or you will damage the battery case. Use the correct blocks or spacers to hold the battery in position in the lift truck. Make sure the battery compartment is clean and dry. All vent caps must be in position when the battery is in service. If the vent caps are not installed, the electrolyte will

Battery Maintenance leak, causing corrosion on the battery case and in the battery compartment. Inspect a new battery for damage. Make sure the electrolyte in each of the cells is at the correct level. Charge the battery for 6 hours or until the specific gravity is correct. Make sure the battery is correctly installed in the lift truck. Use a spreader bar with slings designed for the battery to lift and move the battery. See Figure 10. Always complete the Battery Inspection Report and the Daily Battery Report. See Figure 11 and Figure 12.

CLEANING BATTERY WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Keep the battery compartment clean and dry. Use a clean cloth to wash the battery with water. Dry with compressed air.

CAUTION Do not clean the battery with steam or hot water. Do not use a high-pressure hose. Remove any electrolyte from the battery compartment to prevent corrosion. If there is electrolyte on the top of the battery, apply a solution of bicarbonate of soda. Mix a solution containing 0.5 kg of soda for every 4 liters of water. Apply the solution, then flush the solution from the battery with clean water. Wash the battery and battery compartment as needed, but within a 6-month period as the maximum time. NOTE: If the top of the battery is wet from electrolyte, check that the electrolyte level is not too high or the battery charger is not operating correctly.

Battery Maintenance

2240 YRM 1 Legend for Figure 10 1. INSULATED SPREADER BAR 2. INSULATED STRAPS

Figure 10. Change the Battery

Figure 11. Battery Inspection Report

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Battery Maintenance

Figure 12. Daily Battery Report

ADDING WATER TO BATTERY NOTE: Some batteries have sealed cells. These batteries do not need water added to the electrolyte.

out of the cell through the fill hole. The correct electrolyte level is shown in Figure 13.

Some water is lost from the electrolyte of each cell during the charge and discharge cycle when the battery is in service. Check the electrolyte level daily. Some service persons check some of the cells each day so all cells are checked each week. If the level of the electrolyte goes below the level of the top of the separators for the plates, the cell can be damaged. KEEPING THE ELECTROLYTE LEVEL WITHIN THE CORRECT LIMITS IS THE MOST IMPORTANT ITEM OF BATTERY MAINTENANCE. See the instructions from the manufacturer of your battery for the operating level of the electrolyte. Always use distilled water. If you add distilled water, wait 5 minutes before measuring the specific gravity with a hydrometer. DO NOT add water to a cell before or during the charging cycle; water must be added after the charging cycle. If water is added before the charging cycle, the electrolyte level may rise, which will cause electrolyte to be forced out of the vent plugs. The electrolyte can flow

1. 2. 3. 4. 5. 6. 7.

FILL TUBE BOTTOM OF FILL TUBE CELL COVER MAXIMUM LEVEL OF ELECTROLYTE MINIMUM LEVEL OF ELECTROLYTE PLATE PROTECTOR TOP OF SEPARATORS Figure 13. Electrolyte Level

Battery Maintenance

2240 YRM 1

HYDROMETER NOTE: Some batteries have sealed cells. The specific gravity of the electrolyte cannot be checked on these batteries. Use a hydrometer to measure the specific gravity of the battery. Make sure there is enough electrolyte in the battery cells. See Adding Water to Battery in this section. A high level or low level of the electrolyte can change the specific gravity measurement. When the

1. HIGH FLOAT MEANS HIGH SPECIFIC GRAVITY. 2. LOW FLOAT MEANS LOW SPECIFIC GRAVITY.

electrolyte level is low, the percent of sulfuric acid in the electrolyte increases. When the electrolyte level decreases by 3 mm (1/8 in.), the specific gravity measurement can increase by 3 to 5 points. When you use the hydrometer, make sure there is enough liquid in the barrel to let the float move freely. The float must not touch the side, top, or bottom of the barrel. See Figure 14 for the correct method of reading the hydrometer.

3. CORRECT METHOD OF READING HYDROMETER: EYE LEVEL EVEN WITH SURFACE OF ELECTROLYTE.

Figure 14. Reading Hydrometer

BATTERY TEMPERATURE The temperature of the electrolyte will change the reading of the specific gravity. When the temperature increases approximately 6 C (10 F), the specific gravity will decrease by 0.003 point. See Figure 15 for making specific gravity corrections. If the hydrometer you are using does not have a temperature correction, you will have to use a thermometer. Special battery thermometers are available that will indicate the correction factor directly and add or subtract the correct number of points. See Figure 16. NEVER charge a battery at a rate that will raise the electrolyte temperature above 49 C (120 F). NEVER let a battery stay discharged for long periods. A temperature above this amount will damage the battery. The cells in the center of the battery are normally at the highest temperature. If the battery temperature is too hot, make sure the ventilation of the battery is increased and make

sure the charge or discharge rate is not too high. A recommendation for a battery in service is 8 hours of use (discharge), followed by 8 hours of charging, followed by 8 hours of cooling. To charge the battery, a direct current must pass through the cells in the opposite direction to the discharging current. The ampere-hours must be equal to the discharging ampere-hours plus the energy lost as heat. This additional amount of charge will vary according to the battery and the temperature, but the average additional charge is 12 percent. When the battery is nearly charged, the final charging must be at a low rate. A charging rate that is too high will cause heating in the battery and a high loss of water from the electrolyte. The charging of the battery must be done correctly, or the service life of the battery will be decreased.

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Battery Maintenance sealed cells. The sealed batteries require a different charger. The electrolyte level or specific gravity cannot be checked, and water cannot be added to the electrolyte of these sealed batteries.

WARNING The acid in the electrolyte can cause injury. If electrolyte is spilled, use water to flush the area. Make the acid neutral with a solution of sodium bicarbonate. Batteries generate explosive fumes when they are being charged. Keep fire, sparks, and burning material away from the battery charger area. Prevent sparks from the battery connectors.

Specific Gravity Reading

Electrolyte Temp.

Correction Points

Correct Value

1.210

31 C (88 F)

+0.003

1.213

1.210

27 C (81 F)

+0.001

1.211

1.210

25 C (77 F)

0.000

1.210

18 C (64 F)

0.004

1.206

+0.001 or 0.001 for each 2 degrees C from the 25-degree base value. Figure 15. Specific Gravity Check

Charge batteries only in the special area for charging batteries. When charging the batteries, keep the vent caps clean. The battery charger area must have ventilation so that explosive fumes are removed. Open the hood over the battery or remove the cover if the battery has a cover. Disconnect the battery when doing cleaning and maintenance. If the lift truck has been operated with a low battery, check the contactors for welded contacts before a charged battery is connected. The circuit will not reset and lift truck operation cannot be controlled if the contacts are welded. To check the contacts, see the Contactor inspection procedure for your lift truck.

CAUTION Use only battery chargers approved by the battery manufacturer or dealer.

CAUTION NEVER connect the battery charger plug to the plug of the lift truck. You can damage the traction control circuit. Make sure the charger voltage is the correct voltage for the battery.

Figure 16. Battery Thermometer

CHARGING BATTERY NOTE: There can be one of two types of batteries. One type has removable cell caps. The other type has

Correct use of the hydrometer (see Figure 14) and proper operation of the battery charger is important. Also see Figure 15. Follow the instructions of the charger manufacturer. NEVER let the battery discharge below the minimum value given by the battery manufacturer. A fully charged battery will have a specific gravity of 1.265 to 1.310 at 25 C (77 F). See Figure 15. NEVER charge a battery at a rate that will raise the electrolyte temperature above 49 C (120 F). Never let a battery stay discharged for long periods.

Battery Maintenance

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Types of Battery Charges 1. NORMAL CHARGE. This charge is usually given to a battery that is discharged from normal operation. This is often an 8-hour charge. Many customers charge the battery at regular intervals that depend on use. This procedure will keep the battery correctly charged if the battery is not discharged below the limit. Always use a hydrometer to check the battery if the battery is charged at regular intervals. Frequent charging of a battery that has a 2/3 or more charge can decrease the life of the battery. 2. EQUALIZING CHARGE. This charge is at a low rate and balances the charge in all the cells. The equalizing charge is usually given approximately once a month. It is a charge at a slow rate for 3 to 6 hours in addition to the regular charging cycle. Do not give an equalizing charge more than once a week. The most accurate specific gravity measurements for a charged battery will be after an equalizing charge. If the specific gravity difference is more than 0.020 between cells of the battery after an equalizing charge, there can be a damaged cell. Consult your battery dealer. NOTE: Many customers have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufacturer. Use the recommendations of the battery manufacturer for charging the battery. The discharge limits and the limits for the specific gravity before the battery must be charged again are shown in Figure 17. NEVER discharge a battery below the limits shown in Figure 18. Discharging a battery beyond the design limits will decrease the service life of the battery.

Figure 17. Specific Gravity Versus Percent Discharge

NOTE: Sometimes the capacity of a battery is not enough to complete a work period. Check for the following conditions: • The battery is too small for the job. • The battery is not fully charged. • The battery charger is not operating correctly. • The battery is near the end of its service life.

Figure 18. Specific Gravity Compared to Charging Time

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Methods of Charging There are three methods of charging a battery. 1. GRADUAL CHARGE. This method uses a solidstate automatic battery charger. The charging rate begins at 20 to 25 amps/100 amp-hours and decreases to less than 5 amps/100 amp-hours when the battery is 80 percent charged. The charging current decreases when the voltage across the cell increases during the charging cycle shown in Figure 19. The increase in the voltage from the charger is approximately the same as the increase in the specific gravity in the cells.

Battery Maintenance One resistor controls the charging rate at the beginning of the cycle and a second resistor reduces the charging rate when the voltage in the cells reaches 2.37 volts. A relay automatically controls the second resistor. The two-rate charging cycle is shown in Figure 21.

Figure 20. Modified Constant Voltage Charger

Figure 19. Specific Gravity Compared to Charging Time 2. MODIFIED CONSTANT VOLTAGE. This method uses a generator to generate a constant voltage that is controlled by a resistor. When the charging current decreases, the voltage across the resistor increases. The increasing voltage across the resistor causes an increasing voltage at the battery terminals. The charging is similar to the gradual charge. The resistor must be correctly set, or the charging rate will be wrong. The typical graphs for a modified constant voltage charger are shown in Figure 20. 3. TWO-RATE CHARGE. This method also uses a high charging rate at the beginning followed by a lower rate. Two resistors control the charging rate.

Figure 21. Two-Rate Charging Cycle NOTE: Many users have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufacturer. Use the recommendations of the battery manufacturer for charging the battery.

Battery Maintenance

Troubleshooting Charger Battery chargers normally operate automatically without constant attention. It is necessary to make a periodic check that the charger is operating correctly. Check for the following conditions: 1. Battery temperature is too high. The temperature in a battery will not normally rise more than 14 C (25 F) during an 8-hour charging period. Higher temperatures indicate the charging rate needs adjustment. 2. Continuous operation of the charger. Check the automatic controls on the charger. Check the charging rate. A low charging rate can be the problem. 3. Continuous operation of a charger at a high rate. Normally, the charging rate begins at a high rate and decreases as the battery becomes charged. If the rate does not decrease, the controls need repair or adjustment.

Knowing When Battery Is Fully Charged WARNING Always connect the positive cable to the positive terminal and connect the negative cable to the negative terminal. Any other connection will cause injury and damage. Always charge the battery at the end of the work period (shift). Never let the specific gravity decrease to a level less than the limits shown in the manual. Always de-energize the charger before you connect or disconnect the charger from the battery. NEVER connect the battery charger plug to the plug of the lift truck. You can damage the traction control circuit. Make sure the charger voltage is the correct voltage for the battery. 1. During charging, the voltage increases slowly. When the battery is fully charged, the voltage level is constant. 2. Remove a vent cap and look in the opening. If you see bubbles in the electrolyte, the battery is either fully charged or in the final stage of charging.

2240 YRM 1 3. The specific gravity reading is constant and within the limits of a charged battery. If the temperature increases after the battery is charged, the specific gravity will decrease a small amount. 4. Constant meter indications on the charger will indicate the end of the charging cycle.

WHERE TO CHARGE BATTERIES To increase the service life and reduce maintenance, a special area is needed for charging the batteries. The following information is necessary for the design of this area: • Location of power supply • Ventilation; hydrogen gas comes from the batteries during charging • Drains for cleaning the batteries • Type and size of the batteries • Type of lift trucks • Distances the lift trucks must travel for service • Safety regulations and instructions

Equipment Needed • A lifting device to remove the battery from the lift truck • Racks to hold the batteries during charging and storage (these racks must be made of wood or must not be metal; metal racks that are covered with an insulating material can be used) • A battery charger that will charge your batteries • Tools for maintenance • An area with a drain for cleaning batteries and battery compartments • Distilled water • Air and water supplies for cleaning • Maintenance records (see Figure 11 and Figure 12) • A workbench • Spare parts and repair equipment • Protective clothing and safety equipment for handling batteries • Water source for washing eyes and preventing acid burns • Install a NO SMOKING sign in the service area • Keep the charger in a clean, dry area with good ventilation

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BATTERY CONNECTORS A special heavy-duty connector is used to connect the battery to the electrical system of the lift truck. See Figure 22 and Figure 23. When a connector has a handle and is within the operator’s reach, the connector is also a safety device that can be used to quickly disconnect the battery in an emergency. Most connectors have a handle to connect the two halves of the connector. The connector can be quickly disconnected by pulling the handle upward. This action separates the two halves of the connector. The connector and its attached handle must be kept in good repair so that it will function correctly. The battery connector must be disconnected when maintenance is done on the lift truck that does not require electric power. The SBE, SBX, and FEM or DIN 12- volt battery connectors are shown in Figure 23.

Battery Maintenance Legend for Figure 22 1. SB CONNECTOR FOR BATTERY CABLES 2. SB CONNECTOR FOR POWER CABLES TO LIFT TRUCK 3. BRACKET 4. CONNECT AND DISCONNECT HANDLES

BATTERY CARE 1. Keep batteries clean. Remove any spilled electrolyte. 2. DO NOT overcharge the battery. This action will damage the battery. 3. DO NOT discharge the battery to less than the recommendation. A deep discharge will shorten the battery life. 4. Charge batteries in an area with good ventilation to remove explosive gases and acid fumes. 5. Keep the electrolyte at the correct level. Check the electrolyte level before and after charging the battery. Use distilled water. Do not add acid. 6. Prevent batteries from freezing. 7. Keep batteries charged. A discharged battery in storage will shorten the battery life. 8. Use a battery charger that is correct for the battery. A battery charger that is set for an ampere-hour rate that is too high will cause a high internal heat and damage the battery. A low ampere-hour rate setting on a battery charger can require a longer charging time but will not damage the battery. 9. When batteries are moved, make sure a short circuit does not occur. See the Safety Procedures in Battery Maintenance of this section.

Figure 22. SB Battery Connector

Battery Maintenance

2240 YRM 1

NOTE: INDICATOR INSERT (2). GREEN - FOR BATTERY WITH CELL CAPS. GRAY - FOR BATTERY WITH SEALED CELLS. NOTE: CONNECTOR BODY COLOR [ANDERSON SBE CONNECTOR ONLY (1)]. GRAY - 36-VOLT BATTERY. BLUE - 48-VOLT BATTERY. GREEN - 72-VOLT BATTERY. BLACK - 80-VOLT BATTERY. A. ANDERSON SBE OR SBX CONNECTOR

B. FEM OR DIN CONNECTOR

1. HALF OF CONNECTOR SET 2. RED HOUSING FOR +12 VOLT "BATTERY TAP" 3. LOCK SPRING (TIP OF CONTACT MUST LOCK OVER TOP OF LOCK SPRING) 4. BLACK CONNECTOR HOUSING (ASSEMBLED ON RED HOUSING WITH SLOTS FOR LOCK PINS ALIGNED AS SHOWN - NO WIRE OR CONTACT IN HOUSING) 5. SLOT FOR LOCK PIN 6. CONTACT FOR CONNECTOR OF +12 VOLT BATTERY TAP 7. KEY [RED (2) AND BLACK (4) CONNECTORS ALIGN ON KEY] 8. LOCK PINS FOR +12 VOLT CONNECTOR (MUST INSTALL FROM FRONT OF CONNECTOR THROUGH RED AND BLACK CONNECTORS)

9. +12 VOLT WIRE TO TRUCK (TRUCK HALF) OR TO BATTERY (BATTERY HALF) 10. INDICATOR INSERT FOR BATTERY VOLTAGE AND BATTERY TYPE [ROTATE FOR CORRECT VOLTAGE IN WINDOW (12); COLOR SHOWS BATTERY TYPE] 11. LOCK FOR ALL CABLE TERMINALS AND INDICATOR 12. WINDOW SHOWING BATTERY VOLTAGE 13. IN-LINE FUSE ASSEMBLY AND CONTACT FOR +12 VOLT CONNECTOR (TRUCK HALF OF BATTERY CONNECTOR ONLY) (SBE/SBX CONTACT SHOWN)

Figure 23. Detail of Battery Connectors With +12 Volt Tap

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

2240 YRM 1

2/08 (6/07)(1/06)(11/03)(3/03)(7/02)(12/01) Printed in U.S.A.

Maintenance

MAIN CONTROL VALVES (MANUAL AND E-HYDRAULIC VALVES) ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]; ERC22-35VG (ERC045-070VG) [A968]; ERP22-35VL (ERP045-070VL) [A976]

PART NO. 524319495

2000 YRM 1334

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Main Control Valves

Table of Contents

TABLE OF CONTENTS General.................................................................................................................................................................. 1 Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) ......................... 1 Lift Trucks ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) ..................... 2 Discharging the Capacitors ............................................................................................................................... 5 Manual Hydraulic Control Valve Repair for Lift Truck ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) ..................................................................................................................... 6 Remove ............................................................................................................................................................. 6 Beginning Steps............................................................................................................................................ 6 Disassemble Covers, Links, and Levers ....................................................................................................... 7 Disassemble Handles and Levers ................................................................................................................... 18 Disassemble Manual Control Valve................................................................................................................. 20 Spool Seal Replacement................................................................................................................................. 27 Clean............................................................................................................................................................... 30 Inspect............................................................................................................................................................. 30 Assemble Manual Control Valve ..................................................................................................................... 30 Assemble Handles and Levers........................................................................................................................ 39 Install............................................................................................................................................................... 42 Install Covers, Links, and Levers ................................................................................................................ 42 Ending Steps .............................................................................................................................................. 53 Manual Hydraulic Control Valve Repair for Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) ............................................................................................................... 54 Remove ........................................................................................................................................................... 54 Remove Control Valve ................................................................................................................................ 56 Disassemble Handles and Levers ................................................................................................................... 68 Disassemble Manual Control Valve................................................................................................................. 70 Disassemble Valve...................................................................................................................................... 70 Disassemble Inlet Section........................................................................................................................... 74 Disassemble Lift, Tilt, and Auxiliary Sections ............................................................................................. 74 Spool Seal Replacement................................................................................................................................. 76 Clean............................................................................................................................................................... 77 Inspect............................................................................................................................................................. 77 Assemble Manual Control Valve ..................................................................................................................... 78 Assemble Lift, Tilt, and Auxiliary Sections .................................................................................................. 78 Assemble Inlet Section ............................................................................................................................... 79 Assemble Valve .......................................................................................................................................... 80 Assemble Handles and Levers........................................................................................................................ 87 Install............................................................................................................................................................... 90 Install Control Valve .................................................................................................................................... 90 Ending Steps ............................................................................................................................................ 101 E-Hydraulic Control Valve Repair for Lift Truck ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) ....................................................................................................................................... 101 Remove ......................................................................................................................................................... 101 Disassemble.................................................................................................................................................. 105 Clean............................................................................................................................................................. 109 Inspect........................................................................................................................................................... 110 Assemble ...................................................................................................................................................... 110 Install............................................................................................................................................................. 114 E-Hydraulic Controls ..................................................................................................................................... 118 Replace E-Hydraulic Control Components ............................................................................................... 119 E-Hydraulic Control Valve Repair for Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) ................................................................................................................................... 119

Table of Contents

Main Control Valves

TABLE OF CONTENTS (Continued) Remove ......................................................................................................................................................... Initial Steps ............................................................................................................................................... Fitting Removal for Lift Truck ERC22-35VG (ERC045-070VG) (A968)..................................................... Fitting Removal for Lift Truck ERP22-35VL (ERP045-070VL) (A976) ...................................................... Electrical Disconnect and Control Valve Dismount ................................................................................... Disassemble.................................................................................................................................................. Clean............................................................................................................................................................. Inspect........................................................................................................................................................... Assemble ...................................................................................................................................................... Install............................................................................................................................................................. Electrical Connect and Control Valve Mount............................................................................................. Fitting Installation for Lift Truck ERC22-35VG (ERC045-070VG) (A968).................................................. Fitting Installation for Lift Truck ERP22-35VL (ERP045-070VL) (A976) ................................................... Ending Steps ............................................................................................................................................ E-Hydraulic Controls ..................................................................................................................................... Replace E-Hydraulic Control Components ............................................................................................... Checks and Adjustments for Lift Truck ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) ....................................................................................................................................... Manual Control Valve .................................................................................................................................... Primary Relief Valve ................................................................................................................................. Optional Work Port Relief Valve................................................................................................................ E-Hydraulic Control Valve ............................................................................................................................. Primary Relief Valve ................................................................................................................................. Optional Secondary Port Relief Valve....................................................................................................... Hydraulic System Air Removal...................................................................................................................... Checks and Adjustments for Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) ................................................................................................................................... Manual Control Valve .................................................................................................................................... External Leakage...................................................................................................................................... Primary Relief Cartridge ........................................................................................................................... Secondary Relief Valve............................................................................................................................. E-Hydraulic Control Valve ............................................................................................................................. Primary Relief Valve ................................................................................................................................. Secondary Relief Valve............................................................................................................................. PPRV Pilot Pressure Test ......................................................................................................................... Hydraulic System Air Removal...................................................................................................................... Position Sensor and OPS Check and Adjustment............................................................................................. Position Sensor ............................................................................................................................................. (OPS) Operator Presence Solenoid.............................................................................................................. Manual Control Valve Re-Calibration ............................................................................................................ Calibration Procedure........................................................................................................................................ Control Valve ................................................................................................................................................. Torque Specifications for Lift Truck ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) ....................................................................................................................................... Manual Hydraulic Control Valve .................................................................................................................... Manual Control Valve Handles and Levers ................................................................................................... E-Hydraulic Control Valve ............................................................................................................................. Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) ................................................................................................................................... Manual Hydraulic Control Valve .................................................................................................................... Manual Control Valve Handles and Levers ...................................................................................................

119 119 119 120 122 124 126 127 128 135 135 137 138 139 139 140 140 140 140 141 141 141 142 142 143 143 143 143 144 144 144 145 146 147 148 148 148 148 149 149 150 150 150 150 151 151 151

Main Control Valves

Table of Contents

TABLE OF CONTENTS (Continued) Manual Control Valve Covers ........................................................................................................................ E-Hydraulic Control Valve .............................................................................................................................

151 151

This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]; ERC22-35VG (ERC045-070VG) [A968]; ERP22-35VL (ERP045-070VL) [A976]

iii

2000 YRM 1334

General

General LIFT TRUCKS ERP15-20VT (ERP030-040VT) (G807) AND ERP16-20VF (ERP30-40VF) (A955) This section contains the description and repair procedures for both manual (controlled manually) and e-hydraulic (controlled electronically) main control valves used in the hydraulic system for this series of lift trucks. Each body section of the main control valve is made of cast grey iron; the spools within inlet, lift, tilt, and auxiliary sections are different for each function. The operator presence solenoid (OPS) has a spring loaded plunger which holds the spool in neutral position when no electrical power is supplied to solenoid coil. The position sensor monitors spool movement and produces a variable output signal utilized by the vehicle systems manager (VSM) to regulate hydraulic pump flow. The control valves are mounted to a mounting bracket using washers, capscrews and nuts. The mounting bracket is then attached to the front bulkhead. See Figure 1 and Figure 2.

NOTE: MAJOR COMPONENTS NOT SHOWN FOR CLARITY. NOTE: ARROW POINTS TOWARD FRONT OF LIFT TRUCK. 1. 2. 3. 4. 5. 6. 7. 8.

FRAME FRONT BULKHEAD MOUNTING BRACKET MANUAL CONTROL VALVE BRACKET CAPSCREW WASHER NUT

Figure 1. Manual Control Valve Mounting for Lift Truck ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955)

General

2000 YRM 1334

NOTE: MAJOR COMPONENTS NOT SHOWN FOR CLARITY. NOTE: ARROW POINTS TOWARD FRONT OF LIFT TRUCK. 1. 2. 3. 4. 5.

FRAME FRONT BULKHEAD MOUNTING BRACKET E-HYDRAULIC CONTROL VALVE BRACKET

6. 7. 8. 9. 10.

M10 CAPSCREW WASHER NUT HOLDING BRACKET M8 CAPSCREW

Figure 2. E-Hydraulic Control Valve Mounting for Lift Truck ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955)

LIFT TRUCKS ERC22-35VG (ERC045-070VG) (A968) AND ERP22-35VL (ERP045-070VL) (A976) This section contains the description and repair procedure for both manual (controlled manually) and

e-hydraulic (controlled electronically) main control valves used in this series of lift trucks. The manual control valve is mounted to a mounting bracket using isolators, capscrews, and washers. The mounting bracket is then attached to the front bulkhead using capscrews, nut, and clip nuts Each body section

2000 YRM 1334 of the manual control valve is made of grey cast iron; the inlet, lift, tilt, and auxiliary sections contain spools. The spools are different for each function. See Figure 3.

General The e-hydraulic control valve is mounted to a mounting bracket using washers, capscrews, and nuts. The mounting bracket is then attached to the front bulkhead using brackets, capscrews, washers, and nuts. See Figure 4.

NOTE: MAJOR COMPONENTS NOT SHOWN FOR CLARITY. NOTE: ARROW POINTS TOWARD FRONT OF LIFT TRUCK. 1. 2. 3. 4.

FRAME FRONT BULKHEAD MOUNTING BRACKET MANUAL CONTROL VALVE

5. 6. 7. 8.

CAPSCREW NUT CLIP NUT SPECIAL WASHER

Figure 3. Manual Control Valve Mounting for Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976)

General

2000 YRM 1334

NOTE: MAJOR COMPONENTS NOT SHOWN FOR CLARITY. NOTE: ARROW POINTS TOWARD FRONT OF LIFT TRUCK. 1. 2. 3. 4. 5.

FRAME FRONT BULKHEAD VALVE MOUNTING BRACKET E-HYDRAULIC CONTROL VALVE MOUNTING CAPSCREW

6. 7. 8. 9.

CLIP NUT CAPSCREW SPECIAL WASHER BULKHEAD

Figure 4. E-Hydraulic Control Valve Mounting for Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976)

2000 YRM 1334

General after the battery is disconnected. To prevent an electrical shock and personal injury, discharge the capacitor(s) before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Make certain the Emergency Disconnect switch has not been activated. This will isolate the controller and prevent the capacitors from discharging properly. The proper way to disconnect the battery is by separating the battery connectors. 1. Ensure the capacitors are discharged by performing Step 2 through Step 6 below. 2. Turn key or keyless switch to OFF position. 3. Disconnect the battery by separating the connectors. 4. Block drive wheels to prevent lift truck from moving. 5. Make sure the Emergency Disconnect switch HAS NOT been activated. If the Emergency Disconnect switch is activated, rotate the switch to the right until it pops up. 6. Wait at least 10 seconds to be sure that the capacitors are fully discharged.

Manual Hydraulic Control Valve Repair

2000 YRM 1334

Manual Hydraulic Control Valve Repair for Lift Truck ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) REMOVE

7. Disconnect OPS solenoids from manual hydraulic wire harness. See Figure 5.

Beginning Steps WARNING Before making repairs to the control valve or its linkage, fully lower all parts of the mast and tilt it fully forward. This action will prevent the mast from lowering suddenly when hydraulic lines are disconnected. NOTE: Only perform those steps below necessary for required repair or replacement. 1. Lower mast and tilt forward. 2. Remove battery from lift truck. See How to Change Battery in Operating Manual or Periodic Maintenance 8000 YRM 1339 for lift trucks ERP15-20VT (ERP030-040VT) (G807) or Periodic Maintenance 8000 YRM 1373 for lift trucks ERP16-20VF (ERP30-40VF) (A955). 3. Discharge capacitors by following steps shown in Discharging the Capacitors in General section of this manual. 4. Remove floor mats and floor plates.

WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool.

CAUTION Electrical components to be shielded from hydraulic oil drips if they are below hydraulic valve and lines. NOTE: Tag hydraulic lines during removal to aid in installation. 5. Put a drain pan under the area of the hydraulic valve. Disconnect hydraulic lines from manual control valve. Cap hydraulic lines and manual control valve fittings. 6. Disconnect position sensor electrical connector from manual hydraulic wire harness. See Figure 5.

A. 3-FUNCTION MANUAL CONTROL VALVE B. 4-FUNCTION MANUAL CONTROL VALVE 1. POSITION SENSOR WIRES 2. POSITION SENSOR ELECTRICAL CONNECTOR 3. OPS SOLENOID

Figure 5. Manual Control Valve Electrical Connections

2000 YRM 1334

Manual Hydraulic Control Valve Repair

Disassemble Covers, Links, and Levers NOTE: Original and updated illustrations shown in STEP 1, STEP 6, and STEP 13 through STEP 16. STEP 1. Pull latch handle and allow manual hydraulic linkage and levers to move forward away from mounting plate.

1. LATCH HANDLE 2. MANUAL HYDRAULIC LINKAGE AND LEVERS 3. MOUNTING PLATE

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 1. (Cont)

1. LATCH HANDLE 2. MANUAL HYDRAULIC LINKAGE AND LEVERS 3. MOUNTING PLATE STEP 2. Remove four button-head capscrews and upper front cover from rear cover.

1. BUTTON-HEAD CAPSCREW 2. UPPER FRONT COVER 3. REAR COVER

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 3. Push manual hydraulic linkage and handles upright until secured against mounting plate.

1. MANUAL HYDRAULIC LINKAGE AND HANDLES 2. MOUNTING PLATE STEP 4. Tag and disconnect manual hydraulic wire harness from clamp button connector, emergency disconnect switch connector, and direction control switch connector.

1. CLAMP BUTTON CONNECTOR 2. EMERGENCY DISCONNECT SWITCH CONNECTOR 3. DIRECTION CONTROL SWITCH CONNECTOR 4. MANUAL HYDRAULICS WIRE HARNESS

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 5. Remove two nuts, two washers, two brackets, and two capscrews from mounting plate and front bulkhead.

1. 2. 3. 4. 5. 6.

CAPSCREW FRONT BULKHEAD BRACKET WASHER NUT MOUNTING PLATE

STEP 6. Remove two button-head capscrews and lower cover from lower frame plate or remove captive screw and lower cover from plate.

1. LOWER COVER 2. LOWER FRAME PLATE 3. BUTTON-HEAD CAPSCREW

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 6. (Cont)

1. LOWER COVER 2. CAPTIVE SCREW 3. PLATE STEP 7. Remove five button-head capscrews and rear cover from upper bracket.

1. REAR COVER 2. UPPER BRACKET 3. BUTTON-HEAD CAPSCREW

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 8. Remove two capscrews and two clamps from manual hydraulics wire harness and mounting plate. Move manual hydraulics wire harness aside to avoid damage.

1. 2. 3. 4.

MOUNTING PLATE MANUAL HYDRAULICS WIRE HARNESS CAPSCREW CLAMP

STEP 9. Disconnect emergency disconnect switch from manual hydraulic wire harness and remove from rear cover. See Electrical System 2200 YRM 1337 for procedure.

A. INSERT SCREWDRIVER HERE 1. 2. 3. 4. 5. 6. 7. 8.

SWITCH SWITCH ADAPTER LOCK NUT EMERGENCY DISCONNECT SWITCH WASHER REAR COVER HOLE

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 10. Pull latch handle up and allow manual hydraulic linkage and handles to move forward away from mounting plate.

1. LATCH HANDLE 2. MOUNTING PLATE 3. MANUAL HYDRAULIC LINKAGE AND HANDLES STEP 11. Remove three capscrews and latch assembly from mounting plate.

1. MOUNTING PLATE 2. LATCH ASSEMBLY 3. CAPSCREW

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 12. Remove three hex capscrews from mounting plate and manual control valve.

1. MANUAL CONTROL VALVE 2. MOUNTING PLATE 3. HEX CAPSCREW STEP 13. Remove four nuts, four capscrews, and lower frame plate with mounting bracket from upper bracket or remove locking ring cotter pin, rod end pin, nylon washer, and mounting bracket from upper bracket.

1. 2. 3. 4. 5.

UPPER BRACKET LOWER FRAME PLATE MOUNTING BRACKET NUT CAPSCREW

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 13. (Cont)

1. 2. 3. 4. 5.

UPPER BRACKET LOCKING RING COTTER PIN NYLON WASHER ROD END PIN MOUNTING BRACKET

1. 2. 3. 4.

MANUAL CONTROL VALVE LINK LOCKING RING COTTER PIN ROD END PIN

STEP 14. Remove locking ring cotter pin, rod end pin, and link from manual control valve. Repeat for all links. Discard locking ring cotter pin.

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 14. (Cont)

1. 2. 3. 4.

MANUAL CONTROL VALVE LINK LOCKING RING COTTER PIN ROD END PIN

1. 2. 3. 4.

LINK LEVER LOCKING RING COTTER PIN CLEVIS PIN

STEP 15. Remove locking ring cotter pin, clevis pin, and link from levers. Repeat for all links. Discard locking ring cotter pin.

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 15. (Cont)

1. 2. 3. 4.

LINK LEVER LOCKING RING COTTER PIN CLEVIS PIN

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 16. Remove e-clip at both ends of pivot pin. Slide pivot pin from levers and upper bracket, removing nylon washers, lever spacer if present, and levers.

A. 3-FUNCTION LEVERS

B. 4-FUNCTION LEVERS

1. PIVOT PIN 2. E-CLIP

3. WASHER 4. LEVER SPACER

DISASSEMBLE HANDLES AND LEVERS NOTE: If necessary, handles can be disassembled. Perform Step 1 through Step 4 for lift/lower handle for lift truck equipped with dcs handle, Step 5 and Step 6 for lift/lower, tilt, aux 1, and aux 2 handles, and Step 7 through Step 9 for aux handle with dual function for lift trucks equipped with clamping function. NOTE: Handles described in Step 1 through Step 4 and Step 7 through Step 9 are optional. 1. Remove two outer capscrews and lift/lower with dcs handle from manual lift/lower lever. See Figure 6. 2. Remove one inner capscrew and palm side grip handle from manual lift lever. See Figure 6. 3. Remove dcs cable from cable track. See Figure 6.

5. LEVER 6. UPPER BRACKET

4. Remove two screws, DCS retainer, DCS cup, and directional control switch from lift/lower with dcs handle. See Figure 6 and Figure 7. 5. Remove two outer capscrews and finger side handle from manual tilt or aux 1 lever. See Figure 6. 6. Remove one inner capscrew and palm side grip handle from manual tilt or aux 1 lever. See Figure 6. 7. Remove two outer capscrews and clamp switch handle from manual aux 2 lever. See Figure 6. 8. Remove one inner capscrew and palm side grip handle from manual aux 2 lever. See Figure 6. 9. Remove push-button cable from cable track. See Figure 6. 10. Remove bushings from levers. See Figure 6.

2000 YRM 1334

Manual Hydraulic Control Valve Repair

A. LIFT/LOWER WITH DCS B. LIFT/LOWER, TILT, AUX 1, AUX 2

C. AUX WITH DUAL FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9.

10. 11. 12. 13. 14. 15. 16. 17. 18.

PALM SIDE GRIP HANDLE FINGER SIDE HANDLE CLAMP SWITCH HANDLE LIFT/LOWER WITH DCS HANDLE MANUAL TILT OR AUX 1 LEVER MANUAL AUX 2 LEVER MANUAL LIFT/LOWER LEVER DIRECTIONAL CONTROL SWITCH (DCS) CLAMPING PUSH-BUTTON

INNER CAPSCREW OUTER CAPSCREW BUSHING CABLE TRACK SCREW DCS RETAINER DCS CUP DCS CABLE PUSH-BUTTON CABLE

Figure 6. Manual Hydraulic Control Handles

Manual Hydraulic Control Valve Repair

2000 YRM 1334

CAUTION If O-rings are to be replaced between two sections that have a hydraulic oil leak, replace all O-rings between all sections. This eliminates the possibility of a subsequent oil leak or possible damage to another O-ring. NOTE: Disassemble the manual control valve only as necessary for repairs. Most repairs to the manual control valve will be to replace O-rings and seals. Spools and valve sections are not serviceable individually and must be replaced as a complete valve section with spool. NOTE: Note placement and orientation of fittings prior to disassembly to aid in assembly. 1. Remove inlet fitting, return line fitting, steer supply line fitting, steer return line fitting, and lift/lower fitting from inlet and lift section ports. See Figure 8. 2. Tag and disconnect position sensor wires from position sensor electrical connector. See Figure 8. 3. Remove tilt fittings, 3-function auxiliary fittings, and 4-function auxiliary fittings from tilt, auxiliary, and dual auxiliary sections. See Figure 9. 4. Remove nuts from tie rods on outlet section side of manual control valve. See Figure 10. 1. SCREW 2. DCS RETAINER

3. DCS CUP 4. DCS CABLE

Figure 7. Directional Control Switch

DISASSEMBLE MANUAL CONTROL VALVE CAUTION All power must be disconnected from valve, mast lowered, and hydraulic lines de-pressurized prior to servicing. Before any disassembly, all interfaces, joints, and recesses must be cleaned of residue and dirt to avoid contaminating internal components.

NOTE: Note which tie rod has the position sensor electrical connector attached prior to disassembly to aid in assembly. 5. Remove nut and position sensor electrical connector from tie rod on inlet side of manual control valve. See Figure 10. 6. Remove each section from tie rods starting with outlet section, followed by auxiliary with solenoid section if present, auxiliary section, tilt section, lift section, and finally the inlet section. See Figure 11.

2000 YRM 1334

Manual Hydraulic Control Valve Repair

NOTE: 4-FUNCTION MANUAL CONTROL VALVE SHOWN. 1. 2. 3. 4. 5.

INLET SECTION LIFT SECTION RETURN LINE FITTING STEER RETURN LINE FITTING INLET FITTING

6. 7. 8. 9.

STEER SUPPLY LINE FITTING LIFT/LOWER FITTING POSITION SENSOR WIRES POSITION SENSOR ELECTRICAL CONNECTOR

Figure 8. Manual Control Valve Fittings, Inlet and Lift Sections

Manual Hydraulic Control Valve Repair

1. 2. 3. 4.

TILT SECTION AUXILIARY SECTION DUAL AUXILIARY SECTION OUTLET SECTION

2000 YRM 1334

5. TILT FITTINGS 6. 3-FUNCTION AUXILIARY FITTING 7. 4-FUNCTION AUXILIARY FITTING

Figure 9. Manual Control Valve Fittings, Tilt and Auxiliary Sections

2000 YRM 1334

1. 2. 3. 4. 5. 6.

Manual Hydraulic Control Valve Repair

INLET SECTION OUTLET SECTION LIFT SECTION TILT SECTION AUXILIARY SECTION AUXILIARY WITH SOLENOID SECTION

7. 8. 9. 10. 11. 12.

POSITION SENSOR MANUAL LOWERING VALVE PRIMARY RELIEF VALVE TIE ROD NUT POSITION SENSOR ELECTRICAL CONNECTOR

Figure 10. Manual Control Valve Sections

Manual Hydraulic Control Valve Repair

2000 YRM 1334 NOTE: Note placement of section seals in retaining grooves prior to removal to aid in installation. 7. Remove and discard section seals from retaining grooves of all manual control valve sections. See Figure 12 and Figure 14. 8. Remove plug from outlet section. See Figure 13. NOTE: Perform Step 9 for tilt section. 9. If equipped, remove optional work port relief valve from tilt section. Remove and discard O-rings and backup ring from relief valve. See Figure 12. NOTE: Perform Step 10 for lift section. 10. Remove manual lowering valve from lift section. Remove and discard O-rings and backup ring from valve. See Figure 12.

1. INLET SECTION 2. LIFT SECTION

3. TIE ROD

Figure 11. Manual Control Valve - Sections and Tie Rods

11. Remove steering load sense fitting from inlet section. Remove and discard O-rings from steering load sense fitting. See Figure 14.

2000 YRM 1334

Manual Hydraulic Control Valve Repair

NOTE: VALVE SECTION BODY FOR LIFT, TILT, AND AUXILIARY SECTIONS ARE VISUALLY THE SAME. NOTE: SPOOL, POSITION SENSOR, AND SOLENOID SHOWN PER MANUFACTURERS DOCUMENTATION. 1. LIFT/TILT/AUXILIARY SECTION BODY 2. O-RING 3. OPTIONAL WORK PORT RELIEF VALVE

4. MANUAL LOWERING VALVE 5. BACKUP RING 6. SECTION SEAL

Figure 12. Lift/Tilt/Auxiliary Sections Manual Control Valve

Manual Hydraulic Control Valve Repair

2000 YRM 1334

Legend for Figure 13 1. OUTLET SECTION

Figure 13. Outlet Section of Manual Control Valve

1. 2. 3. 4. 5.

INLET SECTION PRIMARY RELIEF VALVE STEERING LOAD SENSE FITTING PLUG BACKUP RING

6. 7. 8. 9.

O-RING SECTION SEAL ELBOW FITTING DIAGNOSTIC FITTING

Figure 14. Inlet section of Manual Control Valve

2. PLUG

2000 YRM 1334

Manual Hydraulic Control Valve Repair

12. Remove plug from inlet section. Remove and discard O-ring from plug. See Figure 14. 13. Remove primary relief valve from inlet section. Remove and discard O-rings and backup rings from primary relief valve. See Figure 14. 14. Remove diagnostic and elbow fittings from inlet section. Remove and discard O-ring from elbow fitting. See Figure 14.

1. 2. 3. 4. 5. 6.

INLET SECTION OUTLET SECTION LIFT SECTION TILT SECTION AUXILIARY SECTION AUXILIARY WITH SOLENOID SECTION

SPOOL SEAL REPLACEMENT 1. Remove OPS solenoid from lift, tilt, and auxiliary with solenoid sections. See Figure 15 and Figure 16. NOTE: DO NOT lose spring at end of position sensor. See Figure 15. 2. Remove capscrews and position sensor from spool lock body on lift section, tilt section, and auxiliary with solenoid section. See Figure 15, Figure 16, and Figure 18.

7. 8. 9. 10. 11.

POSITION SENSOR OPS SOLENOID CAPSCREW SPOOL LOCK BODY SPRING

Figure 15. Position Sensor and OPS Solenoid 27

Manual Hydraulic Control Valve Repair

2000 YRM 1334

A. ORIENTATION DOT B. OPS END

C. CLEVIS END

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11.

LIFT/TILT/AUXILIARY SECTION BODY POSITION SENSOR OPS SOLENOID SPOOL LOCK BODY CHECK VALVE SPOOL ASSEMBLY

CAPSCREW O-RING SPOOL SEAL SPOOL CLEVIS SPOOL LOCK EXTENSION

Figure 16. Spool and Sensor 3. Remove position sensor from spool lock body. See Figure 15. NOTE: If working on tilt section, use caution not to loose small spool and spring inside main spool and held in place with spool lock extension. 4. Using screwdriver or pin, hold spool clevis and remove spool lock extension from spool assembly. See Figure 16.

5. Pull spool assembly far enough out of the section body to expose spool seal on clevis end of section body. See Figure 16. NOTE: Lubricate new spool seal with clean hydraulic oil prior to installation. 6. Using O-ring pick or similar device remove and discard spool seal from spool assembly. Lightly lubricate new spool seal and install into section body. U

2000 YRM 1334 cup side of seal to be facing inward toward the section body. See Figure 17.

Manual Hydraulic Control Valve Repair 12. Carefully run your finger around exposed edge of seal. You should have a smooth precise ridge with no kinks or twists. NOTE: Perform Step 13 for tilt section. 13. Install small spool and spring inside spool assembly to be held in position by spool extension. See Figure 16 and Figure 15.

CAUTION Spool lock body must be placed with orientation dot up and toward section body for correct fit. If not installed correctly damage to manual control valve may result.

CAUTION To ensure proper assembly, lip of spool seal should point "in" toward valve housing on both ends.

Figure 17. Spool Seal Installation 7. Carefully run your finger around exposed edge of seal. You should have a smooth precise ridge with no kinks or twists.

14. Install spool extension and spool lock body onto spool assembly. See Figure 16 and Figure 15. NOTE: Apply Loctite® 262 on capscrew threads prior to installation. 15. Install spring, position sensor, and capscrews onto lift section, tilt section, and auxiliary with OPS section. See Figure 18. Tighten capscrews to 4.7 N•m (42 lbf in).

CAUTION Pulling the spool’s meter edges across the spool seals can result in damaging the spool seal. 8. Slide spool assembly back into section body to keep spool seal in place. 9. Push spool assembly into section body far enough to expose the spool seal on OPS end of section body. NOTE: Lubricate new spool seal with clean hydraulic oil prior to installation. 10. Using O-ring pick or similar device remove and discard spool seal from spool assembly. Lightly lubricate new spool seal and install onto spool assembly. U cup side of seal to be facing inward toward the section body. See Figure 17.

CAUTION Pulling the spool’s meter edges across the spool seals can result in damaging the spool seal. 11. Slide spool assembly back into section body to keep spool seal in place.

1. POSITION SENSOR 2. CAPSCREW FOR SECTIONS WITH SPOOL LOCKS 3. CAPSCREW FOR SECTIONS WITHOUT SPOOL LOCKS 4. SPRING

Figure 18. Position Sensor Assembly

Manual Hydraulic Control Valve Repair

2000 YRM 1334

16. Install O-ring on OPS solenoid. See Figure 16. 17. Install OPS solenoid into spool lock body on lift, tilt, and auxiliary with solenoid sections. See Figure 15.

CLEAN WARNING Cleaning solvents can be flammable and toxic and cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Clean only metal components of manual control valve with solvent and dry using compressed air. 2. Clean all threaded components with denatured alcohol and dry using compressed air. 3. Clean rubber or plastic components with warm soapy water and dry with a lint free cloth. DO NOT submerge components with electrical connections in water.

INSPECT 1. Check spools and bores for wear or damage. If damaged, entire section must be replaced. Make sure spool moves freely within bore.

1. MOUNTING PLATE 2. RUBBER CHANNEL

Figure 19. Rubber Channels 2. Inspect check valves and relief valves for damage. Replace if damaged.

ASSEMBLE MANUAL CONTROL VALVE

3. Inspect solenoids and position sensors for damage. Replace if damaged.

NOTE: Tie rod ends should protrude one to two threads beyond the edge of the nut.

4. Inspect threaded components to ensure absence of oil or solvent residue.

1. Install position sensor electrical connector and nut onto tie rod as noted during disassembly. See Figure 20.

5. Inspect handles, levers, bushings, and linkages for damage. Replace if damaged. 6. Inspect rubber channels on mounting plate. See Figure 19. 7. Inspect all other components for damage. Replace if damaged.

Make sure position sensor electrical connector is at the correct angle, as shown in Figure 21.

2000 YRM 1334

1. 2. 3. 4. 5. 6.

Manual Hydraulic Control Valve Repair

INLET SECTION OUTLET SECTION LIFT SECTION LIT SECTION AUXILIARY SECTION AUXILIARY WITH SOLENOID SECTION

7. 8. 9. 10. 11. 12.

POSITION SENSOR MANUAL LOWERING VALVE PRIMARY RELIEF VALVE TIE ROD NUT POSITION SENSOR ELECTRICAL CONNECTOR

Figure 20. Manual Control Valve Sections

Manual Hydraulic Control Valve Repair

2000 YRM 1334

Legend for Figure 21 1. POSITION SENSOR ELECTRICAL CONNECTOR 2. NUT 3. Insert tie rod end without nut through inlet section tie rod holes. Repeat for all four tie rods. 4. Lay inlet section with machined surface facing up as shown in Figure 22. NOTE: DO NOT lubricate section seals. 5. Install new section seals into section retaining grooves on inlet section, as noted during disassembly. See Figure 22. 6. Install lift section onto tie rods and against inlet section. See Figure 23. 7. Install new section seals into section retaining grooves on lift section, as noted during disassembly. See Figure 24.

Figure 21. Position Sensor Electrical Connector

Figure 22. Inlet Section of Manual Control Valve

2000 YRM 1334

Manual Hydraulic Control Valve Repair

Legend for Figure 22 1. 2. 3. 4. 5.

INLET SECTION PRIMARY RELIEF VALVE STEERING LOAD SENSE FITTING PLUG BACKUP RING

8. Install tilt section onto tie rods and against lift section. See Figure 23 for example.

6. 7. 8. 9.

O-RING SECTION SEAL ELBOW FITTING DIAGNOSTIC FITTING

15. Install nuts onto tie rods on outlet section side. See Figure 25. Hand tighten nuts only at this time.

9. Install new section seals into section retaining grooves on tilt section, as noted during disassembly. See Figure 24. 10. Install auxiliary section onto tie rods and against tilt section. See Figure 23 for example. 11. Install section seals into section retaining grooves on auxiliary section. See Figure 24. NOTE: Perform Step 12 and Step 13 if control valve is equipped with an auxiliary with solenoid section. If not, go to Step 14. 12. Install auxiliary with solenoid section onto tie rods and against auxiliary section. See Figure 23 for example. 13. Install section seals into section retaining grooves on auxiliary with solenoid section, as noted during disassembly. See Figure 24. 14. Install outlet section onto tie rods and against auxiliary or auxiliary with solenoid section. See Figure 23 for example. NOTE: Tie rod ends should protrude one to two threads beyond the edge of the nut.

1. INLET SECTION 2. LIFT SECTION

3. TIE ROD

Figure 23. Manual Control Valve - Sections and Tie Rods

Manual Hydraulic Control Valve Repair

2000 YRM 1334

NOTE: VALVE SECTION BODY FOR LIFT, TILT, AND AUXILIARY SECTIONS ARE VISUALLY THE SAME. NOTE: SPOOL, POSITION SENSOR AND SOLENOID SHOWN PER MANUFACTURERS DOCUMENTATION. 1. LIFT/TILT/AUXILIARY SECTION BODY 2. O-RING 3. OPTIONAL WORK PORT RELIEF VALVE

4. MANUAL LOWERING VALVE 5. BACKUP RING 6. SECTION SEAL

Figure 24. Lift/Tilt/Auxiliary Sections, Manual Control Valve

2000 YRM 1334

1. 2. 3. 4. 5. 6.

Manual Hydraulic Control Valve Repair

INLET SECTION OUTLET SECTION LIFT SECTION TILT SECTION AUXILIARY SECTION AUXILIARY WITH SOLENOID SECTION

7. 8. 9. 10. 11.

POSITION SENSOR MANUAL LOWERING VALVE TIE ROD NUT POSITION SENSOR ELECTRICAL CONNECTOR

Figure 25. Manual Control Valve Sections

Manual Hydraulic Control Valve Repair

2000 YRM 1334

CAUTION If the proper torque is not applied to the nuts on the tie rods, the valve spools may bind or stick and section seals may extrude. 16. Turn manual control valve until work ports are facing up, and tighten ALL tie rod nuts to 20.3 ± 1.4 N•m (179.7 ± 12.4 lbf in). 17. Install plug in outlet section. See Figure 26. Tighten plug to 26 N•m (19 lbf ft). NOTE: Perform Step 18 if manual control valve is equipped with auxiliary with solenoid section. 18. Install 4-function auxiliary fittings into auxiliary with solenoid section. See Figure 27. 19. Install 3-function auxiliary fittings into auxiliary section. See Figure 27. NOTE: Lubricate new backup rings and O-rings with clean hydraulic oil prior to installation.

24. Install new O-rings onto steering load sense fitting. Install steering load sense fitting into inlet section as shown in Figure 22. Tighten steering load sense fitting to 16 N•m (142 lbf in). 25. Install new backup rings and O-rings on primary relief valve. Install primary relief valve into inlet section as shown in Figure 22. Tighten primary relief valve to 27 N•m (20 lbf ft). 26. Install new O-ring on plug. Install plug into inlet section. Tighten plug to 45 N•m (33 lbf ft). See Figure 22. 27. Install new O-ring on elbow fitting. Install elbow fitting into inlet section and tighten to 16 N•m (142 lbf in). Install diagnostic fitting onto elbow fitting. See Figure 22. 28. Install steer supply line fitting, steer return line fitting, inlet fitting, and return line fitting into inlet section ports. See Figure 28.

NOTE: Perform Step 20 and Step 21 for tilt section. 20. If equipped, install new backup ring and O-rings onto optional work port relief valve. Install optional work port relief valve into tilt section. See Figure 24. Tighten optional work port relief valve to 26 N•m (19 lbf ft). 21. Install tilt fittings into tilt sections. See Figure 27. NOTE: Perform Step 22 and Step 23 for lift section. 22. Install new backup ring and O-rings onto manual lowering valve. Install manual lowering valve into lift section as shown in Figure 24. Tighten manual lowering valve to 26 N•m (19 lbf ft). 23. Install lift/lower fitting into lift section. ure 28.

See Fig1. OUTLET SECTION

NOTE: Perform Step 24 through Step 28 for inlet section.

2. PLUG

Figure 26. Outlet Section of Manual Control Valve

2000 YRM 1334

1. 2. 3. 4.

Manual Hydraulic Control Valve Repair

TILT SECTION AUXILIARY SECTION FIRST AUXILIARY SECTION OUTLET SECTION

5. TILT FITTINGS 6. 3-FUNCTION FITTING 7. 4-FUNCTION FITTING

Figure 27. Manual Control Valve Fittings, Tilt and Auxiliary Sections

Manual Hydraulic Control Valve Repair

2000 YRM 1334

NOTE: 4-FUNCTION MANUAL CONTROL VALVE SHOWN. 1. 2. 3. 4. 5.

INLET SECTION LIFT SECTION RETURN LINE FITTING STEER RETURN LINE FITTING INLET FITTING

6. 7. 8. 9.

STEER SUPPLY LINE FITTING LIFT/LOWER FITTING POSITION SENSOR WIRES POSITION SENSOR ELECTRICAL CONNECTOR

Figure 28. Manual Control Valve Fittings, Inlet and Lift Sections

2000 YRM 1334

Manual Hydraulic Control Valve Repair

ASSEMBLE HANDLES AND LEVERS NOTE: If levers and handles have been disassembled, perform Step 2 through Step 4 for aux handle with dual function for lift trucks equipped with clamping function; perform Step 5 and Step 6 for lift, tilt, aux 1, and aux 2 handles; perform Step 7 through Step 13 for lift/lower with dcs handles. NOTE: Table 1 indicates installed handle positions. Optional handles and levers are described in Step 2 through Step 4 and Step 7 through Step 13. 1. Install bushings into levers. See Figure 29. 2. Route push-button cable through cable track on manual aux 2 lever. See Figure 29. 3. Install palm side handle and one inner capscrew on manual aux 2 lever. See Figure 29.

4. Install clamp switch handle and two outer capscrews on manual aux 2 lever. See Figure 29. Tighten outer capscrews to 1.35 to 1.65 N•m (11.9 to 14.6 lbf in). 5. Install palm side handle and one inner capscrew on manual tilt or aux 1 lever. See Figure 29. 6. Install finger side handle and two outer capscrews on manual tilt or aux 1 lever. See Figure 29. Tighten outer capscrews to 1.35 to 1.65 N•m (11.9 to 14.6 lbf in). 7. Install directional control switch into DCS cup. See Figure 29. 8. Install DCS cup and directional control switch into lift/lower with dcs handle. See Figure 29 and Figure 30.

NOTE: Ensure clamping push-button is in correction position on clamp switch handle during assembly.

Table 1. Handle Options 3-Function

4-Function

Handle Position

Option

Handle Position

Option

None

Lift/lower with DCS

None

Aux with dual function

Manual Hydraulic Control Valve Repair

2000 YRM 1334

A. LIFT/LOWER WITH DCS B. LIFT, TILT, AUX 1, AUX 2

C. AUX HANDLE WITH DUAL FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9.

10. 11. 12. 13. 14. 15. 16. 17. 18.

INNER CAPSCREW OUTER CAPSCREW BUSHING CABLE TRACK SCREW DCS RETAINER DCS CUP DCS CABLE PUSH-BUTTON CABLE

Figure 29. Manual Hydraulic Control Handles

2000 YRM 1334

Manual Hydraulic Control Valve Repair

Legend for Figure 30 1. SCREW 2. DCS RETAINER 3. DCS CUP

4. DCS CABLE

9. Install DCS retainer onto back side of DCS cup, inside lift/lower with dcs handle. See Figure 29 and Figure 30. 10. Install two screws through retainer and DCS cup into directional control switch. See Figure 29 and Figure 30. 11. Route dcs cable through cable track on manual lift/ lower lever. See Figure 29. 12. Install palm side handle and one capscrew on manual lift/lower lever. See Figure 29. 13. Install lift/lower with dcs handle and two outer capscrews on manual lift/lower lever. See Figure 29. Tighten outer capscrews to 1.35 to 1.65 N•m (11.9 to 14.6 lbf in).

Figure 30. Directional Control Switch

Manual Hydraulic Control Valve Repair

2000 YRM 1334

INSTALL

Install Covers, Links, and Levers NOTE: Update illustrations shown in STEP 1 through STEP 4, and STEP 10. STEP 1. Slide pivot pin through one side of upper bracket, nylon washer, lever spacer if required, levers, nylon washer, and out the other side of upper bracket. Install e-clip onto each end of pivot pin holding levers to upper bracket.

A. 3-FUNCTION LEVERS

B. 4-FUNCTION LEVERS

1. PIVOT PIN 2. E-CLIP 3. WASHER

4. LEVER SPACER 5. LEVER 6. UPPER BRACKET

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 2. Install link, clevis pin, and new locking ring cotter pin onto lever, Repeat for all links.

1. 2. 3. 4.

LINK LEVER LOCKING RING COTTER PIN CLEVIS PIN

1. 2. 3. 4.

LINK LEVER LOCKING RING COTTER PIN CLEVIS PIN

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 3. Install link, rod end pin, and new locking ring cotter pin onto manual control valve. Repeat for all links.

1. 2. 3. 4.

MANUAL CONTROL VALVE LINK LOCKING RING COTTER PIN ROD END PIN

1. 2. 3. 4.

MANUAL CONTROL VALVE LINK LOCKING RING COTTER PIN ROD END PIN

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 4. Install lower frame plate with mounting bracket, four capscrews, and four nuts onto upper bracket or install mounting bracket, rod end pin, nylon washer, and locking ring cotter pin on upper bracket.

1. 2. 3. 4. 5.

UPPER BRACKET LOWER FRAME PLATE MOUNTING BRACKET NUT CAPSCREW

1. 2. 3. 4. 5.

UPPER BRACKET LOCKING RING COTTER PIN NYLON WASHER ROD END PIN MOUNTING BRACKET

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 5. Install three hex capscrews into mounting plate and manual control valve.

1. MANUAL CONTROL VALVE 2. MOUNTING PLATE 3. HEX CAPSCREW STEP 6. Install latch assembly and three capscrews onto mounting plate.

1. MOUNTING PLATE 2. LATCH ASSEMBLY 3. CAPSCREW

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 7. Install emergency disconnect switch into rear cover. See Electrical System 2200 YRM 1337 for procedure.

A. INSERT SCREWDRIVER HERE 1. 2. 3. 4. 5. 6. 7. 8.

SWITCH SWITCH ADAPTER LOCK NUT EMERGENCY DISCONNECT SWITCH WASHER REAR COVER HOLE

1. 2. 3. 4.

MOUNTING PLATE MANUAL HYDRAULICS WIRE HARNESS CAPSCREW CLAMP

STEP 8. Install two clamps and two capscrews on manual hydraulic wire harness and mounting plate. Route manual hydraulic wire harness and confirm it will not be crushed when moving lever assembly fore and aft. Place connectors inside rear cover.

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 9. Install rear cover and four button-head capscrews onto upper bracket.

1. REAR COVER 2. UPPER BRACKET 3. BUTTON-HEAD CAPSCREW STEP 10. Install lower cover and two button-head capscrews onto lower frame plate or install lower cover and captive screw on plate.

1. LOWER COVER 2. LOWER FRAME PLATE 3. BUTTON-HEAD CAPSCREW

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 10. (Cont)

1. LOWER COVER 2. CAPTIVE SCREW 3. PLATE STEP 11. Install two brackets, two washers, two hex capscrews, and two nuts onto front bulkhead and mounting plate.

1. 2. 3. 4. 5. 6.

HEX CAPSCREW FRONT BULKHEAD BRACKET WASHER NUT MOUNTING PLATE

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 12. Connect manual hydraulics wire harness, as tagged during disassembly, to clamp button connector, emergency disconnect switch connector, and direction control switch connector.

1. CLAMP BUTTON CONNECTOR 2. EMERGENCY DISCONNECT SWITCH CONNECTOR 3. DIRECTION CONTROL SWITCH CONNECTOR 4. MANUAL HYDRAULICS WIRE HARNESS

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 13. Pull latch handle and allow manual hydraulic linkage and handles to move forward away from mounting plate.

1. MANUAL HYDRAULIC LINKAGE AND HANDLES 2. LATCH HANDLE 3. MOUNTING PLATE

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 14. Install upper front cover and four button-head capscrews onto rear cover.

1. UPPER FRONT COVER 2. BUTTON-HEAD CAPSCREW 3. REAR COVER STEP 15. Pull manual hydraulic linkage and handles upright until secured against mounting plate.

1. MANUAL HYDRAULIC LINKAGE AND HANDLES 2. MOUNTING PLATE

2000 YRM 1334

Ending Steps 1. Connect position sensor wires to rear of position sensor connector as tagged during removal. See Table 2 and Figure 31. 2. Connect position sensor connector to manual hydraulic wire harness. See Figure 31. 3. Connect spool lock solenoids to manual hydraulic wire harness. See Figure 31.

Manual Hydraulic Control Valve Repair

Legend for Figure 31 A. 3-FUNCTION MANUAL CONTROL VALVE B. 4-FUNCTION MANUAL CONTROL VALVE 1. POSITION SENSOR WIRES 2. POSITION SENSOR ELECTRICAL CONNECTOR 3. OPS SOLENOID 4. Raise manual hydraulic linkage and handles to upright position and secure latch. See Figure 32. 5. Connect hydraulic lines to fittings as tagged during removal.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 6. Dispose of drain pan contents. 7. Install floor plates and floor mats. 8. Install battery into lift truck. See How to Change Battery in Operating Manual or Periodic Maintenance 8000 YRM 1339 for lift trucks ERP15-20VT (ERP030-040VT) (G807) or Periodic Maintenance 8000 YRM 1373 for lift trucks ERP16-20VF (ERP30-40VF) (A955).

1. LATCH HANDLE 2. MOUNTING PLATE 3. MANUAL HYDRAULIC LINKAGE AND HANDLES

Figure 32. Latch Figure 31. Manual Control Valve Electrical Connections

Manual Hydraulic Control Valve Repair

2000 YRM 1334

9. Turn lift truck ON; operate hydraulic functions; check for leaks.

10. Calibrate manual control valve as outlined in Calibration Procedure.

Table 2. Position Sensor Connector Pin Layout PIN

SOCKET

PIN 1

SPOOL 1 POS

PIN 5

SPOOL 1 OUTPUT

PIN 12

SPOOL 1 NEG

PIN 2

SPOOL 2 POS

PIN 6

SPOOL 2 OUTPUT

PIN 11

SPOOL 2 NEG

PIN 3

SPOOL 3 POS

PIN 7

SPOOL 3 OUTPUT

PIN 10

SPOOL 3 NEG

PIN 4

SPOOL 4 POS

PIN 8

SPOOL 4 OUTPUT

PIN 9

SPOOL 4 NEG

Manual Hydraulic Control Valve Repair for Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) REMOVE

WARNING

WARNING Before making repairs to the control valve or its linkage, fully lower all parts of the mast and tilt it fully forward. This actions will prevent the mast from lowering suddenly when hydraulic lines are disconnected. NOTE: Only perform the steps below necessary for required repair or replacement.

How to or Perilift truck or Perilift truck

3. Discharge capacitors by following steps shown in Discharging the Capacitors in General section of this manual. 4. Remove floor mats and floor plates.

CAUTION For lift truck ERC22-35VG (ERC045-070VG) (A968), electrical components to be shielded from hydraulic oil drips if they are below hydraulic valve and lines. NOTE: Tag hydraulic hoses during removal to aid in installation.

1. Lower mast and tilt forward. 2. Remove battery from lift truck. See Change Battery in Operating Manual odic Maintenance 8000 YRM 1364 for ERC22-35VG (ERC045-070VG) (A968) odic Maintenance 8000 YRM 1372 for ERP22-35VL (ERP045-070VL) (A976).

Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool.

5. Put a drain pan under the area of the control valve assembly. Disconnect hydraulic hoses from control valve fittings. Cap hydraulic hoses and control valve fittings. 6. Disconnect position sensor electrical connector from manual hydraulic wire harness. See Figure 33. 7. Disconnect OPS solenoids from manual hydraulic wire harness. See Figure 33.

2000 YRM 1334

Manual Hydraulic Control Valve Repair

Legend for Figure 33 A. 3-FUNCTION MANUAL CONTROL VALVE B. 4-FUNCTION MANUAL CONTROL VALVE 1. POSITION SENSOR WIRES 2. POSITION SENSOR ELECTRICAL CONNECTOR 3. OPS SOLENOID

Figure 33. Manual Control Valve Electrical Connections

Manual Hydraulic Control Valve Repair

2000 YRM 1334

Remove Control Valve STEP 1. Pull latch handle, tilt manual hydraulic linkage and handles forward, and remove four button-head capscrews and upper front cover from rear cover.

1. 2. 3. 4. 5.

UPPER FRONT COVER BUTTON-HEAD CAPSCREW REAR COVER LATCH HANDLE MANUAL HYDRAULIC LINKAGE AND HANDLES

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 2. Remove nut and capscrews, and clip-nut from mounting plate and front bulkhead.

1. 2. 3. 4. 5.

FRONT BULKHEAD MOUNTING PLATE NUT CAPSCREW CLIP-NUT

STEP 3. Lift mounting plate with attached components away from front bulkhead and out of lift truck.

1. FRONT BULKHEAD 2. MOUNTING PLATE 3. ATTACHED COMPONENTS

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 4. Disconnect manual hydraulic wire harness from clamp button connector, emergency disconnect switch connector, and direction control switch connector.

1. CLAMP BUTTON CONNECTOR 2. EMERGENCY DISCONNECT SWITCH CONNECTOR 3. DIRECTION CONTROL SWITCH CONNECTOR 4. MANUAL HYDRAULICS WIRE HARNESS

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 5. Remove five button-head capscrews and rear cover from upper bracket.

1. REAR COVER 2. BUTTON-HEAD CAPSCREW 3. UPPER BRACKET

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 6. Remove emergency disconnect switch from rear cover. See Electrical System 2200 YRM 1369 for procedure.

A. INSERT SCREWDRIVER HERE 1. 2. 3. 4. 5. 6. 7. 8.

SWITCH SWITCH ADAPTER LOCK NUT EMERGENCY DISCONNECT BUTTON BUSHING UPPER REAR COVER HOLE

STEP 7. Remove two button-head capscrews and lower cover from lower bracket.

1. LOWER COVER 2. BUTTON-HEAD CAPSCREW 3. LOWER BRACKET

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 8. Pull latch handle up an allow manual hydraulic linkage and handles to move forward away from mounting plate.

1. LATCH HANDLE 2. MOUNTING PLATE 3. HYDRAULIC LINKAGE AND HANDLES STEP 9. Remove three capscrews and latch assembly from mounting plate.

1. MOUNTING PLATE 2. LATCH ASSEMBLY 3. CAPSCREW

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 10. Remove locking ring cotter pins, rod end pins and links from clevis’ at top of manual control valve sections.

1. 2. 3. 4.

CLEVIS LINK LOCKING RING COTTER PIN ROD END PIN

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 11. Remove two locking ring cotter pins, two rod end pins, two nylon washers, and mounting bracket from lower bracket.

1. 2. 3. 4. 5.

LOWER BRACKET MOUNTING BRACKET LOCKING RING COTTER PIN ROD END PIN NYLON WASHER

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 12. Remove four nuts, four capscrews and lower bracket from upper bracket.

1. 2. 3. 4.

UPPER BRACKET LOWER BRACKET CAPSCREW NUT

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 13. Remove three capscrews, three special washers, and manual control valve from mounting bracket

1. 2. 3. 4.

MANUAL CONTROL VALVE MOUNTING BRACKET SPECIAL WASHER CAPSCREW

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 14. Remove locking ring cotter pins, clevis pins, and links from levers. Discard locking ring cotter pins.

1. 2. 3. 4.

LINK LEVER LOCKING RING COTTER PIN CLEVIS PIN

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 15. Remove e-clip at both ends of pivot pin. Slide pivot pin from levers and upper bracket. Remove nylon washers, lever spacer if present, and levers from upper bracket.

A. 3-FUNCTION LEVERS

B. 4-FUNCTION LEVERS

1. PIVOT PIN 2. E-CLIP 3. WASHER

4. LEVER SPACER 5. LEVER 6. UPPER BRACKET

Manual Hydraulic Control Valve Repair

DISASSEMBLE HANDLES AND LEVERS NOTE: Follow procedure for disassembling links and brackets before disassembling handles. NOTE: If necessary, handles can be disassembled. Perform Step 1 through Step 4 for lift/lower handle for lift truck equipped with dcs handle, Step 5 and Step 6 for lift/lower, tilt, aux 1, and aux 2 handles, and Step 7 through Step 9 for aux handle with dual function for lift trucks equipped with clamping function.

2000 YRM 1334 NOTE: Handles described in Step 1 through Step 4 and Step 7 through Step 9 are optional. 1. Remove two outer capscrews and lift/lower with dcs handle from manual lift/lower lever. See Figure 34. 2. Remove one inner capscrew and palm side grip handle from manual lift lever. See Figure 34. 3. Remove dcs cable from cable track. See Figure 34.

Figure 34. Manual Hydraulic Control Handles

2000 YRM 1334

Manual Hydraulic Control Valve Repair

Legend for Figure 34 A. LIFT/LOWER WITH DCS B. LIFT/LOWER, TILT, AUX 1, AUX 2

C. AUX WITH DUAL FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9.

10. 11. 12. 13. 14. 15. 16. 17. 18.

INNER CAPSCREW OUTER CAPSCREW BUSHING CABLE TRACK SCREW DCS RETAINER DCS CUP DCS CABLE PUSH-BUTTON CABLE

4. Remove two screws, DCS retainer, DCS cup, and directional control switch from lift/lower with dcs handle. See Figure 34 and Figure 35. 5. Remove two outer capscrews and finger side handle from manual tilt or aux 1 lever. See Figure 34. 6. Remove one inner capscrew and palm side grip handle from manual tilt or aux 1 lever. See Figure 34. 7. Remove two outer capscrews and clamp switch handle from manual aux 2 lever. See Figure 34. 8. Remove one inner capscrew and palm side grip handle from manual aux 2 lever. See Figure 34. 9. Remove push-button cable from cable track. See Figure 34. 10. Remove bushings from levers. See Figure 34.

1. SCREW 2. DCS RETAINER

3. DCS CUP 4. DCS CABLE

Figure 35. Directional Control Switch

Manual Hydraulic Control Valve Repair

2000 YRM 1334

DISASSEMBLE MANUAL CONTROL VALVE Disassemble Valve CAUTION All power must be disconnected from valve, mast lowered, and hydraulic lines de-pressurized prior to servicing. Before any disassembly, all interfaces, joints, and recesses must be cleaned of residue and dirt to avoid contaminating internal components.

CAUTION If O-rings are to be replaced between two sections that have a hydraulic oil leak, replace all O-rings between all sections. This eliminates the possibility of subsequent oil leak or possible damage to another O-ring. NOTE: Disassemble the manual control valve only as necessary for repairs. Most repairs to the manual control valve will be to replace O-rings and seals. Spools and valve sections are not serviceable individually, and must be replaced as a complete valve section with spool. NOTE: Note placement and orientation of fittings prior to disassembly to aid in assembly. 1. Remove return line fitting, pressure line fitting, steer supply fitting, steer return fitting, steer load sense fitting, and hoist line fitting from inlet and lift sections of manual control valve. Remove and discard all O-rings from fittings. See Figure 36.

NOTE: 4-FUNCTION MANUAL CONTROL VALVE SHOWN. 1. INLET SECTION 2. LIFT SECTION 3. RETURN LINE FITTING 4. PRESSURE LINE FITTING 5. STEER SUPPLY FITTING

6. STEER RETURN FITTING 7. STEER LOAD SENSE FITTING 8. HOIST LINE FITTING 9. DIAGNOSTIC FITTING

Figure 36. Manual Control Valve Fittings, Inlet and Lift Sections

2000 YRM 1334

Manual Hydraulic Control Valve Repair

NOTE: 3-Function manual control valve does not contain optional auxiliary section.

NOTE: Tag position sensor wires during disassembly to aid in assembly.

2. Remove tilt line fittings, optional auxiliary, and auxiliary fittings from tilt, optional auxiliary, and auxiliary sections. Remove and discard all O-rings from fittings. See Figure 37.

3. Disconnect position sensor wires from position sensor electrical connector. See Figure 38. 4. Remove nut and position sensor electrical connector from tie rod on inlet side of manual control valve. See Figure 38 and Figure 39. 5. Place manual control valve with inlet section on work surface and auxiliary section pointing upward. See Figure 40.

NOTE: 4-FUNCTION MANUAL CONTROL VALVE SHOWN. 1. TILT SECTION 2. OPTIONAL AUXILIARY SECTION 3. AUXILIARY SECTION

4. TILT LINE FITTING 5. OPTIONAL AUXILIARY FITTING 6. AUXILIARY FITTING

1. POSITION SENSOR WIRE 2. POSITION SENSOR ELECTRICAL CONNECTOR 3. NUT

Figure 38. Position Sensor Wires and Connector

Figure 37. Manual Control Valve Fittings, Tilt and Auxiliary Sections

Manual Hydraulic Control Valve Repair

1. 2. 3. 4. 5. 6.

INLET SECTION LIFT SECTION TILT SECTION OPTIONAL AUXILIARY SECTION AUXILIARY SECTION POSITION SENSOR

2000 YRM 1334

7. 8. 9. 10. 11.

MANUAL LOWERING VALVE PRIMARY RELIEF VALVE TIE ROD STEER LOAD SENSE FITTING SECONDARY RELIEF VALVE

Figure 39. Manual Control Valve

2000 YRM 1334

Manual Hydraulic Control Valve Repair section if present, tilt section, lift section, and finally the inlet section. See Figure 41 for example. NOTE: Note placement of section seals in retaining grooves prior to removal to aid in installation. 8. Remove and discard section seals from retaining grooves of all manual control valve sections. See Figure 42.

1. AUXILIARY SECTION 2. NUT

3. TIE ROD 4. INLET SECTION

Figure 40. Auxiliary Section Tie Rods and Nuts 6. Remove nuts from tie rods on auxiliary section side of manual control valve. See Figure 40.

CAUTION Care must be taken to ensure section seals do not become dislodged during disassembly, they can become wedged into holes which will result in problems during assembly. 7. Remove each section from tie rods starting with auxiliary section, followed by optional auxiliary

1. INLET SECTION 2. LIFT SECTION

3. TIE ROD

Figure 41. Manual Control Valve - Sections and Tie Rods

Manual Hydraulic Control Valve Repair

2000 YRM 1334

1. PRIMARY RELIEF VALVE 2. SMALL PORT PLUG 3. COMPENSATOR PLUG 4. O-RING 1. INLET SECTION BODY 2. LIFT/TILT/AUXILIARY SECTION BODY 3. SECTION SEAL

Figure 42. Manual Control Valve Section Seals

Disassemble Inlet Section 1. Remove primary relief valve, compensator plug, small port plugs, medium port plug, and large port plug from inlet section body. Remove and discard O-rings and backup rings from primary relief valve and compensator plug. See Figure 43.

5. BACKUP RING 6. INLET SECTION BODY 7. MEDIUM PORT PLUG 8. LARGE PORT PLUG

Figure 43. Inlet Section Body

Disassemble Lift, Tilt, and Auxiliary Sections NOTE: Prior to disassembly, all interfaces, joints, and recesses must be cleaned of residue and dirt to avoid contaminating internal components. NOTE: Note placement and orientation of springs during disassembly to aid in assembly NOTE: Perform steps Step 1 and Step 2 if section is equipped with OPS solenoid. 1. Remove OPS solenoid from spool lock body. Remove and discard O-ring from solenoid. See Figure 44.

2000 YRM 1334

Manual Hydraulic Control Valve Repair NOTE: Perform steps Step 3 and Step 4 for lift section. 3. Remove manual lowering valve from lift section body. Remove and discard O-ring from manual lowering valve. See Figure 44. 4. Remove lift port plug-short and lift port plug-long from lift section body. Remove and discard O-ring from lift port plug-long. See Figure 44. NOTE: Perform step Step 5 for tilt section. 5. Remove secondary relief valve from tilt section body. Remove and discard O-rings and backup rings from secondary relief valve. See Figure 44. NOTE: Perform step Step 6 for auxiliary section. 6. Remove auxiliary port plugs from auxiliary section body. See Figure 44. 7. Remove any remaining port plugs. Remove and discard O-rings, if present, from port plugs. 8. If spool seal for any valve section requires replacement, see Spool Seal Replacement section.

1. LIFT/TILT/AUXILIARY SECTION BODY 2. OPS SOLENOID 3. SPOOL LOCK BODY 4. O-RING 5. POSITION SENSOR 6. CAPSCREW 7. CHECK VALVE 8. MANUAL LOWERING VALVE

9. LIFT PORT PLUG-SHORT 10. SECONDARY RELIEF VALVE 11. BACKUP RING 12. AUXILIARY PORT PLUG 13. SPOOL SEAL 14. SPOOL 15. LIFT PORT PLUG-LONG

Figure 44. Lift, Tilt, and Auxiliary Section Body NOTE: DO NOT lose springs. 2. Remove capscrews, position sensor, spring, and spool lock body from section body. See Figure 45.

1. 2. 3. 4.

POSITION SENSOR ASSEMBLY CAPSCREW - WITH SPOOL LOCKS CAPSCREW - WITHOUT SPOOL LOCKS SPRING

Figure 45. Position Sensor Assembly

Manual Hydraulic Control Valve Repair

SPOOL SEAL REPLACEMENT NOTE: If working on tilt section, use caution not to lose small spool and spring inside main spool and held in place with spool lock extension. 1. Using screwdriver or pin, hold spool clevis and remove spool lock extension from spool assembly. See Figure 46.

2000 YRM 1334 2. Pull spool assembly far enough out of section body to expose spool seal on clevis end of section body. See Figure 46. NOTE: Lubricate new spool seal with clean hydraulic oil prior to installation. 3. Using O-ring pick or similar device remove and discard spool seal from spool assembly. Lightly lubricate new spool seal and install into grooves in section body. See Figure 47.

A. ORIENTATION DOT B. OPS END

C. CLEVIS END

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11.

LIFT/TILT/AUXILIARY SECTION BODY POSITION SENSOR OPS SOLENOID SPOOL LOCK BODY CHECK VALVE SPOOL ASSEMBLY

CAPSCREW O-RING SPOOL SEAL SPOOL CLEVIS SPOOL LOCK EXTENSION

Figure 46. Lift/Tilt/Auxiliary Sections Manual Control Valve

2000 YRM 1334

Manual Hydraulic Control Valve Repair 9. Carefully run your finger around expose edge of seal. You should have a smooth, precise ridge with no kinks or twists. NOTE: Perform Step 10 for tilt section. 10. Install small spool and spring inside spool assembly to be held in position by spool extension. See Figure 46.

CLEAN WARNING Cleaning solvents can be flammable and toxic and cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

CAUTION To ensure proper assembly, lip of spool seal should point "in" toward section body. 1. SPOOL SEAL

Figure 47. Spool Seal Installation 4. Carefully run your finger around expose edge of seal. You should have a smooth, precise ridge with no kinks or twists.

CAUTION Pulling the spools meter edges across the spool seals can result in damage to the spool seal. 5. Slide spool assembly back into section body to keep spool seal in place. 6. Push spool assembly into section body far enough to expose the spool seal on OPS end of section body. NOTE: Lubricate new spool seal with clean hydraulic oil prior to installation. 7. Using O-ring pick or similar device remove and discard spool seal from spool assembly. Lightly lubricate new spool seal and install onto spool assembly. See Figure 47.

CAUTION Pulling the spools meter edges across the spool seals can result in damage to the spool seal. 8. Slide spool assembly back into section body to keep spool seal in place.

INSPECT 1. Check spools and bores for wear or damage. If damaged, entire section must be replaced. Make sure spool moves freely within bore. 2. Inspect check valves and relief valves for damage. Replace if damaged. 3. Inspect solenoids and position sensors for damage. Replace if damaged. 4. Inspect threaded components to ensure absence of oil or solvent residue. 5. Inspect handles, levers, bushings, and linkages for damage. Replace if damaged. 6. Inspect all other components for damage. Replace if damaged.

Manual Hydraulic Control Valve Repair

2000 YRM 1334

ASSEMBLE MANUAL CONTROL VALVE Assemble Lift, Tilt, and Auxiliary Sections NOTE: Perform Step 1 for auxiliary section(s). 1. Install auxiliary port plug into auxiliary section body. See Figure 48. Tighten auxiliary port plug to 14 N•m (124 lbf in). NOTE: Perform Step 2 for tilt section. NOTE: Lubricate O-rings and backup rings with clean hydraulic oil prior to installation. 2. Install new O-rings and backup rings onto secondary relief valve. Install secondary relief valve into tilt section body. See Figure 48. Tighten secondary relief valve to 27 N•m (20 lbf ft). NOTE: Perform Step 3 through Step 5 for lift section. 3. Install new O-ring onto lift port plug-long. Install lift port plug-long into lift section body. See Figure 48. Tighten lift port plug-long to 27 N•m (20 lbf ft). 4. Install lift port plug-short into lift section body. See Figure 48. Tighten lift port plug-short to 54 N•m (40 lbf ft). 5. Install new O-ring onto manual lowering valve. Install manual lowering valve into lift section body. See Figure 48. Tighten manual lowering valve to 54 N•m (40 lbf ft). 1. LIFT/TILT/AUXILIARY SECTION BODY 2. OPS SOLENOID 3. SPOOL LOCK BODY 4. O-RING 5. POSITION SENSOR 6. CAPSCREW 7. CHECK VALVE 8. MANUAL LOWERING VALVE

9. LIFT PORT PLUG-SHORT 10. SECONDARY RELIEF VALVE 11. BACKUP RING 12. AUXILIARY PORT PLUG 13. SPOOL SEAL 14. SPOOL 15. LIFT PORT PLUG-LONG

Figure 48. Lift, Tilt, and Auxiliary Section Body

2000 YRM 1334

Manual Hydraulic Control Valve Repair

CAUTION Spool lock body must be placed with orientation dot up and toward section body for correct fit. If not installed correctly damage to manual control valve may result. NOTE: Perform Step 6 and Step 7 if section is equipped with OPS solenoid. NOTE: Apply Loctite® 262 to capscrew threads prior to installation. NOTE: Install spring as noted during disassembly. 6. Install spool lock body, position sensor, and capscrews to section body. See Figure 49. Tighten capscrews to 4.7 N•m (42 lbf in). 7. Install new O-ring onto OPS solenoid. Install OPS solenoid into spool lock body. See Figure 48. Tighten OPS solenoid to 7.5 N•m (66 lbf in).

1. POSITION SENSOR ASSEMBLY 2. CAPSCREW WITH SPOOL LOCKS

1. Install new O-rings and backup rings onto primary relief valve. Install primary relief valve to inlet section body. See Figure 50. Tighten primary relief valve to 27 N•m (20 lbf ft). 2. Install new O-ring onto compensator plug. Install compensator plug to inlet section body. See Figure 50. Tighten compensator plug to 47 N•m (35 lbf ft). 3. Install small port plugs to inlet section body. See Figure 50. Tighten small port plugs to 13.5 N•m (119 lbf in). 4. Install medium port plug to inlet section body. See Figure 50. Tighten medium port plug to 65 N•m (48 lbf ft). 5. Install large port plug to inlet section body. See Figure 50. Tighten large port plug to 60 to 72 N•m (44 to 53 lbf ft).

3. CAPSCREW WITHOUT SPOOL LOCKS 4. SPRING

Figure 49. Position Sensor Assembly

Assemble Inlet Section NOTE: Lubricate new O-rings and backup rings with clean hydraulic oil prior to installation.

1. PRIMARY RELIEF VALVE 2. SMALL PORT PLUG 3. COMPENSATOR PLUG 4. O-RING

5. BACKUP RING 6. INLET SECTION BODY 7. MEDIUM PORT PLUG 8. LARGE PORT PLUG

Figure 50. Inlet Section Body

Manual Hydraulic Control Valve Repair

2000 YRM 1334

Assemble Valve 1. Install a nut on one end of each tie rod and hand-tighten only at this time. Thread opposite end through inlet section tie rod holes. See Figure 51. 2. Place inlet section with machined surface facing up as shown in Figure 51. NOTE: DO NOT lubricate section seals prior to installation. Lubricants on these seals can distort valve body, resulting in spool bind. 3. Install section seals into retaining grooves of inlet section as noted during disassembly. See Figure 52. 4. Install lift section over tie rods and against inlet section. See Figure 53. 5. Install section seals into retaining grooves of lift section as noted during disassembly. See Figure 52. 6. Install tilt section over tie rods and against lift section. See Figure 53 for example. 7. Install section seals into retaining grooves of tilt section as noted during disassembly. See Figure 52.

1. INLET SECTION BODY 2. LIFT/TILT/AUXILIARY SECTION BODY 3. SECTION SEAL

Figure 52. Manual Control Valve Section Seals NOTE: 3-Function manual control valve is not equipped with a optional auxiliary section. 8. Install optional auxiliary section over tie rods and against tilt section. See Figure 53 for example. 9. Install section seals into retaining grooves of optional auxiliary section as noted during disassembly. See Figure 52. A. MACHINED FACE 1. TIE ROD HOLE

Figure 51. Manual Control Valve Inlet Section Machined Face

10. Install auxiliary section over tie rods and against optional auxiliary or tilt section. See Figure 53 for example.

2000 YRM 1334

Manual Hydraulic Control Valve Repair NOTE: Tie rods to extend beyond nuts for one to two threads. 13. Install position sensor electrical connector and nut onto tie rod on inlet side of manual control valve. See Figure 55 and Figure 56. Tighten jam nut to 18 to 20 N•m (156 to 180 lbf in).

1. INLET SECTION 2. LIFT SECTION

3. TIE ROD

Figure 53. Manual Control Valve - Sections and Tie Rods 11. Install a nut onto end of each tie rod and handtighten only at this time. See Figure 54.

CAUTION If proper value of torque is not applied to the nuts on the tie rods, the valve spools may bind or stick and section seals may extrude. 12. Reposition manual control valve with work ports facing up, then tighten eight nuts on tie rods to 20.3 ± 1.4 N•m (179.7 ± 12.4 lbf in).

1. 2. 3. 4.

AUXILIARY SECTION NUT TIE ROD INLET SECTION

Figure 54. Auxiliary Section Tie Rods and Nuts 14. Connect position sensor wires to back of position sensor electrical connector as tagged during disassembly. See Table 3 and Figure 56.

Table 3. Position Sensor Electrical Connector Pin Layout PIN

SOCKET

PIN 1

SPOOL 1 POS

PIN 5

SPOOL 1 OUTPUT

PIN 12

SPOOL 1 NEG

PIN 2

SPOOL 2 POS

PIN 6

SPOOL 2 OUTPUT

PIN 11

SPOOL 2 NEG

PIN 3

SPOOL 3 POS

PIN 7

SPOOL 3 OUTPUT

PIN 10

SPOOL 3 NEG

PIN 4

SPOOL 4 POS

PIN 8

SPOOL 4 OUTPUT

PIN 9

SPOOL 4 NEG

Manual Hydraulic Control Valve Repair

1. 2. 3. 4. 5. 6.

INLET SECTION LIFT SECTION TILT SECTION OPTIONAL AUXILIARY SECTION AUXILIARY SECTION POSITION SENSOR

2000 YRM 1334

7. 8. 9. 10. 11.

MANUAL LOWERING VALVE PRIMARY RELIEF VALVE TIE ROD STEER LOAD SENSE FITTING SECONDARY RELIEF VALVE

Figure 55. Manual Control Valve

2000 YRM 1334

Manual Hydraulic Control Valve Repair

1. POSITION SENSOR WIRE 2. POSITION SENSOR ELECTRICAL CONNECTOR 3. JAM NUT

Figure 56. Position Sensor Wires and Connector NOTE: Lubricate new O-rings with clean hydraulic oil prior to installation.

NOTE: 4-FUNCTION MANUAL CONTROL VALVE SHOWN.

15. Install new O-rings onto auxiliary fittings. Install auxiliary fittings into auxiliary section as noted during disassembly. See Figure 57, Figure 58, and Figure 59.

1. TILT SECTION 2. OPTIONAL AUXILIARY SECTION 3. AUXILIARY SECTION

4. TILT LINE FITTING 5. OPTIONAL AUXILIARY FITTING 6. AUXILIARY FITTING

Figure 57. Manual Control Valve Fittings - Tilt and Auxiliary Sections

Manual Hydraulic Control Valve Repair

2000 YRM 1334

A. 3-FUNCTION MANUAL CONTROL VALVE

B. 4-FUNCTION MANUAL CONTROL VALVE

1. AUXILIARY FITTING 2. OPTIONAL AUXILIARY FITTING

3. TILT LINE FITTING 4. PRESSURE LINE FITTING

Figure 58. Fitting Orientation 1 for Lift Truck ERC22-35VG (ERC045-070VG) (A968) NOTE: 3-Function manual control valve does not contain optional auxiliary section. 16. Install new O-rings onto optional auxiliary fittings. Install optional auxiliary fittings into optional auxiliary section as noted during disassembly. See Figure 57, Figure 58, and Figure 59 for fitting placement and orientation.

17. Install new O-rings onto tilt line fittings. Install tilt line fittings into tilt section as noted during disassembly. See Figure 57, Figure 58, and Figure 59. 18. Install new O-ring onto hoist line fitting. Install hoist line fitting into lift section as noted during disassembly. See Figure 60.

2000 YRM 1334

Manual Hydraulic Control Valve Repair

A. 3-FUNCTION MANUAL CONTROL VALVE

B. 4-FUNCTION MANUAL CONTROL VALVE

1. AUXILIARY FITTING 2. OPTIONAL AUXILIARY FITTING

3. TILT LINE FITTING 4. PRESSURE LINE FITTING

Figure 59. Fitting Orientation 1 for Lift Truck ERP22-35VL (ERP045-070VL) (A976)

Manual Hydraulic Control Valve Repair

2000 YRM 1334 19. Install new O-rings onto steer return fitting, return line fitting, and steer supply fitting. Install steer return fitting, return line fitting, and steer supply fitting into inlet section as noted during disassembly. See Figure 60. 20. Install new O-ring onto pressure line fitting. Install pressure line fitting into inlet section as noted during disassembly. See Figure 60 and Figure 58. 21. Install new O-ring onto diagnostic fitting. Install diagnostic fitting into inlet section as noted during disassembly. See Figure 60. Tighten diagnostic fitting to 16 N•m (142 lbf in). NOTE: Steer load sense fitting contains special internal features and CANNOT be replaced with standard hydraulic fitting. 22. Install new O-ring onto steer load sense fitting. Install steer load sense fitting into inlet section as noted during disassembly. See Figure 60 and Figure 61. Tighten steer load sense fitting to 16 N•m (142 lbf in).

NOTE: 4-FUNCTION MANUAL CONTROL VALVE SHOWN. 1. INLET SECTION 2. LIFT SECTION 3. RETURN LINE FITTING 4. PRESSURE LINE FITTING 5. STEER SUPPLY FITTING

6. STEER RETURN FITTING 7. STEER LOAD SENSE FITTING 8. HOIST LINE FITTING 9. DIAGNOSTIC FITTING

Figure 60. Manual Control Valve Fittings, Inlet and Lift Sections

2000 YRM 1334

Manual Hydraulic Control Valve Repair

A. 90° ADAPTER

B. 45° ADAPTER

1. STEER LOAD SENSE FITTING

Figure 61. Fitting Orientation 2

NOTE: Table 4 indicates installed handle positions. Optional handles and levers are described in Step 2 through Step 4 and Step 7 through Step 13. 1. Install bushings into levers. See Figure 62. 2. Route push-button cable through cable track on manual aux 2 lever. See Figure 62.

Table 4. Handle Options 3-Function

4-Function

Handle Position

Option

Handle Position

Option

None

Lift/lower with DCS

None

Aux with dual function

Manual Hydraulic Control Valve Repair

2000 YRM 1334

A. LIFT/LOWER WITH DCS B. LIFT, TILT, AUX 1, AUX 2

C. AUX HANDLE WITH DUAL FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9.

10. 11. 12. 13. 14. 15. 16. 17. 18.

INNER CAPSCREW OUTER CAPSCREW BUSHING CABLE TRACK SCREW DCS RETAINER DCS CUP DCS CABLE PUSH-BUTTON CABLE

Figure 62. Manual Hydraulic Control Handles

2000 YRM 1334 3. Install palm side handle and one inner capscrew on manual aux 2 lever. See Figure 62.

Manual Hydraulic Control Valve Repair Tighten outer capscrews to 1.35 to 1.65 N•m (11.9 to 14.6 lbf in).

NOTE: Ensure clamping push-button is in correction position on clamp switch handle during assembly. 4. Install clamp switch handle and two outer capscrews on manual aux 2 lever. See Figure 62. Tighten outer capscrews to 1.35 to 1.65 N•m (11.9 to 14.6 lbf in). 5. Install palm side handle and one inner capscrew on manual tilt or aux 1 lever. See Figure 62. 6. Install finger side handle and two outer capscrews on manual tilt or aux 1 lever. See Figure 62. Tighten outer capscrews to 1.35 to 1.65 N•m (11.9 to 14.6 lbf in). 7. Install directional control switch into DCS cup. See Figure 62. 8. Install DCS cup and directional control switch into lift/lower with dcs handle. See Figure 62 and Figure 63. 9. Install DCS retainer onto back side of DCS cup, inside lift/lower with dcs handle. See Figure 62 and Figure 63. 10. Install two screws through retainer and DCS cup into directional control switch. See Figure 62 and Figure 63. 11. Route dcs cable through cable track on manual lift/ lower lever. See Figure 62. 12. Install palm side handle and one capscrew on manual lift/lower lever. See Figure 62.

1. SCREW 2. DCS RETAINER

3. DCS CUP 4. DCS CABLE

Figure 63. Directional Control Switch

13. Install lift/lower with dcs handle and two outer capscrews on manual lift/lower lever. See Figure 62.

Manual Hydraulic Control Valve Repair

2000 YRM 1334

INSTALL

Install Control Valve STEP 1. Slide pivot pin through side of upper bracket. Install one nylon washer, lever spacer if required, levers, and one nylon washer. Slide pivot pin out the other side of upper bracket. Install e-clip onto each end of pivot pin holding levers to upper bracket.

A. 3-FUNCTION LEVERS

B. 4-FUNCTION LEVERS

1. PIVOT PIN 2. E-CLIP 3. NYLON WASHER

4. LEVER SPACER 5. LEVER 6. UPPER BRACKET

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 2. While holding link in lever slot, install clevis pin through lever and link, then install new locking ring cotter pin through clevis pin. Repeat for all links.

1. 2. 3. 4.

LINK LEVER LOCKING RING COTTER PIN CLEVIS PIN

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 3. Install manual control valve, three special washers, and three capscrews onto mounting bracket.

1. 2. 3. 4.

MANUAL CONTROL VALVE MOUNTING BRACKET SPECIAL WASHER CAPSCREW

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 4. Install lower bracket, four capscrews, and four nuts onto upper bracket.

1. 2. 3. 4.

UPPER BRACKET LOWER BRACKET CAPSCREW NUT

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 5. Install mounting bracket, two nylon washers, two rod end pins, and two locking ring cotter pins onto lower bracket.

1. 2. 3. 4. 5.

LOWER BRACKET MOUNTING BRACKET LOCKING RING COTTER PIN ROD END PIN NYLON WASHER

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 6. Install links, rod end pins, and locking ring cotter pins into clevis’ at top of manual control valve sections.

1. 2. 3. 4.

CLEVIS LINK LOCKING RING COTTER PIN ROD END PIN

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 7. Install latch assembly and three capscrews onto mounting bracket.

1. MOUNTING BRACKET 2. LATCH ASSEMBLY 3. CAPSCREW STEP 8. Raise hydraulic linkage and handles upright against mounting bracket. Ensure latch handle fastens securely.

1. LATCH HANDLE 2. MOUNTING BRACKET 3. HYDRAULIC LINKAGE AND HANDLES

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 9. Install lower cover and two button-head capscrews onto lower bracket. Tighten capscrews to 2.82 to 3.16 N•m (24.95 to 27.97 lbf in).

1. LOWER COVER 2. BUTTON-HEAD CAPSCREW 3. LOWER BRACKET STEP 10. Install emergency disconnect switch into rear cover. See Electrical System 2200 YRM 1369 for procedures.

A. INSERT SCREWDRIVER HERE 1. 2. 3. 4. 5. 6. 7. 8.

SWITCH SWITCH ADAPTER LOCK NUT EMERGENCY DISCONNECT BUTTON BUSHING UPPER REAR COVER HOLE

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 11. Install rear cover and five button-head capscrews onto upper bracket. Tighten capscrews to 1.35 to 1.65 N•m (11.95 to 14.60 lbf in).

1. REAR COVER 2. BUTTON-HEAD CAPSCREW 3. UPPER BRACKET

2000 YRM 1334

Manual Hydraulic Control Valve Repair

STEP 12. Connect manual hydraulic wire harness to direction control switch connector, emergency disconnect switch connector, and clamp button connector.

1. CLAMP BUTTON CONNECTOR 2. EMERGENCY DISCONNECT SWITCH CONNECTOR 3. DIRECTION CONTROL SWITCH CONNECTOR 4. MANUAL HYDRAULICS WIRE HARNESS STEP 13. Install mounting bracket with attached components onto front bulkhead in lift truck.

1. FRONT BULKHEAD 2. MOUNTING BRACKET 3. ATTACHED COMPONENTS

Manual Hydraulic Control Valve Repair

2000 YRM 1334

STEP 14. Install clip nut, capscrews, and nut onto front bulkhead and mounting bracket.

1. 2. 3. 4. 5.

FRONT BULKHEAD MOUNTING BRACKET NUT CAPSCREW CLIP NUT

STEP 15. Install upper front cover and four button-head capscrews onto rear cover. Tighten capscrews to 2.82 to 3.16 N•m (24.96 to 27.97 lbf in). Pull manual hydraulic linkage and handles upright and secure with latch handle.

1. UPPER FRONT COVER 2. BUTTON-HEAD CAPSCREW 3. REAR COVER

100

2000 YRM 1334

E-Hydraulic Control Valve Repair

Ending Steps

4. Install floor plates and floor mats.

1. Connect spool lock solenoids to manual hydraulic wire harness. See Figure 33.

5. Install battery into lift truck. See How to Change Battery in Operating Manual or Periodic Maintenance 8000 YRM 1364 for lift truck ERC22-35VG (ERC045-070VG) (A968) or Periodic Maintenance 8000 YRM 1372 for lift truck ERP22-35VL (ERP045-070VL) (A976).

2. Connect position sensor connector to manual hydraulic wire harness. See Figure 33.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. NOTE: Remove caps from hydraulic hoses and control valve fittings as connections are made.

6. Turn lift truck ON, operate hydraulic functions, then check for leaks. 7. Calibrate manual control valve as outlined in Calibration Procedure.

3. Connect hydraulic hoses to control valve fittings as tagged during removal. Dispose of drain pan contents.

E-Hydraulic Control Valve Repair for Lift Truck ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) REMOVE WARNING Before making repairs to the control valve, fully lower all parts of the mast and tilt it fully forward. This action will prevent the mast from lowering suddenly when hydraulic lines are disconnected. NOTE: Only perform those steps below necessary for required repair or replacement. 1. Lower mast and tilt forward. 2. Remove battery from lift truck. See How to Change Battery in Operating Manual or Periodic Maintenance 8000 YRM 1339 for lift trucks ERP15-20VT (ERP030-040VT) (G807) or Periodic Maintenance 8000 YRM 1373 for lift trucks ERP16-20VF (ERP30-40VF) (A955). 3. Discharge capacitors by following steps shown in Discharging the Capacitors in General section of this manual.

4. Remove floor mats and floor plates.

WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool. NOTE: Tag hydraulic lines during removal to aid in installation. 5. Put a drain pan under the area of the hydraulic control assembly. Disconnect hydraulic lines from E-hydraulic control assembly. Cap hydraulic lines. NOTE: Note placement and orientation of fittings prior to removal to aid in installation. NOTE: Note placement of O-rings on fittings prior to removal to aid in installation. 6. Remove fittings, as specified in Figure 64, from inlet, lift, tilt, and auxiliary section(s). Remove and discard O-rings from fittings.

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NOTE: 4-FUNCTION CONTROL VALVE SHOWN. 1. 2. 3. 4. 5. 6. 7.

RETURN LINE FITTING INLET FITTING STEER RETURN FITTING LIFT/LOWER FITTING TILT FITTING 3-FUNCTION AUXILIARY FITTING 4-FUNCTION AUXILIARY FITTING

8. 9. 10. 11. 12. 13. 14.

INLET SECTION LIFT SECTION TILT SECTION SPACER SECTION FIRST AUXILIARY SECTION (OPTIONAL) OUTLET COVER SECOND AUXILIARY SECTION

Figure 64. E-Hydraulic Control Valve Fittings 7. Remove steer load sense fitting from inlet section. See Figure 65. 8. Disconnect upper solenoid connector from e-hydraulic main wire harness. See Figure 65. 9. Disconnect lower solenoid connector from e-hydraulic main wire harness. See Figure 65.

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10. Remove nut, washers, M10 capscrew, and bracket from mounting bracket and front bulkhead. See Figure 66. 11. Lift mounting bracket, with E-hydraulic control valve attached, up and out of holding brackets on front bulkhead. See Figure 66.

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E-Hydraulic Control Valve Repair

NOTE: 4-FUNCTION E-HYDRAULIC CONTROL VALVE SHOWN. 1. LOWER SOLENOID CONNECTOR 2. UPPER SOLENOID CONNECTOR 3. UPPER SOLENOID WIRE

4. LOWER SOLENOID WIRE 5. JAM NUT 6. STEER LOAD SENSE FITTING

Figure 65. Solenoid Wires and Connectors 12. Remove three M8 capscrews, mounting bracket, and three washers from E-hydraulic control valve. See Figure 66. NOTE: Tag solenoid wires during removal to aid in installation.

13. Disconnect upper solenoid wires from upper solenoid connector. See Figure 65. 14. Disconnect lower solenoid wires from lower solenoid connector. See Figure 65.

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NOTE: ARROW POINTING TO FRONT OF LIFT TRUCK. 1. 2. 3. 4. 5.

FRAME FRONT BULKHEAD MOUNTING BRACKET E-HYDRAULIC CONTROL VALVE BRACKET

6. 7. 8. 9. 10.

M10 CAPSCREW WASHER NUT HOLDING BRACKET M8 CAPSCREW

Figure 66. E-Hydraulic Control Valve Mounting

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DISASSEMBLE NOTE: Disassemble the e-hydraulic control valve only as necessary for repairs. Most repairs to the e-hydraulic control valve will be to replace O-rings and seals. Spools and valve sections are not serviceable individually and must be replaced as a complete valve section with spool.

1. Remove lower solenoid assemblies from the lift, tilt, and auxiliary sections. See Figure 67. 2. Remove upper solenoid assembly from lift, tilt, and auxiliary sections. See Figure 67. 3. Remove nuts from tie rods on outlet side of E-hydraulic control valve. See Figure 68 and Figure 69.

NOTE: The 3-function E-hydraulic control valve is not equipped with a first auxiliary section.

4. Remove outlet cover from tie rods and second auxiliary section.

1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15. 16.

INLET SECTION LIFT SECTION TILT SECTION SPACER SECTION (OPTIONAL) FIRST AUXILIARY SECTION (OPTIONAL) SECOND AUXILIARY SECTION PRIMARY RELIEF VALVE MANUAL LOWERING VALVE

COMPENSATOR PLUG OPTIONAL SECONDARY RELIEF VALVE LOWER SOLENOID ASSEMBLY UPPER SOLENOID ASSEMBLY PILOT CARTRIDGE ELBOW FITTING DIAGNOSTIC FITTING O-RING

Figure 67. E-Hydraulic Control Valve

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Legend for Figure 68 A. INLET SIDE

B. OUTLET SIDE

1. TIE ROD 2. NUT

3. JAM NUT

Figure 68. Tie Rods and Nuts for E-Hydraulic Control Valve

A. 3 FUNCTION CONTROL VALVE

B. 4 FUNCTION CONTROL VALVE

1. 2. 3. 4. 5.

6. 7. 8. 9.

INLET SECTION LIFT SECTION TILT SECTION SPACER SECTION SECOND AUXILIARY SECTION

OUTLET CAP TIE ROD NUT FIRST AUXILIARY SECTION (OPTIONAL)

Figure 69. E-Hydraulic Control Valve Sections

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E-Hydraulic Control Valve Repair 9. Remove pilot cartridge from inlet section. Remove and discard O-rings from pilot cartridge. See Figure 67. 10. Remove primary relief valve from inlet section. Remove and discard O-rings and backup ring from primary relief valve. See Figure 67. 11. If required, remove elbow fitting and diagnostic fitting from inlet section. Remove and discard O-ring from elbow fitting. See Figure 67.

1. INLET SECTION 2. OUTLET COVER 3. FIRST AUXILIARY SECTION (OPTIONAL)

4. SECOND AUXILIARY SECTION

Figure 70. E-Hydraulic Control Valve 5. Remove each section from tie rods and adjacent section starting with the second auxiliary section, followed by the first auxiliary section if present, the spacer section if present, the tilt section, and the lift section. See Figure 71 for example. NOTE: Note placement of jam nuts and solenoid connectors on tie rods prior to removal to aid in installation. 6. Remove two jam nuts, upper solenoid connector, and lower solenoid connector from tie rods and inlet section. See Figure 65 and Figure 68. 7. Remove tie rods from inlet section. See Figure 69. NOTE: Note placement of section seals in retaining grooves prior to removal to aid in installation.

1. INLET SECTION 2. LIFT SECTION

3. TIE ROD

Figure 71. E-Hydraulic Control Valve - Sections and Tie Rods

8. Remove and discard section seals from retaining grooves of all sections. See Figure 72 and Figure 73.

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1. 2. 3. 4. 5.

STEER LOAD SENSE FITTING O-RING INLET SECTION BODY BACKUP RING PILOT CARTRIDGE

2000 YRM 1334

6. 7. 8. 9. 10.

COMPENSATOR PLUG SECTION SEAL PRIMARY RELIEF VALVE ELBOW FITTING DIAGNOSTIC FITTING

Figure 72. Inlet Section E-Hydraulic Control Valve 12. Remove manual lowering valve from lift section. Remove and discard O-ring from manual lowering valve. See Figure 67.

15. Remove steer load sense fitting from inlet section. Remove and discard O-rings from steer load sense fitting. See Figure 72.

13. Remove compensator plug from tilt section. Remove and discard O-ring from compensator plug. See Figure 67.

16. Remove lift section plug from lift section. Remove and discard O-ring from lift section plug. See Figure 73.

14. Remove optional secondary relief valve from tilt section. Remove and discard O-rings and backup rings from optional secondary relief valve. See Figure 67.

NOTE: Perform the following step only if the tilt section plug is installed.

NOTE: Perform the following step if steer load sense fitting has not been removed from inlet section.

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17. Remove tilt section plug from tilt section. Remove and discard O-rings and backup rings from tilt section plug. See Figure 73.

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E-Hydraulic Control Valve Repair

NOTE: SPACER SECTION NOT ILLUSTRATED. 1. 2. 3. 4. 5.

MANUAL LOWERING VALVE PORT OPTION PLUG O-RING OPTIONAL SECONDARY RELIEF VALVE LIFT SECTION PLUG

6. 7. 8. 9.

TILT SECTION PLUG BACKUP RING LIFT/TILT/AUXILIARY SECTION BODY SECTION SEAL

Figure 73. Lift/Tilt/Auxiliary Sections E-Hydraulic Control Valve

CLEAN WARNING Cleaning solvents can be flammable and toxic and cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING Compressed air can move particles so they cause injury to the user or to other personnel. Make sure

the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Clean only metal components of E-hydraulic control valve with solvent and dry using compressed air. Avoid getting solvent in electrical connectors. 2. Clean all threaded components with denatured alcohol and dry using compressed air. 3. Clean rubber or plastic components with warm soapy water and dry with a lint free cloth.

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INSPECT 1. Inspect section bodies for damage. Replace if damaged. 2. Inspect threaded components to ensure absence of oil or solvent residue. 3. Inspect all other components for damage. Replace if damaged.

ASSEMBLE

2000 YRM 1334 NOTE: Perform the following step if E-hydraulic control valve is NOT equipped with secondary relief valve. 1. Install new O-rings and backup rings onto tilt section plug. Install tilt section plug into tilt section. See Figure 74. Tighten tilt section plug to 27 N•m (20 lbf ft). 2. Install O-rings and backup rings onto optional secondary relief valve. Install optional secondary relief valve into tilt section. See Figure 74. Tighten optional secondary relief valve to 27 N•m (20 lbf ft).

NOTE: Lubricate all new O-rings and backup rings with hydraulic oil prior to installation. DO NOT lubricate section seals.

1. 2. 3. 4. 5.

MANUAL LOWERING VALVE PORT OPTION PLUG O-RING OPTIONAL SECONDARY RELIEF VALVE LIFT SECTION PLUG

6. 7. 8. 9.

TILT SECTION PLUG BACKUP RING LIFT/TILT/AUXILIARY SECTION BODY SECTION SEAL

Figure 74. Lift/Tilt/Auxiliary Section of E-Hydraulic Control Valve

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3. Install new O-ring onto port option plug. Install port option plug into tilt section. See Figure 74. Tighten port option plug to 54 N•m (40 lbf ft). 4. Install new O-ring onto lift section plug. Install lift section plug into lift section. See Figure 74. Tighten lift section plug to 27 N•m (20 lbf ft). 5. Install new O-ring onto manual lowering valve. Install manual lowering valve into lift section. See Figure 74. Tighten manual lowering valve to 54 N•m (40 lbf ft).

1. 2. 3. 4. 5. 6. 7. 8.

INLET SECTION LIFT SECTION TILT SECTION SPACER SECTION (OPTIONAL) FIRST AUXILIARY SECTION (OPTIONAL) SECTION AUXILIARY SECTION PRIMARY RELIEF VALVE MANUAL LOWERING VALVE

6. If removed, install diagnostic fitting onto elbow fitting. Install O-ring onto elbow fitting, then install elbow fitting into inlet section. See Figure 75. Tighten elbow fitting to 16 N•m (142 lbf in). 7. Install new O-rings onto steer load sense fitting. Install steer load sense fitting into inlet section. See Figure 76. Tighten steer load sense fitting to 16 N•m (142 lbf in).

9. 10. 11. 12. 13. 14. 15. 16.

COMPENSATOR PLUG OPTIONAL SECONDARY RELIEF VALVE LOWER SOLENOID ASSEMBLY UPPER SOLENOID ASSEMBLY PILOT CARTRIDGE ELBOW FITTING DIAGNOSTIC FITTING O-RING

Figure 75. E-Hydraulic Control Valve

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1. 2. 3. 4. 5.

STEER LOAD SENSE FITTING O-RING INLET SECTION BODY BACKUP RING PILOT CARTRIDGE

2000 YRM 1334

6. 7. 8. 9. 10.

COMPENSATOR PLUG SECTION SEAL PRIMARY RELIEF VALVE ELBOW FITTING DIAGNOSTIC FITTING

Figure 76. Inlet Section E-Hydraulic Control Valve 8. Install new O-rings and backup rings onto pilot cartridge. Install pilot cartridge into inlet section. See Figure 76. Tighten pilot cartridge to 65 N•m (48 lbf ft). 9. Install new O-rings onto primary relief valve. Install primary relief valve into inlet section. See Figure 76. Tighten primary relief valve to 27 N•m (20 lbf ft). 10. If removed, install nuts on inlet side of tie rods. See Figure 77. Hand tighten nuts only at this time. 11. Install tie rod end without nut through inlet section. See Figure 78 for example.

Figure 77. Tie Rods and Nuts for E-Hydraulic Control Valve

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Legend for Figure 77 A. INLET SIDE

B. OUTLET SIDE

1. TIE ROD 2. NUT

3. JAM NUT

NOTE: DO NOT lubricate section seals. 13. Install section seals into retaining grooves in inlet section face. See Figure 76. 14. Install lift section onto tie rods against inlet section. See Figure 78 for example. 15. Install section seals into retaining grooves in lift section face. See Figure 74. 16. Install tilt section onto tie rods against lift section. See Figure 78 for example. 17. Install section seals into retaining grooves in tilt section face. See Figure 74. NOTE: Perform Step 18 and Step 19 if E-hydraulic control valve is equipped with spacer section. 18. Install spacer section onto tie rods against tilt section. See Figure 78 for example. 19. Install section seals into retaining grooves on spacer section face. NOTE: Perform Step 20 and Step 21 if E-hydraulic control valve is equipped with a first auxiliary section.

1. INLET SECTION 2. LIFT SECTION

3. TIE ROD

Figure 78. E-Hydraulic Control Valve - Sections and Tie Rods 12. Install upper solenoid connector, lower solenoid connector, and two jam nuts, as noted during disassembly, onto tie rod ends. Make sure upper and lower solenoid connectors are installed at the correct angles as shown in Figure 79. Hand tighten jam nuts to hold connectors onto inlet section.

20. Install first auxiliary section onto tie rods against spacer section. See Figure 78 for example. 21. Install section seals into retaining grooves on first auxiliary section face. See Figure 74. 22. Install second auxiliary section onto tie rods against spacer section or first auxiliary section. See Figure 78 for example. 23. Install section seals into retaining grooves on second auxiliary section face. See Figure 74. 24. Install outlet cap onto tie rods against second auxiliary section. See Figure 80.

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1. INLET SECTION 2. OUTLET COVER 3. FIRST AUXILIARY SECTION (OPTIONAL)

4. SECOND AUXILIARY SECTION

Figure 80. E-Hydraulic Control Valve 27. Tighten jam nuts to 7 to 11 N•m (62 to 97 lbf in) keeping connectors at the correct angle, as shown in Figure 79. 28. Install upper solenoid assemblies into lift, tilt, and auxiliary sections. See Figure 75. Tighten upper solenoid assembly to 5 N•m (48 lbf in).

1. 2. 3. 4. 5. 6.

UPPER SOLENOID CONNECTOR LOWER SOLENOID CONNECTOR JAM NUT DIAGNOSTIC FITTING ELBOW FITTING STEER LOAD SENSE FITTING

Figure 79. E-Hydraulic Solenoid Connectors 25. Install nuts on tie rods on outlet side of E-hydraulic control valve. See Figure 77. Hand tighten nuts only at this time. NOTE: Tie rods should extend one or two threads past nuts on both sides. 26. After ensuring tie rods are completely through all sections of E-hydraulic control valve tighten nuts to 20.3 ±1.4 N•m (179.7 ±12.4 lbf in).

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29. Install lower solenoid assemblies into lift, tilt, and auxiliary sections. See Figure 75. Tighten lower solenoid assembly to 5 N•m (48 lbf in).

INSTALL 1. Connect lower solenoid wires to lower solenoid connector as tagged during removal. See Table 5 and Figure 81.

Table 5. Lower Solenoid Connector Pin Layout Pin

Socket

PIN 8

1B NEG

PIN 1

1B POS

PIN 7

2B NEG

PIN 2

2B POS

PIN 6

3B NEG

PIN 3

3B POS

PIN 5

4B NEG

PIN 4

4B POS

2000 YRM 1334

E-Hydraulic Control Valve Repair

NOTE: 4-FUNCTION E-HYDRAULIC CONTROL VALVE SHOWN. 4. LOWER SOLENOID WIRE 5. JAM NUT 6. STEER LOAD SENSE FITTING

1. LOWER SOLENOID CONNECTOR 2. UPPER SOLENOID CONNECTOR 3. UPPER SOLENOID WIRE

Figure 81. Solenoid Wires and Connectors 2. Connect upper solenoid wires to upper solenoid connector as tagged during removal. See Table 6 and Figure 81.

3. Install three washers, mounting bracket, and three M8 capscrews onto E-hydraulic control valve. See Figure 82.

Table 6. Upper Solenoid Connector Pin Layout

4. Install mounting bracket, with E-hydraulic control valve attached, into holding brackets on front bulkhead. See Figure 82.

Socket

PIN 8

1A NEG

PIN 1

1A POS

PIN 7

2A NEG

PIN 2

2A POS

PIN 6

3A NEG

PIN 3

3A POS

PIN 5

4A NEG

PIN 4

4A POS

5. Install bracket, M10 capscrew, washers, and nut onto mounting bracket and front bulkhead. See Figure 82. 6. Connect lower solenoid connector to wire harness. 7. Connect upper solenoid connector to wire harness.

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NOTE: ARROW POINTING TO FRONT OF LIFT TRUCK. 1. 2. 3. 4. 5.

FRAME FRONT BULKHEAD MOUNTING BRACKET E-HYDRAULIC CONTROL VALVE BRACKET

6. 7. 8. 9. 10.

M10 CAPSCREW WASHER NUT HOLDING BRACKET M8 CAPSCREW

Figure 82. E-Hydraulic Control Valve Mounting NOTE: Lubricate O-rings with clean hydraulic oil prior to installation.

NOTE: Perform Step 9 for E-hydraulic control valve equipped with both first and second auxiliary sections.

8. Lubricate new O-rings and install on return line fitting, inlet fitting, steer return fitting, tilt fittings, lift/ lower fittings, and auxiliary fittings. See Figure 83.

9. Install auxiliary fittings into second auxiliary section as noted during removal. See Figure 83.

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NOTE: 4-FUNCTION CONTROL VALVE SHOWN. 1. 2. 3. 4. 5. 6. 7.

RETURN LINE FITTING INLET FITTING STEER FITTING LIFT/LOWER FITTING TILT FITTING 3-FUNCTION AUXILIARY FITTING 4-FUNCTION AUXILIARY FITTING

8. 9. 10. 11. 12. 13. 14.

INLET SECTION LIFT SECTION TILT SECTION SPACER SECTION FIRST AUXILIARY SECTION (OPTIONAL) OUTLET COVER SECOND AUXILIARY SECTION

Figure 83. E-Hydraulic control Valve Fittings NOTE: Perform Step 10 for E-hydraulic control valve equipped with second auxiliary section. 10. Install auxiliary fittings into second auxiliary section as noted during removal. See Figure 83. 11. Install tilt fittings into tilt section as noted during removal. See Figure 83. 12. Install lift/lower fittings into lift section as noted during removal. See Figure 83. 13. Install steer fittings into inlet section as noted during removal. See Figure 83.

14. Install inlet fitting into inlet section as noted during removal. Tighten fitting to 16 N•m (142 lbf in). See Figure 83. 15. Install return line fitting into inlet section as noted during removal. See Figure 83. NOTE: Remove caps from hydraulic lines as they are connected. 16. Connect hydraulic lines to fittings as tagged during removal.

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CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 17. Dispose of drain pan contents. 18. Check hydraulic oil level; refill system as needed. See Periodic Maintenance 8000 YRM 1339 for lift trucks ERP15-20VT (ERP030-040VT) (G807) or Periodic Maintenance 8000 YRM 1373 for lift trucks ERP16-20VF (ERP30-40VF) (A955) for procedures. 19. Install floor plates and floor mats. 20. Install battery. See How to Change Battery in Operating Manual or Periodic Maintenance 8000 YRM 1339 for lift trucks ERP15-20VT (ERP030-040VT) (G807) or Periodic Maintenance 8000 YRM 1373 for lift trucks ERP16-20VF (ERP30-40VF) (A955). 21. Connect battery connectors.

1. 2. 3. 4. 5. 6. 7.

ARMREST EMERGENCY DISCONNECT SWITCH HORN BUTTON DIRECTION CONTROL SWITCH (OPTIONAL) MINI-LEVER MLM WIRE HARNESS MOMENTARY BUTTON (OPTIONAL)

22. Operate hydraulic functions, then check for leaks.

Figure 84. E-Hydraulic Controls

23. Perform procedures outlined in Calibration Procedure section of this manual.

Mini-levers are available in single function or dual function. See Figure 85 for examples.

E-HYDRAULIC CONTROLS E-hydraulic controls for the lift truck are part of the minilever module (MLM) installed on an armrest. The emergency disconnect switch is mounted on the outside of the armrest and connected to the MLM wire harness. Mounting for a direction control switch (optional) has been provided on the armrest and will connect to the MLM wire harness. The horn button is mounted on the inside of the armrest and connected to the MLM wire harness. The MLM wire harness is routed beside the seat and connects to the main wire harness. See Figure 84.

Figure 85. Mini-Levers and Armrest

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Legend for Figure 85 A. 3-FUNCTION MINI-LEVER MODULE B. 4-FUNCTION MINI-LEVER MODULE 1. 2. 3. 4. 5.

BLANK CAPSCREW AUX 1 LEVER AUX 2 LEVER MOMENTARY BUTTON (OPTIONAL)

E-Hydraulic Control Valve Repair

Replace E-Hydraulic Control Components 1. For procedures to replace the armrest, emergency disconnect switch, horn button, direction control switch, and mini-levers see Electrical System 2200 YRM 1337.

E-Hydraulic Control Valve Repair for Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) REMOVE Initial Steps WARNING

NOTE: Tag hydraulic lines during removal to aid in installation. 5. Put a drain pan under the area of the hydraulic control assembly. Disconnect hydraulic lines from E-hydraulic control assembly. Cap hydraulic lines.

Before making repairs to the control valve, fully lower all parts of the mast and tilt it fully forward. This action will prevent the mast from lowering suddenly when hydraulic lines are disconnected.

Fitting Removal for Lift Truck ERC22-35VG (ERC045-070VG) (A968)

NOTE: Only perform those steps below necessary for required repair or replacement.

NOTE: Note placement and orientation of fittings prior to removal to aid in installation. Note placement of O-rings on fittings prior to removal to aid in installation.

1. Lower mast and tilt forward. 2. Remove battery from lift truck. See How to Change Battery in Operating Manual or Periodic Maintenance 8000 YRM 1364 for Lift Truck ERC22-35VG (ERC045-070VG) (A968) or Periodic Maintenance 8000 YRM 1372for Lift Truck ERP22-35VL (ERP045-070VL) (A976). 3. Discharge capacitors by following steps shown in Discharging the Capacitors in General section of this manual. 4. Remove floor mats and floor plates.

WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool.

CAUTION For Lift Truck ERC22-35VG (ERC045-070VG) (A968) electrical components to be shielded from hydraulic oil drips if they are below hydraulic valve and lines.

1. Remove return line fitting, inlet fitting, steer fittings from inlet section. Remove and discard O-rings from fittings. See Figure 86. 2. Remove steer load sense fitting from inlet section. Remove and discard O-rings from fitting. See Figure 86. 3. Remove lift/lower fitting from lift section. See Figure 86. 4. Remove tilt fittings from tilt section. See Figure 86. NOTE: Perform Step 5 if E-hydraulic control valve is equipped with first auxiliary section. 5. Remove first auxiliary fittings from first auxiliary section. See Figure 86. NOTE: Perform Step 5 and Step 6 if E-hydraulic control valve is equipped with first and second auxiliary sections. 6. Remove second auxiliary fittings from second auxiliary section. See Figure 86.

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NOTE: 4-FUNCTION CONTROL VALVE SHOWN. A. INLET AND LIFT SECTION FITTINGS

B. TILT AND AUXILIARY SECTION FITTINGS

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13. 14.

INLET SECTION RETURN LINE FITTING INLET FITTING DIAGNOSTIC FITTING STEER LOAD SENSE FITTING STEER FITTING LIFT SECTION

LIFT/LOWER FITTING TILT SECTION TILT FITTING FIRST AUXILIARY SECTION (OPTIONAL) FIRST AUXILIARY FITTING SECOND AUXILIARY SECTION SECOND AUXILIARY FITTING

Figure 86. E-Hydraulic Control Valve Fittings for Lift Truck ERC22-35VG (ERC045-070VG) (A968)

Fitting Removal for Lift Truck ERP22-35VL (ERP045-070VL) (A976) NOTE: Note placement and orientation of fittings prior to removal to aid in installations. Note place of O-rings on fittings prior to removal to aid in installation. 1. Remove return line fitting, inlet fitting, steer fittings, and park brake fittings from inlet section. Remove and discard O-rings from fittings. See Figure 87.

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2. Remove steer load sense fitting from inlet section. Remove and discard O-ring from fitting. See Figure 87. 3. Remove lift/lower fitting from lift section. Remove and discard O-ring from fitting. See Figure 87. 4. Remove tilt fittings from tilt section. Remove and discard O-rings from fittings. See Figure 87.

2000 YRM 1334

E-Hydraulic Control Valve Repair

NOTE: 4-FUNCTION CONTROL VALVE SHOWN. A. INLET AND LIFT SECTION FITTINGS

B. TILT AND AUXILIARY SECTION FITTINGS

1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15.

INLET SECTION RETURN LINE FITTING INLET FITTING DIAGNOSTIC FITTING STEER LOAD SENSE FITTING STEER FITTING PARK BRAKE FITTING LIFT SECTION

LIFT/LOWER FITTING TILT SECTION TILT LINE FITTING FIRST AUXILIARY SECTION FIRST AUXILIARY FITTING SECOND AUXILIARY SECTION SECOND AUXILIARY FITTING

Figure 87. E-Hydraulic Control Valve Fittings for Lift Truck ERP22-35VL (ERP045-070VL) (A976) NOTE: Perform Step 5 if E-hydraulic control valve is equipped with first auxiliary section. 5. Remove first auxiliary fittings from first auxiliary section. Remove and discard O-rings from fittings. See Figure 87.

NOTE: Perform Step 5 and Step 6 if E-hydraulic control valve is equipped with first and second auxiliary sections. 6. Remove second auxiliary fittings from second auxiliary section. Remove and discard O-rings from fittings. See Figure 87.

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Electrical Disconnect and Control Valve Dismount

5. Disconnect upper solenoid wires from upper solenoid electrical connector. See Figure 88.

1. Disconnect upper solenoid electrical connector from e-hydraulic main wire harness. See Figure 88.

NOTE: Tag lower solenoid wires during removal to aid in installation.

2. Disconnect lower solenoid electrical connector from e-hydraulic main wire harness. See Figure 88. 3. Remove mounting capscrew and valve mounting bracket, with E-hydraulic control valve, from clip nut and bulkhead. See Figure 89. 4. Remove three capscrews, three special washers, and valve mounting bracket from E-hydraulic control valve. See Figure 89.

6. Disconnect lower solenoid wires from lower solenoid electrical connector. See Figure 88. NOTE: Note placement of jam nuts and solenoid connectors on tie rods prior to removal to aid in installation. 7. Remove two jam nuts, upper solenoid electrical connector, and lower solenoid electrical connector from tie rods on inlet section side. See Figure 88.

NOTE: Tag upper solenoid wires during removal to aid in installation.

NOTE: 4-FUNCTION E-HYDRAULIC CONTROL VALVE SHOWN. 1. LOWER SOLENOID ELECTRICAL CONNECTOR 2. UPPER SOLENOID ELECTRICAL CONNECTOR 3. UPPER SOLENOID WIRE

4. LOWER SOLENOID WIRE 5. JAM NUT

Figure 88. Solenoid Wires and Connectors

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NOTE: FRAME AND FRONT BULKHEAD SHOWN ONLY FOR VALVE PLACEMENT PURPOSES. NOTE: ARROW POINTING TO FRONT OF LIFT TRUCK. 1. 2. 3. 4. 5.

FRAME FRONT BULKHEAD VALVE MOUNTING BRACKET E-HYDRAULIC CONTROL VALVE MOUNTING CAPSCREW

6. 7. 8. 9.

CLIP NUT CAPSCREW SPECIAL WASHER BULKHEAD

Figure 89. E-Hydraulic Control Valve Mounting

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DISASSEMBLE NOTE: The 3-function E-hydraulic control valve is not equipped with a first auxiliary section. 1. Remove lower solenoid from the lift, tilt, and auxiliary sections. See Figure 90. 2. Remove upper solenoid from lift, tilt, and auxiliary sections. See Figure 90. 3. Remove nuts from tie rods on outlet side of E-hydraulic control valve. See Figure 91.

1. 2. 3. 4. 5. 6. 7.

INLET SECTION LIFT SECTION TILT SECTION FIRST AUXILIARY SECTION (OPTIONAL) SECOND AUXILIARY SECTION PRIMARY RELIEF VALVE PILOT CARTRIDGE

4. Remove two jam nuts, upper solenoid connector, and lower solenoid connector from tie rods on inlet side. See Figure 88. NOTE: Note placement of section seals in retaining grooves of each section prior to removal to aid in installation. 5. Remove each section from tie rods and adjacent section starting with the second auxiliary section, followed by the first auxiliary section if present, the tilt section, and the lift section. See Figure 92 for example.

8. 9. 10. 11. 12. 13.

MANUAL LOWERING VALVE SECONDARY RELIEF VALVE LOWER SOLENOID UPPER SOLENOID DIAGNOSTIC FITTING ELBOW FITTING

Figure 90. E-Hydraulic Control Valve

124

2000 YRM 1334

E-Hydraulic Control Valve Repair

A. 3 FUNCTION E-HYDRAULIC CONTROL VALVE

B. 4 FUNCTION E-HYDRAULIC CONTROL VALVE

1. 2. 3. 4.

5. SECOND AUXILIARY SECTION 6. TIE ROD 7. NUT

INLET SECTION LIFT SECTION TILT SECTION FIRST AUXILIARY SECTION (OPTIONAL)

Figure 91. E-Hydraulic Control Valve Sections

125

E-Hydraulic Control Valve Repair

2000 YRM 1334 11. Remove elbow fitting and diagnostic fitting from inlet section. Remove and discard O-ring from elbow fitting. See Figure 93. 12. Remove manual lowering valve from lift section. Remove and discard O-ring from valve. See Figure 94. 13. Remove lift section plug from lift section. Remove and discard O-ring from plug. See Figure 94. 14. Remove port option plug from tilt section. Remove and discard O-ring from plug. See Figure 94. 15. Remove secondary relief valve or tilt section plug from tilt section. Remove and discard O-rings and backup rings from valve or plug. See Figure 94.

CLEAN WARNING 1. INLET SECTION 2. LIFT SECTION

3. TIE ROD

Figure 92. E-Hydraulic Control Valve - Sections and Tie Rods 6. Remove tie rods from inlet section. See Figure 92. 7. Remove and discard section seals from retaining grooves of all sections. See Figure 93 and Figure 94. 8. Remove pilot cartridge from inlet section. Remove and discard O-rings from pilot cartridge. See Figure 93 and Figure 90. 9. Remove primary relief valve from inlet section. Remove and discard O-rings and backup ring from primary relief valve. See Figure 93 and Figure 90. 10. Remove compensator plug from inlet section. Remove and discard O-ring from plug. See Figure 93.

126

Cleaning solvents can be flammable and toxic and cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Clean only metal components of E-hydraulic control valve with solvent and dry using compressed air. Avoid getting solvent in electrical connectors. 2. Clean all threaded components with denatured alcohol and dry using compressed air. 3. Clean rubber or plastic components with warm soapy water and dry with a lint free cloth.

2000 YRM 1334

1. 2. 3. 4. 5.

E-Hydraulic Control Valve Repair

INLET SECTION O-RING BACKUP RING PILOT CARTRIDGE PRIMARY RELIEF VALVE

6. 7. 8. 9.

COMPENSATOR PLUG SECTION SEAL ELBOW FITTING DIAGNOSTIC FITTING

Figure 93. Inlet Section E-Hydraulic Control Valve

INSPECT 1. Inspect section bodies for damage. Replace if damaged.

3. Inspect all other components for damage. Replace if damaged.

2. Inspect threaded components to ensure absence of oil or solvent residue.

127

E-Hydraulic Control Valve Repair

1. 2. 3. 4. 5.

MANUAL LOWERING VALVE PORT OPTION PLUG O-RING SECONDARY RELIEF VALVE LIFT SECTION PLUG

2000 YRM 1334

6. 7. 8. 9.

TILT SECTION PLUG BACKUP RING LIFT/TILT/AUXILIARY SECTION SECTION SEAL

Figure 94. Lift/Tilt/Auxiliary Sections E-Hydraulic Control Valve

ASSEMBLE NOTE: Lubricate all new O-rings and backup rings with clean hydraulic oil prior to installation. DO NOT lubricate section seals. NOTE: Perform Step 1 if E-hydraulic control valve is NOT equipped with secondary relief valve.

128

1. Install new O-rings, new backup rings, and tilt section plug into tilt section. See Figure 95. Tighten tilt section plug to 27 N•m (20 lbf ft). 2. Install O-rings, new backup rings, and secondary relief valve into tilt section. See Figure 95. Tighten secondary relief valve to 27 N•m (20 lbf ft).

2000 YRM 1334

1. 2. 3. 4. 5.

E-Hydraulic Control Valve Repair

MANUAL LOWERING VALVE PORT OPTION PLUG O-RING SECONDARY RELIEF VALVE LIFT SECTION PLUG

6. 7. 8. 9.

TILT SECTION PLUG BACKUP RING LIFT/TILT/AUXILIARY SECTION SECTION SEAL

Figure 95. Lift/Tilt/Auxiliary Sections - E-Hydraulic Control Valve 3. Install new O-ring and port option plug onto tilt section. See Figure 95. Tighten port option plug to 54 N•m (40 lbf ft).

5. Install new O-ring and manual lowering valve onto lift section. See Figure 95. Tighten manual lowering valve to 54 N•m (40 lbf ft).

4. Install new O-ring and lift section plug onto lift section. See Figure 95. Tighten lift section plug to 27 N•m (20 lbf ft).

6. Install new O-ring onto elbow fitting. Install diagnostic fitting onto elbow fitting. Install elbow fitting into inlet section. See Figure 96. Tighten elbow fitting to 16 N•m (142 lbf in).

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E-Hydraulic Control Valve Repair

1. 2. 3. 4. 5.

INLET SECTION O-RING BACKUP RING PILOT CARTRIDGE PRIMARY RELIEF VALVE

2000 YRM 1334

6. 7. 8. 9.

COMPENSATOR PLUG SECTION SEAL ELBOW FITTING DIAGNOSTIC FITTING

Figure 96. Inlet Section - E-Hydraulic Control Valve 7. Install new O-ring onto compensator plug. Install compensator plug into inlet section. See Figure 96. 8. Install new O-rings and backup rings onto primary relief valve. Install primary relief valve into inlet section. See Figure 96. Tighten primary relief valve to 27 N•m (20 lbf ft).

130

9. Install new O-rings and new backup rings onto pilot cartridge. Install pilot cartridge into inlet section. See Figure 96. Tighten pilot cartridge to 65 N•m (48 lbf ft). 10. If removed, install nuts on inlet side of tie rods. See Figure 97. Hand tighten nuts only at this time.

2000 YRM 1334

E-Hydraulic Control Valve Repair

A. 3-FUNCTION E-HYDRAULIC CONTROL VALVE

B. 4-FUNCTION E-HYDRAULIC CONTROL VALVE

1. 2. 3. 4.

5. SECOND AUXILIARY SECTION 6. TIE ROD 7. NUT

INLET SECTION LIFT SECTION TILT SECTION FIRST AUXILIARY SECTION (OPTIONAL)

Figure 97. E-Hydraulic Control Valve Sections

131

E-Hydraulic Control Valve Repair

2000 YRM 1334 11. Install tie rod end without nut through inlet section. See Figure 92 for example. 12. Install upper solenoid electrical connector and jam nut, as noted during disassembly, onto tie end. See Figure 99. 13. Position upper solenoid electrical connector as shown in Figure 100 and hand tighten jam nut. 14. Install lower solenoid electrical connector and jam nut, as noted during disassembly, onto tie rod end. See Figure 99. 15. Position lower solenoid electrical connector as shown in figure Figure 100 and hand tighten jam nut. NOTE: DO NOT lubricate section seals. 16. Install section seals into retaining grooves in inlet section face. See Figure 96.

1. INLET SECTION 2. LIFT SECTION

3. TIE ROD

17. Install lift section onto tie rods against inlet section. See Figure 98 for example.

Figure 98. E-Hydraulic Control Valve - Sections and Tie Rods

Figure 99. Solenoid Wires and Connectors

132

2000 YRM 1334

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Legend for Figure 99 NOTE: 4-FUNCTION E-HYDRAULIC CONTROL VALVE SHOWN. 1. LOWER SOLENOID ELECTRICAL CONNECTOR 2. UPPER SOLENOID ELECTRICAL CONNECTOR 3. UPPER SOLENOID WIRE

4. LOWER SOLENOID WIRE 5. JAM NUT 20. Install section seals into retaining grooves in tilt section face. See Figure 95. NOTE: The 3-function E-hydraulic control valve is not equipped with a first auxiliary section. 21. Install first auxiliary section onto tie rods against tilt section. See Figure 98 for example. 22. Install section seals into retaining grooves on first auxiliary section face. See Figure 95. 23. Install second auxiliary section onto tie rods against first auxiliary section. See Figure 98 for example. 24. Install nuts on tie rods on outlet side of E-hydraulic control valve. See Figure 97. Hand tighten nuts only at this time. NOTE: Tie rods to extend one or two threads beyond nut on each end. 25. After ensuring tie rods are completely through all sections of E-hydraulic control valve tighten nuts on both inlet and outlet side to 20.3 ± 1.4 N•m (179.7 ± 12.4 lbf in). 26. Tighten jam nuts to 7 to 11 N•m (62 to 97 lbf in) keeping connectors at the correct angle, as shown in Figure 100.

1. UPPER SOLENOID ELECTRICAL CONNECTOR 2. LOWER SOLENOID ELECTRICAL CONNECTOR 3. JAM NUT

27. Install upper solenoid into lift, tilt, and auxiliary sections. See Figure 101. Tighten upper solenoids to 5 N•m (48 lbf in).

Figure 100. E-Hydraulic Solenoid Electrical Connectors

28. Install lower solenoid into lift, tilt, dual auxiliary, and auxiliary sections. See Figure 101. Tighten lower solenoids to 5 N•m (48 lbf in).

18. Install section seals into retaining grooves in lift section face. See Figure 95. 19. Install tilt section onto tie rods against lift section. See Figure 98 for example.

133

E-Hydraulic Control Valve Repair

1. 2. 3. 4. 5. 6. 7.

2000 YRM 1334

INLET SECTION LIFT SECTION TILT SECTION FIRST AUXILIARY SECTION (OPTIONAL) SECOND AUXILIARY SECTION PRIMARY RELIEF VALVE PILOT CARTRIDGE

8. 9. 10. 11. 12. 13.

MANUAL LOWERING VALVE SECONDARY RELIEF VALVE LOWER SOLENOID UPPER SOLENOID DIAGNOSTIC FITTING ELBOW FITTING

Figure 101. E-Hydraulic Control Valve

134

2000 YRM 1334

INSTALL Electrical Connect and Control Valve Mount 1. Connect lower solenoid wires to lower solenoid connector as tagged during removal. See Table 7 and Figure 99. 2. Connect upper solenoid wires to upper solenoid connector as tagged during removal. See Table 8 and Figure 99. 3. Install three special washers, valve mounting bracket, and three capscrews onto E-hydraulic control valve. See Figure 102.

E-Hydraulic Control Valve Repair 7. Connect lower solenoid electrical connector to e-hydraulic main wire harness.

Table 7. Lower Solenoid Connector Pin Layout Pin

Socket

PIN 8

1B NEG

PIN 1

1B POS

PIN 7

2B NEG

PIN 2

2B POS

PIN 6

3B NEG

PIN 3

3B POS

PIN 5

4B NEG

PIN 4

4B POS

Table 8. Upper Solenoid Connector Pin Layout Pin

Socket

4. Install clip nut onto bulkhead. See Figure 102.

PIN 8

1A NEG

PIN 1

1A POS

5. Install valve mounting bracket, with E-hydraulic control valve attached, onto bulkhead. Install mounting capscrew into clip nut and bulkhead. See Figure 102.

PIN 7

2A NEG

PIN 2

2A POS

PIN 6

3A NEG

PIN 3

3A POS

PIN 5

4A NEG

PIN 4

4A POS

6. Connect upper solenoid electrical connector to e-hydraulic main wire harness.

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E-Hydraulic Control Valve Repair

2000 YRM 1334

NOTE: FRAME AND FRONT BULKHEAD SHOWN ONLY FOR VALVE PLACEMENT PURPOSES. NOTE: ARROW POINTING TO FRONT OF LIFT TRUCK. 1. 2. 3. 4. 5.

FRAME FRONT BULKHEAD VALVE MOUNTING BRACKET E-HYDRAULIC CONTROL VALVE MOUNT CAPSCREW

6. 7. 8. 9.

CLIP NUT CAPSCREW SPECIAL WASHER BULKHEAD

Figure 102. E-Hydraulic Control Valve Mounting

136

2000 YRM 1334

E-Hydraulic Control Valve Repair

Fitting Installation for Lift Truck ERC22-35VG (ERC045-070VG) (A968)

3. Install new O-rings onto tilt fittings. Install tilt fittings into tilt section. See Figure 103.

NOTE: Lubricate new O-rings with clean hydraulic oil prior to installation.

4. Install new O-ring onto lift/lower fitting. Install lift/ lower fitting into lift section. See Figure 103.

1. Install new O-rings onto 4th function fittings. Install 4th function fittings into auxiliary section. See Figure 103.

5. Install new O-ring onto steer load sense fitting. Install steer load sense fitting into inlet section. See Figure 103.

NOTE: Perform Step 2 if control valve is equipped with first auxiliary section.

6. Install new O-rings onto steer fittings. Install steer fittings into inlet section. See Figure 103.

2. Install new O-rings onto first auxiliary fittings. Install first auxiliary fittings into first auxiliary section. See Figure 103.

7. Install new O-ring onto inlet fitting. Install inlet fitting into inlet section. See Figure 103. 8. Install new O-ring onto return line fitting. Install return line fitting into inlet section. See Figure 103.

NOTE: 4-FUNCTION CONTROL VALVE SHOWN. A. INLET AND LIFT SECTION FITTINGS 1. 2. 3. 4. 5.

INLET SECTION RETURN LINE FITTING INLET FITTING DIAGNOSTIC FITTING STEER LOAD SENSE FITTING

6. 7. 8. 9. 10.

B. TILT AND AUXILIARY SECTION FITTINGS STEER FITTING LIFT SECTION LIFT/LOWER FITTING TILT SECTION TILT FITTING

11. FIRST AUXILIARY SECTION (OPTIONAL) 12. FIRST AUXILIARY FITTING 13. SECOND AUXILIARY SECTION 14. SECOND AUXILIARY FITTING

Figure 103. E-Hydraulic Control Valve Fittings for Lift Truck ERC22-35VG (ERC045-070VG) (A968)

137

E-Hydraulic Control Valve Repair

Fitting Installation for Lift Truck ERP22-35VL (ERP045-070VL) (A976) NOTE: Lubricate new O-rings with clean hydraulic oil prior to installation.

2000 YRM 1334 2. Install new O-rings onto 3rd function auxiliary fittings. Install 3rd function auxiliary fittings into dual auxiliary section. See Figure 104. 3. Install new O-rings onto tilt fittings. Install tilt fittings into tilt section. See Figure 104.

1. Install new O-rings onto second auxiliary fittings. Install second auxiliary fittings into second auxiliary section. See Figure 104.

4. Install new O-ring onto lift/lower fitting. Install lift/ lower fitting into lift section. See Figure 104.

NOTE: Perform Step 2 if control valve is equipped with dual auxiliary section.

5. Install new O-rings onto steer load sense fitting. Install steer load sense fitting into inlet section. See Figure 104.

NOTE: 4-FUNCTION CONTROL VALVE SHOWN. A. INLET AND LIFT SECTION FITTINGS

B. TILT AND AUXILIARY SECTION FITTINGS

1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15.

INLET SECTION RETURN LINE FITTING INLET FITTING DIAGNOSTIC FITTING STEER LOAD SENSE FITTING STEER FITTING PARK BRAKE FITTING LIFT SECTION

LIFT/LOWER FITTING TILT SECTION TILT LINE FITTING FIRST AUXILIARY SECTION FIRST AUXILIARY FITTING SECOND AUXILIARY SECTION SECOND AUXILIARY FITTING

Figure 104. E-Hydraulic Control Valve Fittings for Lift Truck ERP22-35VL (ERP045-070VL) (A976)

138

2000 YRM 1334 6. Install new O-rings onto park brake fittings. Install park brake fittings into inlet section. See Figure 104. 7. Install new O-rings onto steer fittings. Install steer fittings into inlet section. See Figure 104. 8. Install new O-ring onto inlet fitting. Install inlet fitting into inlet section. See Figure 104. 9. Install new O-ring onto return line fitting. Install return line fitting into inlet section. See Figure 104.

Ending Steps NOTE: Remove caps from hydraulic lines as they are connected to appropriate fitting.

E-Hydraulic Control Valve Repair 8. Perform procedures outlined in Calibration Procedure section of this manual.

E-HYDRAULIC CONTROLS E-hydraulic controls for the lift truck are part of the minilever module (MLM) installed on an armrest. An emergency disconnect switch is mounted on the outside of the armrest and connected to the MLM wire harness. Mounting for a direction control switch (optional) has been provided on the armrest and will connect to the MLM wire harness. The horn button is mounted on the inside of the armrest and connected to the MLM wire harness. The MLM wire harness is routed beside the seat and connects to the main wire harness. See Figure 105.

1. Connect hydraulic lines to fittings as tagged during removal.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 2. Dispose of drain pan contents. 3. Check hydraulic oil level; refill system as needed. See Periodic Maintenance 8000 YRM 1364 for Lift Truck ERC22-35VG (ERC045-070VG) (A968) or Periodic Maintenance 8000 YRM 1372 for Lift Truck ERP22-35VL (ERP045-070VL) (A976) type of oil required and fill procedure. 4. Install floor plates and floor mats. 5. Install battery. See How to Change Battery in Operating Manual or Periodic Maintenance 8000 YRM 1364 for Lift Truck ERC22-35VG (ERC045-070VG) (A968) or Periodic Maintenance 8000 YRM 1372 for Lift Truck ERP22-35VL (ERP045-070VL) (A976). 6. Connect battery connectors.

1. ARMREST 2. EMERGENCY DISCONNECT SWITCH 3. HORN BUTTON 4. DIRECTION CONTROL SWITCH (OPTIONAL)

5. MINI-LEVER 6. MLM WIRE HARNESS 7. MOMENTARY BUTTON (OPTIONAL)

Figure 105. E-Hydraulic Controls

7. Operate hydraulic functions, then check for leaks.

139

Checks and Adjustments

2000 YRM 1334

Mini-levers are available in single function or dual function. See Figure 106 for examples.

Legend for Figure 106 A. 3-FUNCTION MINI-LEVER MODULE B. 4-FUNCTION MINI-LEVER MODULE 1. 2. 3. 4. 5.

BLANK CAPSCREW AUX 1 LEVER AUX 2 LEVER MOMENTARY BUTTON (OPTIONAL)

Figure 106. Mini-Levers and Armrest

Checks and Adjustments for Lift Truck ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) MANUAL CONTROL VALVE

6. If pressure is outside of range, replace primary relief valve as directed below:

Primary Relief Valve 1. Remove cap from diagnostic fitting. ure 107.

a. Lower forks to ground, turn lift truck OFF. See Fig-

2. Install 200 bar (3000 psi) pressure gauge into diagnostic fitting. 3. Run lift truck to ensure hydraulic oil temperature has stabilized at 65 to 70°C (150 to 160°F).

b. Remove primary relief valve cartridge from inlet section and replace with new primary relief valve cartridge. c. Repeat Step 3 through Step 5 to verify new primary relief valve is set correctly. d. Lower forks to ground and turn lift truck OFF.

4. Raise mast enough for forks to clear when tilted fully forward. 5. Tilt forks either forward or backward until they reach end of travel and record pressure reading. Pressure should be 180 ±5 bar (2611 ±75 psi).

140

7. Remove pressure gauge from diagnostic fitting and replace cap.

2000 YRM 1334

Checks and Adjustments 4. Perform auxiliary function as required to reach end of stroke and record pressure reading. Pressure should be 180 ±5 bar (2611 ±75 psi). 5. If pressure is out of range, adjust optional work port relief valve screw adjustment as directed below: a. Turn screw adjustment CLOCKWISE to increase pressure setting. b. Turn screw adjustment COUNTERCLOCKWISE to decrease pressure setting. c. Lower forks to ground and turn lift truck OFF.

CAUTION Hydraulic oil is hot after system operation and can cause burns. Allow lift truck to cool down sufficiently prior to any work that may expose hydraulic fluid. 6. Remove pressure gauge from diagnostic fitting and replace cap.

E-HYDRAULIC CONTROL VALVE 1. DIAGNOSTIC FITTING WITH CAP

Primary Relief Valve

Figure 107. Manual Control Valve Pressure Gauge Port

NOTE: Primary relief valve is not externally adjustable.

Optional Work Port Relief Valve

1. Remove cap from diagnostic fitting. ure 108.

See Fig-

NOTE: If lift truck is equipped with optional work port relief valve follow this procedure.

2. Install 200 bar (3000 psi) pressure gauge into diagnostic fitting.

NOTE: The optional work port relief valve is externally screw-adjustable.

3. Run lift truck to ensure hydraulic oil temperature has stabilized at 65 to 70°C (150 to 160°F).

1. Install a 200 bar (3000 psi) pressure gauge into diagnostic fitting.

4. Raise mast enough for forks to clear when tilted fully forward.

2. Run lift truck to ensure hydraulic oil temperature has stabilized at 49°C (120°F).

5. Tilt forks either forward or backward until they reach end of travel and record pressure reading. Pressure should be 179 ±5 bar (2600 ±75 psi).

3. Raise mast enough for forks to clear when tilted fully forward.

141

Checks and Adjustments

2000 YRM 1334 7. Remove pressure gauge from diagnostic fitting and replace cap.

Optional Secondary Port Relief Valve NOTE: If lift truck is equipped with optional secondary relief valve follow this procedure. NOTE: The optional secondary relief valve is externally screw-adjustable. 1. Install a 200 bar (3000 psi) pressure gauge into diagnostic fitting. 2. Run lift truck to ensure hydraulic oil temperature has stabilized at 49°C (120°F). 3. Raise mast enough for forks to clear when tilted fully forward. 4. Perform auxiliary function as required to reach end of stroke and record pressure reading. Pressure should be 179 ±5 bar (2600 ±75 psi). 5. If pressure is out of range, adjust optional secondary relief valve screw adjustment as directed below: a. Turn screw adjustment CLOCKWISE to increase pressure setting. 1. DIAGNOSTIC FITTING WITH CAP

Figure 108. E-Hydraulic Control Valve Pressure Gauge Port 6. If pressure is outside of range, replace primary relief valve as directed below: a. Lower forks to ground, turn lift truck OFF.

CAUTION Hydraulic oil is hot after system operation and can cause burns. Allow lift truck to cool down sufficiently prior to any work that may expose hydraulic fluid. b. Replace primary relief valve cartridge with new one. c. Repeat Step 3 through Step 5 to verify new primary relief valve is set correctly. d. Lower forks to ground and turn lift truck OFF.

142

b. Turn screw adjustment COUNTERCLOCKWISE to decrease pressure setting. c. Lower forks to ground and turn lift truck OFF. 6. Remove pressure gauge from diagnostic fitting and replace cap.

HYDRAULIC SYSTEM AIR REMOVAL 1. Remove cap from diagnostic fitting. See Figure 107 and Figure 108. 2. Install 200 bar (3000 psi) pressure gauge into diagnostic fitting. 3. Turn lift truck ON; make sure lift truck is in neutral and park brake is set. NOTE: Step 4 is required warm up for service. This is to ensure that the fluid temperature is optimal for calibrations. 4. Activate tilt at relief pressure until the hydraulic fluid temperature is 50 to 65°C (122 to 149°F).

2000 YRM 1334 NOTE: Perform Step 5 and Step 6 for hoist valve air bleed. This is required if the carriage moves slightly (approximately 25.4 mm (1 in.)) alternating between lifting and lowering. 5. Activate lift control from neutral to full lift and back to neutral at a rate of one to two times per second. Repeat until lift function is operating smoothly with no uncommanded mast movements.

Checks and Adjustments NOTE: Perform Step 7 for cylinder air bleed. This is required if the cylinders have not been previously cycled, or if the lift function is not operating smoothly. 7. Cycle function completely two or three times; repeat if necessary. It is not necessary to turn the lift truck ON or OFF if you are performing other procedures.

6. Lift carriage to maximum height and run over hydraulic relief for 15 to 30 seconds.

Checks and Adjustments for Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) MANUAL CONTROL VALVE External Leakage 1. If leaking between sections, loosen mounting bolts, loosen tie rod nuts and re-torque tie rod nuts to 19 to 21 N•m (168 to 192 lbf in). Tighten mounting bolts and check for leaks. If leakage continues, replace section seals, see Assemble Manual Control Valve section in this manual. 2. If relief cartridges, lowering valves, plugs, or fittings are leaking, tighten to measurements indicated in Assemble Manual Control Valve section of this manual. If leakage continues, replace O-rings.

Primary Relief Cartridge 1. Remove cap and Install pressure gauge capable of reading 250 bar (3625 psi) on diagnostic fitting in inlet section. See Figure 109.

5. If pressure is outside of range, follow procedure below to adjust primary relief valve cartridges: a. Remove plug at end of large hex of cartridge and insert hex wrench into adjustment plug. b. Turning adjustment plug CLOCKWISE increases spring compression (higher pressure setting); turning adjustment plug COUNTERCLOCKWISE decreases spring compressions (lower pressure setting). 6. Lower forks to the ground and turn OFF lift truck.

CAUTION Hydraulic fluid may be hot, allow lift truck to cool down sufficiently prior to any work that may expose hydraulic fluid.

2. Run lift truck to ensure oil temperature has stabilized to 65 to 70°C (150 to 160°F).

7. To replace primary relief valve, unscrew cartridge from inlet cover and replace with new cartridge. See Parts Manual for replacement part information.

3. Lift mast high enough for forks to clear when fully tilted forward.

8. Repeat Step 3 through Step 6 to verify new primary relief valve is set properly.

4. Tilt forks either forward or backward until they reach end of travel, and record pressure reading.

9. Remove pressure gauge and replace cap on diagnostic fitting in inlet section.

143

Checks and Adjustments

2000 YRM 1334 c. Lower forks to ground and turn lift truck OFF. 6. Remove pressure gauge from diagnostic fitting and replace cap.

E-HYDRAULIC CONTROL VALVE Primary Relief Valve NOTE: Primary relief valve is not externally adjustable. 1. Remove cap from diagnostic fitting. ure 110.

See Fig-

2. Install a 250 bar (3625 psi) pressure gauge into diagnostic fitting. 3. Run lift truck to ensure hydraulic oil temperature has stabilized at 65 to 75°C (150 to 160°F). 4. Actuate lift function as required to reach end of stroke and record pressure reading. 5. See Table 9 for pressure specifications.

1. DIAGNOSTIC FITTING WITH CAP

Figure 109. Manual Control Valve Pressure Gauge Port

Secondary Relief Valve NOTE: The secondary relief valve is externally screwadjustable. 1. Install a 200 bar (3000 psi) pressure gauge into diagnostic fitting. See Figure 109. 2. Run lift truck to ensure hydraulic oil temperature has stabilized at 49°C (120°F). 3. Raise mast enough for forks to clear when tilted fully forward. 4. Actuate tilt or auxiliary function as required to reach end of stroke and record pressure reading. Pressure should be 155 bar (2250 psi). 5. If pressure is out of range, adjust secondary relief valve screw adjustment as directed below: a. Turn screw adjustment CLOCKWISE to increase pressure setting. b. Turn screw adjustment COUNTERCLOCKWISE to decrease pressure setting.

144

1. DIAGNOSTIC FITTING WITH CAP

Figure 110. E-Hydraulic Control Valve Pressure Gauge Port

2000 YRM 1334

Checks and Adjustments

Table 9. Pressure Specifications Model

Control Valve

Pressure

ERC22-30VG (ERC045-060VG) (A968), ERP22-30VL (ERP040-060VL) (A976)

3- Function

219 bar (3176 psi)

ERC30-35VG (ERC060-070VG) (A968), ERP30-35VL (ERP060-070VL) (A976)

3-Function

239 bar (3466 psi)

ERC22-30VG (ERC045-060VG) (A968), ERP22-30VL (ERP040-060VL) (A976)

4-Function

219 bar (3176 psi)

ERC30-35VG (ERC060-070VG) (A968), ERP30-35VL (ERP060-070VL) (A976)

4-Function

239 bar (3466 psi)

6. If pressure is outside of range, replace primary relief valve as directed below:

3. Run lift truck to ensure hydraulic oil temperature has stabilized at 65 to 75°C (150 to 160°F).

a. Lower forks to ground, turn lift truck OFF.

4. Raise mast enough for forks to clear when tilted fully forward.

CAUTION Hydraulic oil is hot after system operation and can cause burns. Allow lift truck to cool down sufficiently prior to any work that may expose hydraulic fluid.

5. Actuate auxiliary function as required to reach end of stroke and record pressure reading. Pressure should be 155 ±5 bar (2250 ±75 psi). 6. If pressure is out of range, adjust secondary relief valve screw as indicated below.

b. Replace primary relief valve with new one. c. Repeat Step 3 through Step 5 to verify new primary relief valve is set correctly.

a. Turn screw adjustment CLOCKWISE to increase pressure setting.

d. Lower forks to ground, turn lift truck OFF.

b. Turn screw adjust COUNTERCLOCKWISE to decrease pressure setting.

7. Remove pressure gauge from diagnostic fitting and replace cap.

c. After adjustment, repeat Step 3 through Step 5 to verify pressure.

Secondary Relief Valve

d. Lower forks to ground and turn lift truck OFF.

1. Remove cap from diagnostic fitting. ure 110.

See Fig-

7. Remove pressure gauge from diagnostic fitting and replace cap.

2. Install a 200 bar (3000 psi) pressure gauge into diagnostic fitting.

145

Checks and Adjustments

2000 YRM 1334

PPRV Pilot Pressure Test This test is to determine if Pilot Pressure Reducing Valve (PPRV) is hydraulically supplying correct pressure to move the valve spool in E-Valve. This test should be done after confirming that the PPRV solenoid is getting correct current and that Pilot Supply pressure has been checked.

Table 10. Test Specifications Oil Temperature Minimum Pilot Pressure 1.5 amps at 12 volts

50 to 65°C (122 to 150°F) 1000 kPa (145 psi)

Table 11. Service Tools Pilot Pressure "A" Test Plug (Smaller)

Yale P/N 582003102

Pilot Pressure "B" Test Plug (Larger)

Yale P/N 582010530

1. Check actuating current at solenoid while shifting appropriate MLM lever by using Display Switch Cluster (DSC) display. If no reading, DSC will display a Diagnostic Trouble Code (DTC). See Diagnostic Troubleshooting Manual 9000 YRM 1377.

WARNING Hot hydraulic oil can cause serious burns to skin. DO NOT touch hydraulic components or oil during test. Make sure hydraulic oil has cooled to safe temperature before installing or removing test equipment.

WARNING

Pilot Pressure Test Gauge

0 to 7.0 MPa (0 to 1000 psi)

Pilot Supply Test Gauge

0 to 7.0 MPa (0 to 1000 psi)

Pilot Supply Test Port Size

NOTE: A functioning solenoid valve will make a clicking sound when current is applied. This clicking can also be felt but solenoids may be too hot to touch if truck has been operating.

SAE #4 O-ring Port (7/16 - 20 UNF)

Hydraulic oil under pressure can be injected into the skin. Lower forks to ground and relieve all circuit pressure before removing test plugs from valve. 2. Lower forks to ground and remove key from display. Apply park brake and disconnect battery.

CAUTION

NOTE: Check that pump RPM is at correct speed for all functions with no load on forks. See section

DO NOT permit dirt or other contaminants to enter the hydraulic system. Disconnected hoses, tubes, open valves, cylinder fittings, and ports should be protected with clean caps or plugs.

Capacities And Specifications 8000 YRM 1374 for lift truck models • ERC22-35VG (ERC045-070VG) (A968)

NOTE: The Pilot Supply Pressure gauge is shown as an additional gauge to use if pilot pressure is low.

Capacities And Specifications 8000 YRM 1375 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) NOTE: If all functions are lower flow than expected or none at all, then check the Pilot Supply pressure setting according to Table 10.

146

3. Remove floor mat and floor plates. Unplug foot pedal connector. 4. Install pilot pressure test plug(s) into section with suspected faulty solenoid valve and install pilot pressure test gauge. See Figure 111.

2000 YRM 1334

Checks and Adjustments 8. If pressure is not within specifications, check pressure reading on Pilot Supply Test Port gauge and compare to Table 10. If Pilot Supply pressure is okay, remove PPRV and inspect for the following: • Plugged inlet screen on PPRV • Failed sealing ring on PPRV • Sticking valve 9. Turn key to OFF position, disconnect battery, remove test equipment, and reinstall original port plugs onto control valve.

HYDRAULIC SYSTEM AIR REMOVAL 1. Install hydraulic valve pressure gauge as indicated in External Leakage 2. Turn lift truck ON; make sure lift truck is in neutral and park brake is set. NOTE: CONTROL VALVE IS SHOWN UPSIDE DOWN. A. FRONT SIDE VIEW B. RIGHT SIDE VIEW 1. PILOT SUPPLY TEST PORT WITH GAUGE 2. PILOT SUPPLY CARTRIDGE VALVE WITH TAMPERPROOF CAP 3. AUXILIARY 4A PLUG (SMALLER), SEE TABLE 11 4. AUXILIARY 4A SOLENOID 5. AUXILIARY 4B PLUG (LARGER), SEE TABLE 11 6. AUXILIARY 4B SOLENOID 7. PILOT PRESSURE TEST PORT WITH GAUGE

Figure 111. PPRV Pilot Pressure Test 5. Reconnect battery. Insert key into display and turn to ON position while sitting on seat. 6. Operate hydraulic system until oil temperature is at test specifications. See Table 10. 7. Shift MLM lever of test function and hold over relief. Check gauge reading when relief valve is open. Measure current flow to solenoid using DSC display. Compare to specifications. NOTE: The PPRV is not repairable except for cleaning or replacing solenoid valve.

NOTE: Step 3 is required warm up for service. This is to ensure that the fluid temperature is optimal for calibrations. 3. Activate tilt at relief pressure until the hydraulic fluid temperature is 50 to 65°C (122 to 149°F). NOTE: Perform Step 4 and Step 5 for hoist valve air bleed. This is required if the carriage moves slightly (approximately 25.4 mm (1 in.)) alternating between lifting and lowering. 4. Activate lift control from neutral to full lift and back to neutral at a rate of one to two times per second. Repeat until lift function is operating smoothly with not uncommanded mast movements. 5. Lift carriage to maximum height and run over hydraulic relief for 15 to 30 seconds. NOTE: Perform Step 6 for cylinder air bleed. This is required if the cylinders have not been previously cycled, or if the lift function is not operating smoothly. 6. Cycle function completely two or three times; repeat if necessary. It is not necessary to turn the lift truck ON or OFF if you are performing other procedures.

147

Position Sensor and OPS Check and Adjustment

2000 YRM 1334

Position Sensor and OPS Check and Adjustment POSITION SENSOR NOTE: The position sensors are calibrated to the lift trucks’s electronics and must be re-calibrated if they are removed or adjusted. 1. Check sensors to verify they are working properly. See Table 12 for correct wiring.

Table 12. Position Sensor Wiring Wire Color

Purpose

Red Wire

Input, 5 VDC

Black Wire

Ground

White Wire

Output

b. Measure pin length from solenoid as shown in Figure 112. c. Measure resistance across the connector terminals. (1)

Acceptable resistance: Ohms @ 25°C (77°F).

29.8 to 36.6

d. Power solenoid 10 times with 24VDC and verify pin retractions into solenoid. Plunger to be fully retracted into housing or protrude a maximum of 0.254 mm (0.01 in.) from housing. e. Replace solenoid if any of these measurements are out of specification.

a. With power supplied to the sensor, record sensor output voltages and compare to Table 13.

Table 13. Sensor Power Check Spool Position

Sensor Output

Neutral

2.5 ±0.3 volts

Spool In

0.5 ±0.1 volts

Spool Out

4.5 ±0.1 volts

b. If outputs are out of tolerance, replace position sensor and re-calibrate. See Calibration Procedure section in this manual.

(OPS) OPERATOR PRESENCE SOLENOID NOTE: The OPS is a simple on-off solenoid, and has no adjustments. With no power provided, the plunger is extended as shown in Figure 112. 1. Mark each connector and solenoid location prior to removal to aid in installation. a. Disconnect solenoid connector and remove solenoid from spool lock body.

148

A. EXTENDED PLUNGER

B. PIN LENGTH

Figure 112. Solenoid Measurements

MANUAL CONTROL VALVE RE-CALIBRATION 1. Removal and installation of position sensors require manual control valve to be re-calibrated. See Calibration Procedure section of this manual.

2000 YRM 1334

Calibration Procedure

Calibration Procedure CONTROL VALVE

16. While still holding the control lever, press Enter Key (*) when forks begin to creep in the B (raise) direction.

1. Turn key or keyless switch to ON position. 2. Lift forks approximately 25 cm (10 in.) ground.

off the

3. Center all auxiliary functions of the truck to allow for movement in both directions of each function. NOTE: Perform Step 4 through Step 6 if password option is enabled. 4. From the operator screen, on the display, scroll to the right one screen to the password entry screen.

17. The Display will repeat Step 11 through Step 16 for the remaining functions. (indicted by a non-zero setting for the maximum flow rate). 18. Display will transition back to Calibrations Maintenance Menu List. 19. E-Hydraulic calibration is complete. 20. Turn power OFF, wait 10 seconds, then turn power ON.

5. Enter password. 6. Press Enter Key (*) 7. From the operator screen, scroll to the right three times to the calibrations screen. See Figure 113. 8. Press Enter Key (*) 9. Scroll down once to the Valve Threshold Submenu. 10. Press Enter Key (*) 11. The display will prompt a hydraulic input for function 1 in the A (lower) direction until the forks begin to "creep". 12. Slowly move the function 1 control lever forward (lower). 13. While still holding the control lever, press Enter Key (*) when forks begin to creep in the A (lower) direction. 14. The display will prompt a hydraulic input for function 1 in the B (raise) direction until the forks begin to "creep".

Figure 113. Calibrations Screen

15. Slowly move the function 1 control lever backward (raise).

149

Torque Specifications

2000 YRM 1334

Torque Specifications for Lift Truck ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) MANUAL HYDRAULIC CONTROL VALVE Tie Rod Nuts 20.3 ± 1.4 N•m (179.7 ± 12.4 lbf in) Elbow Fitting, Inlet Section 16 N•m (142 lbf in) Primary Relief Valve 27 N•m (20 lbf ft) Manual Lowering Valve 26 N•m (19 lbf ft) Optional Work Port Relief Valve 26 N•m (19 lbf ft) Spool Lock Solenoid 7 N•m (62 lbf in) Steering Load Sense Fitting 16 N•m (142 lbf in) Plug, Inlet Section 45 N•m (33 lbf ft) Plug, Outlet Section 26 N•m (19 lbf ft) Position Sensor Capscrews 4.7 N•m (42 lbf in)

MANUAL CONTROL VALVE HANDLES AND LEVERS Outer Capscrews 1.35 to 1.65 N•m (11.9 to 14.6 lbf in)

E-HYDRAULIC CONTROL VALVE Tie Rod Nuts 20.3 ± 1.4 N•m (179.7 ± 12.4 lbf in)

150

Jam Nuts 7 to 11 N•m (62 to 97 lbf in) Elbow Fitting, Inlet Section 16 N•m (142 lbf in) Compensator Plug 47 N•m (35 lbf ft) Primary Relief Valve 27 N•m (20 lbf ft) Pilot Cartridge 65 N•m (48 lbf ft) Plug, Lift Section 27 N•m (20 lbf ft) Manual Lowering Valve 54 N•m (40 lbf ft) Port Option Plug, Tilt Section 54 N•m (40 lbf ft) Plug, Tilt Section 27 N•m (20 lbf ft) Optional Secondary Relief Valve 27 N•m (20 lbf ft) Steer Load Sense Fitting 16 N•m (142 lbf in) Solenoid 5 N•m (48 lbf in)

2000 YRM 1334

Torque Specifications

Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) MANUAL HYDRAULIC CONTROL VALVE Tie Rod Nuts 20.3 ± 1.4 N•m (179.7 ± 12.4 lbf in) Position Sensor Connector Nut 18 to 20 N•m (156 to 180 lbf in)

MANUAL CONTROL VALVE HANDLES AND LEVERS Outer Capscrews 1.36 to 1.65 N•m (11.9 to 14.6 lbf in)

MANUAL CONTROL VALVE COVERS

Steer Load Sense Fitting 16 N•m (142 lbf in)

Lower Cover Capscrews 2.82 to 3.16 N•m (24.95 to 27.97 lbf in)

Diagnostic Fitting 16 N•m (142 lbf in)

Front Cover Capscrews 2.82 to 3.16 N•m (24.95 to 27.97 lbf in)

Primary Relief Valve 27 N•m (20 lbf ft)

Rear Cover Capscrews 1.35 to 1.65 N•m (11.9 to 14.6 lbf in)

Compensator Plug 47 N•m (35 lbf ft)

E-HYDRAULIC CONTROL VALVE

Small Port Plugs, Inlet Section 13.5 N•m (119 lbf in)

Tie Rod Nuts 20.3 ± 1.4 N•m (179.7 ± 12.4 lbf in)

Medium Port Plugs, Inlet Section 65 N•m (48 lbf ft)

Connector Jam Nuts 7 to 11 N•m (62 to 97 lbf in)

Large Port Plugs, Inlet Section 60 to 72 N•m (44 to 53 lbf ft)

Solenoids 5 N•m (48 lbf in)

Manual Lowering Valve 54 N•m (40 lbf ft)

Pilot Cartridge 65 N•m (45 lbf ft)

Port Plug-Long, Lift Section 27 N•m (20 lbf ft)

Primary Relief Valve 27 N•m (20 lbf ft)

Port Plug-Short, Lift Section 54 N•m (40 lbf ft)

Elbow Fitting 16 N•m (142 lbf in)

Secondary Relief Valve 27 N•m (20 lbf ft)

Manual Lowering Valve 54 N•m (40 lbf ft)

Port Plugs, Auxiliary Section 14 N•m (124 lbf in)

Lift Section Plug 27 N•m (20 lbf ft)

Position Sensor Capscrews 4.7 N•m (42 lbf in)

Port Option Plug, Tilt Section 54 N•m (40 lbf ft)

OPS Solenoid 7.5 N•m (66 lbf in)

Optional Secondary Relief Cartridge 27 N•m (20 lbf ft) Tilt Section Plug 27 N•m (20 lbf ft)

151

152

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

2000 YRM 1334

4/11 (7/10)(2/10)(9/09)(4/09)(10/08)(8/08) Printed in U.S.A.

Maintenance

MAST REPAIR 2-, 3-, AND 4-STAGE HEAVY DUTY MASTS ERP16-20VF (ERP30-40VF) [A955]; ERP15-20VT (ERP030-040VT) [G807]; ESC030-40AC [B883]

PART NO. 524333799

4000 YRM 1405

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Mast Repair

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Safety Procedures When Working Near Mast ..................................................................................................... Fork Repair.......................................................................................................................................................... Remove ........................................................................................................................................................... Install............................................................................................................................................................... Checks ............................................................................................................................................................ Carriages Repair ................................................................................................................................................. Standard Carriage........................................................................................................................................... Remove....................................................................................................................................................... Clean and Inspect ....................................................................................................................................... Install .......................................................................................................................................................... Integral Sideshift Carriage............................................................................................................................... Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Clean and Inspect ....................................................................................................................................... Assemble .................................................................................................................................................... Install .......................................................................................................................................................... Two-Stage Mast With Limited Free-Lift Repair .................................................................................................... Remove ........................................................................................................................................................... Disassemble.................................................................................................................................................... Clean and Inspect ........................................................................................................................................... Assemble ........................................................................................................................................................ Install............................................................................................................................................................... Header Hose Installation and Adjustment....................................................................................................... Install .......................................................................................................................................................... Adjust .......................................................................................................................................................... Two-Stage Mast With Full Free-Lift Repair .......................................................................................................... Remove ........................................................................................................................................................... Disassemble.................................................................................................................................................... Clean and Inspect ........................................................................................................................................... Assemble ........................................................................................................................................................ Install............................................................................................................................................................... Header Hose Installation and Adjustment....................................................................................................... Install .......................................................................................................................................................... Adjust .......................................................................................................................................................... Three-Stage Mast With Full Free-Lift Repair ....................................................................................................... Remove ........................................................................................................................................................... Disassemble.................................................................................................................................................... Clean and Inspect ........................................................................................................................................... Assemble ........................................................................................................................................................ Install............................................................................................................................................................... Header Hose Installation and Adjustment....................................................................................................... Install .......................................................................................................................................................... Adjust .......................................................................................................................................................... Four-Stage Mast With Full Free-Lift Repair ......................................................................................................... Remove ........................................................................................................................................................... Disassemble.................................................................................................................................................... Clean and Inspect ........................................................................................................................................... Assemble ........................................................................................................................................................ Install............................................................................................................................................................... Header Hose Installation and Adjustment.......................................................................................................

1 1 4 4 4 5 6 6 6 9 9 10 10 13 14 14 16 17 17 23 25 26 27 28 28 33 34 34 41 44 46 47 48 48 55 56 56 61 65 67 68 69 69 75 77 77 80 84 85 86 87

Table of Contents

Mast Repair

TABLE OF CONTENTS (Continued) Lift Chains Adjustment......................................................................................................................................... Carriage Adjustments .......................................................................................................................................... Tilt Cylinders Adjustment..................................................................................................................................... Mast Adjustments ................................................................................................................................................ Load Roller, Adjust .......................................................................................................................................... Mast Side Kicking, Adjust................................................................................................................................ This section is for the following models: ERP16-20VF (ERP30-40VF) [A955]; ERP15-20VT (ERP030-040VT) [G807]; ESC030-40AC [B883]

91 93 93 94 94 96

4000 YRM 1405

Safety Procedures When Working Near Mast

General WARNING Before working on or near the mast, see the section Safety Procedures When Working Near Mast in this YRM. NOTE: Hoses have a service life that is determined by application and time. Install a new hose if the hose is worn, damaged, soft or hard, and no longer flexible. If necessary, make a comparison to a new hose that is the correct replacement for the hose you are inspecting.

This section has the repair procedures for the Two-Stage, Limited Free-Lift (LFL); Two-Stage, Full Free-Lift (FFL), Three-Stage, Full Free-Lift (FFL), and Four-Stage, Full Free-Lift (FFL) Heavy Duty mast and carriages. Procedures for adjusting the carriage, lift chains, mast, and tilt cylinders are located at the end of this manual.

WARNING Mast parts are heavy and can shift. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage. • Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed. Also make sure that the power is OFF and the key is removed. Put a DO NOT OPERATE tag in the operator’s compartment. Disconnect the battery and put a tag or lock on the battery connector. • Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury. • DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast. • Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in this section. WHEN WORKING NEAR THE MAST ALWAYS: • Lower the mast and carriage completely: Turn the key switch to the ON position and push the lift/lower control lever forward until there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered. OR

of the mast. Connect moving parts to a part that does not move. Follow these procedures: 1. Put mast in vertical position. 2. Raise mast to align bottom crossmember of mast upright that moves in outer mast with crossmember on outer mast. On the two-stage mast, the moving part is the inner mast. On the three-stage mast, it is the intermediate mast. On the four-stage mast, it is the first intermediate mast. See Figure 1 or Figure 2. 3. Use a 3/8-inch minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Put hook on back side of mast. Make sure hook is completely engaged with a link in the chain. Make sure safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast. 4. Lower mast until there is tension in safety chain and free-lift cylinder (full free-lift models) is completely retracted. NOTE: Apply the parking brake. After lowering or restraining the mast, shut off the power, and remove key. Put a DO NOT OPERATE tag in the operator’s compartment. Disconnect battery and put a tag or lock on battery connector. 5. Install another safety chain (9.5 mm (3/8 in.) minimum) between the top or bottom bar of the carriage (6) and a crossmember on the outer mast as a secondary safety device. Install a DO NOT REMOVE tag on the safety chain(s).

• If parts of the mast must be in a raised position, install a safety chain to restrain the moving parts

Safety Procedures When Working Near Mast

4000 YRM 1405

A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST

C. THREE-STAGE FFL MAST D. FOUR-STAGE FFL MAST

1. 2. 3. 4.

5. 6. 7. 8.

OUTER MAST INNER MAST INTERMEDIATE MAST HOOK

FREE-LIFT CYLINDER CARRIAGE BAR CROSSMEMBER FIRST INTERMEDIATE MAST

Figure 1. Safety Chaining the Mast (Sit-Down Lift Trucks)

4000 YRM 1405

Safety Procedures When Working Near Mast

NOTE: TWO-STAGE MASTS SHOWN. FOR THREE-STAGE MAST, ALIGN THE CROSSEMEMBER OF INTERMEDIATE WELDMENT ALONG WITH INNER AND OUTER WELDMENTS WHEN CHAINING THE MAST. A. LIMITED FREE-LIFT MAST

B. FULL FREE-LIFT MAST

1. SAFETY CHAIN AND HOOK 2. MAST CROSSMEMBERS ALIGNED 3. INNER WELDMENT

4. CARRIAGE (TOP BAR) 5. FREE-LIFT CYLINDER 6. OUTER WELDMENT

Figure 2. Safety Chaining the Mast (Stand-Up Lift Trucks)

Fork Repair

4000 YRM 1405

Fork Repair The forks are held on the carriage by hooks. The forks are kept in position by pins that fit through the top fork hooks and into slots in the top bar carriage. If pin does not remain engaged in carriage slot, replace with new pin. Always check that the pins for the forks keep the forks in position on the carriage. Replace damaged fork pin parts. The forks can be removed from the carriage by aligning the forks with the fork removal notch. The fork removal notch is in the bottom bar of the carriage. See Figure 3.

A fork can be removed from the carriage for replacement of the fork or other maintenance. Slide the fork to the fork removal notch in the bottom bar of the carriage. See Figure 3. Lower the fork onto blocks so the bottom hook of the fork moves through the fork removal notch. See Figure 4. Lower the carriage further so the top hook of the fork is disengaged from the top carriage bar. Move the carriage away from the fork or use a lifting device to move the fork away from the carriage.

INSTALL REMOVE

DO NOT try to remove a fork without a lifting device. Each hook fork for these lift trucks can weigh 45 to 115 kg (99 to 254 lb).

Move the fork and carriage so the top hook on the fork can engage the upper carriage bar. Raise the carriage to move the lower hook through the fork removal notch. Slide the fork on the carriage so both upper and lower hooks engage the carriage bars. Engage the latch pin with a notch in the upper carriage bar.

1. 2. 3. 4. 5.

6. 7. 8. 9. 10.

WARNING

LOAD BACKREST CARRIAGE FORKS FORK KNOB

WEDGE WASHER SPRING PIN FORK REMOVAL NOTCH

Figure 3. Carriage and Forks

4000 YRM 1405

Fork Repair

Table 1. Fork Tip Alignment (Continued) Fork Tip Alignment Specifications Standard Fork Lengths

1. CARRIAGE BARS 2. HOOK FORK

3. BLOCKS

Maximum Fork Tip Difference 1

(in.)

1219

(48)

(1.44)

1372

(54)

(1.62)

1524

(60)

(1.80)

1829

(72)

(2.16)

1Difference of alignment between fork tips must be no more than 3% of the total fork length.

Figure 4. Hook Fork Removal

CHECKS WARNING Never repair damaged forks by heating or welding. Forks are made of tempered steel using special procedures. Always replace damaged forks as a pair. Inspect the forks for cracks and wear. Check the alignment of the fork tips. The difference in height of the fork tips must be less than three percent of the length of the forks. See Table 1 and Figure 5. Some applications may require closer alignment. If the forks do not meet specification, they both must be replaced. Check that the bottom of each fork is not excessively worn. Check for smooth and proper operation of the fork lock pins. Repair or replace any damaged or broken fork lock pins or components and lubricate, as necessary. See Figure 3. Table 1. Fork Tip Alignment Fork Tip Alignment Specifications Standard Fork Lengths

Maximum Fork Tip Difference 1

(in.)

914

(36)

(1.08)

1067

(42)

(1.26)

A. HEEL OF FORK (MUST BE 90% OF DIMENSION B) B. ORIGINAL FORK THICKNESS (DIMENSION B) 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF FORK LENGTH) 2. CRACKS 3. MAXIMUM ANGLE 93 4. FORK REMOVAL NOTCH 5. CARRIAGE Figure 5. Fork Check

Carriages Repair

4000 YRM 1405

Carriages Repair STANDARD CARRIAGE

Remove

NOTE: The four-stage FFL mast covered in this section is used only on lift truck models ERP030-040VT (G807) and ESC030-40AC (B883).

1. Remove the forks. See Fork Repair. 2. Remove four socket head capscrews and remove the load backrest. See Figure 6.

NOTE: THREE-STAGE FFL CARRIAGE SHOWN. LOAD BACK REST MOUNTED THE SAME WAY ON TWOSTAGE FFL AND TWO-STAGE LFL CARRIAGES. MOUNTING OF LOAD BACK REST IS SIMILAR ON FOURSTAGE FFL MAST. 1. SOCKET HEAD CAPSCREW 2. WASHER 3. NUT

4. CARRIAGE 5. LOAD BACKREST Figure 6. Load Backrest Removal

4000 YRM 1405

Carriages Repair

3. Connect a lifting device to the carriage. Lift the carriage so that the lift chains become loose.

WARNING When disconnecting the lift chains, keep control of the ends. Use wire to temporarily connect the ends of the lift chains to the mast. This procedure will prevent the lift chains from falling and causing an injury or damage. 4. Remove the chain pin from each chain anchor at the carriage. See Figure 7 and Figure 8. Disconnect the lift chains from the carriage. Use wire to connect the ends of the lift chains to a part of the mast. Make sure the chains can move freely when the inner mast is raised.

5. Use the lift cylinders to raise the inner or intermediate mast. If the hydraulic system cannot be used, disconnect the lift cylinders from the inner or intermediate mast. See the section Cylinder Repair 2100 YRM 1382. Connect a crane [the capacity of the crane must be at least 681 kg (1501 lb), for two and three-stage mast and 1100 kg (2385 lb) for four-stage mast] to the top of the inner mast. Carefully raise the inner mast until it is above the load rollers of the carriage. Install safety chains to secure the mast in its extended position and disconnect the crane. See Safety Procedures When Working Near Mast. 6. Move lift truck away from the carriage. Completely lower the inner mast.

WARNING To help prevent possible injury, make sure the carriage is stable and will not fall over when the inner mast is raised above the load rollers of the carriage.

NOTE: THREE-STAGE FFL CARRIAGE SHOWN. TWO-STAGE LFL, AND TWO-STAGE FFL CARRIAGES ARE SIMILAR. 1. 2. 3. 4. 5.

SNAP RING ANCHOR PIN COTTER PIN CARRIAGE SPACER

6. 7. 8. 9. 10.

LOAD ROLLER SHIM STUBSHAFT CHAIN PIN CHAIN ANCHOR

Figure 7. Standard Carriage, Three-Stage FFL Mast

Carriages Repair

1. 2. 3. 4. 5. 6. 7. 8.

LOAD ROLLER MOUNT SHIM LOAD ROLLER SHIM RETAINING CAP CAPSCREW THRUST ROLLER LOCKWASHER

4000 YRM 1405

9. 10. 11. 12. 13. 14. 15.

CAPSCREW CHAIN ANCHOR ANCHOR PIN COTTER PIN JAM NUTS THIN JAM NUT THICK JAM NUT

Figure 8. Standard Carriage, Four-Stage FFL Mast

4000 YRM 1405

Clean and Inspect 1. If load rollers must be replaced, make a note of the location and number of the shims. Install the shims, load rollers, and snap rings. See Carriage Adjustments for correct adjustment of the load rollers.

Carriages Repair 4. Clean and inspect the chain anchors and chain anchor pins. See Figure 7 and Figure 8. Check chain anchors and anchor pins for wear and serviceability. Discard worn or unserviceable chain anchors and chain anchor pins. Discard cotter pins.

Install WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

WARNING Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

CAUTION DO NOT use cleaning solvent, compressed air, or steam to clean lift chain sheaves or load rollers. The bearings in the lift chain sheaves and load rollers are sealed and lubricated. Cleaning solvent, compressed air, and steam can damage the load roller bearings. 2. Clean any oil, grease, dirt, and other debris from the carriage frame. Use a cleaning solvent and compressed air to dry.

WARNING Improper welding procedures can damage the structure of the mast or cause incorrect function of the mast. Consult Resident Service Engineering through the Contact Management System before welding on the mast. 3. If the carriage bars have any protruding welds or damaged notches, repair by grinding, filing, or welding.

1. Connect a crane [the capacity of the crane must be at least 681 kg (1501 lb), for two and three-stage mast and 1100 kg (2385 lb) for four-stage mast] to the top of the inner mast. Carefully raise the inner mast until it is above the load rollers of the carriage. Install safety chains to secure the mast in its extended position and disconnect the crane. See Safety Procedures When Working Near Mast. 2. Move the lift truck toward the carriage until the inner mast is aligned with the carriage rollers. If the inner mast has been raised and secured using a crane and safety chains, connect the crane, raise the inner mast, and remove the safety chains. Carefully lower the inner mast until it engages all of the load rollers. Disconnect the crane, if attached, and reconnect the lift cylinders. See the section Cylinder Repair 2100 YRM 1382. 3. Check the clearance of the load rollers. See Carriage Adjustments in this section. NOTE: Use new cotter pins each time the chain pins are removed. 4. Connect the lift chains to the chain anchors at the carriage. Install new cotter pins in the chain pins. Adjust the lift chains as described in Carriage Adjustments in this section. 5. Install the load backrest on the carriage (see Figure 6). Tighten the socket head capscrews to 195 N•m (144 lbf ft). 6. Install the forks. See Fork Repair.

Carriages Repair

INTEGRAL SIDESHIFT CARRIAGE NOTE: The four-stage FFL mast covered in this section is used only on lift truck models ERP030-040VT (G807) and ESC030-40AC (B883).

Remove 1. Lower the carriage completely. Remove the forks. See Fork Repair for removal procedures. 2. Remove the four capscrews securing the load backrest to the carriage. See Figure 6. Remove the load backrest.

WARNING Before disconnecting the hydraulic hoses, relieve the pressure in the hydraulic system. Serious injury can occur if pressure is not relieved from hydraulic system prior to disconnecting hydraulic hoses. 3. Relieve hydraulic pressure to the sideshift cylinder by moving sideshift lever in both directions several times.

WARNING Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil. Thoroughly wash oil from exposed areas of skin as soon as possible. The hydraulic oil is hot at normal operating temperatures. Be careful when draining the oil. Never check for leaks by putting hands on hydraulic lines or components under pressure. Hydraulic oil under pressure can be injected into the skin.

4000 YRM 1405

CAUTION Protect the hydraulic system from dirt and contaminants when servicing the hydraulic system. NOTE: Tag hydraulic lines and fittings prior to disconnecting to aid in connecting during installation. 4. Disconnect hydraulic lines from sideshift cylinder. Put caps and plugs on open lines and cylinder ports. NOTE: Perform Step 5 for lift trucks equipped with two and three-stage FFL mast and two-stage LFL masts. 5. Remove four capscrews securing lower mounting hooks to outer frame. See Figure 9. NOTE: Perform Step 6 for lift trucks equipped with fourstage FFL mast. 6. Remove capscrews and lower retainers from bottom of outer frame. See Figure 10.

WARNING On integral sideshift carriage for four-stage FFL mast, the cylinder rod should be pushed in cylinder block before removing outer frame from inner frame to avoid injury to personnel. 7. Use a crane with a capacity of at least 450 kg (992 lb) to lift outer frame away from the inner frame (see Figure 11). Lay the outer frame flat on a pallet or workbench.

4000 YRM 1405

Carriages Repair

NOTE: TWO-STAGE LFL CARRIAGE SHOWN. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY FOR TWO AND THREE-STAGE FFL IS SIMILAR. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

CAPSCREW WASHER FORK REMOVAL NOTCH OUTER FRAME LOWER HOOK LUBE FITTING LOWER BEARING HAIRPIN CLEVIS PIN PIN UPPER BEARING

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

SNAP RING COTTER PIN CHAIN ANCHOR CHAIN ANCHOR MOUNTING BRACKET INNER FRAME STUBSHAFT SHIMS LOAD ROLLER SIDESHIFT CYLINDER SPACER

Figure 9. Integral Sideshift Carriage, Two and Three-Stage FFL Mast and Two-Stage LFL Mast

Carriages Repair

1. 2. 3. 4. 5. 6. 7. 8.

OUTER FRAME LUBE FITTING LOWER RETAINER CAPSCREW UPPER BEARING CYLINDER ROD INNER FRAME GLAND

4000 YRM 1405

9. 10. 11. 12. 13. 14. 15.

O-RING WIPER SEAL LOWER BEARING HYDRAULIC FITTING CYLINDER BLOCK LOAD ROLLER STUBSHAFT

Figure 10. Integral Sideshift Carriage, Four-Stage FFL Mast

4000 YRM 1405

Carriages Repair e. Remove and discard the seals and O-ring from each retainer with a brass O-ring tool. DO NOT scratch the grooves. NOTE: Perform Step 4 on lift trucks equipped with fourstage FFL mast. 4. Disassemble sideshift cylinder as follows: NOTE: When removing gland from cylinder block, do not scratch cylinder rod on cylinder block threads. a. Place suitable container under cylinder block. Loosen gland from cylinder block thread and let oil drain into container.

NOTE: OUTER FRAME FOR INTEGRAL SIDESHIFT CARRIAGE USED ON TWO AND THREE-STAGE FFL MAST AND TWO-STAGE LFL MASTS SHOWN. REMOVAL OF OUTER FRAME ON FOUR-STAGE FFL MAST THE SAME. 1. OUTER FRAME 2. LIFTING HOOK

3. LIFTING DEVICE

Figure 11. Remove Outer Frame

b. After oil has drained, remove gland from cylinder block. See Figure 10. c. Push gland all the way down cylinder rod and remove gland from cylinder rod. d. Remove O-ring, wiper, and seal from gland. Discard these parts after removal. See Figure 10. e. Perform above steps for other side of sideshift cylinder.

Disassemble 1. Remove the upper and lower bearings from the inner frame. See Figure 9 and Figure 10. 2. If damaged, remove lube fittings from outer frame. NOTE: Perform Step 3 for lift trucks equipped with two and three-stage FFL mast and two-stage LFL mast. 3. Remove two hairpins and two clevis pins from sideshift cylinder and remove cylinder from sideshift carriage. See Figure 9. Disassemble the sideshift cylinder as follows (see Figure 12): a. Clamp one end of the cylinder shell in a vise between the hydraulic fitting and the retainer on the same end. b. Unscrew the retainer from the cylinder. Slide the retainer off the cylinder rod. c. Clamp the other end of the cylinder shell in a vise between the hydraulic fitting and the retainer on the same end. d. Unscrew the retainer from the cylinder.

1. CYLINDER SHELL AND ROD 2. SEAL

3. O-RING 4. RETAINER 5. WIPER

Figure 12. Integral Sideshift Cylinder, Two and Three-Stage FFL Mast and Two-Stage LFL Mast

Carriages Repair

Clean and Inspect NOTE: Perform Step 1 on lift trucks equipped with two and three-stage FFL mast and two-stage LFL mast 1. Inspect the lower mounting hooks for wear. Replace the hooks if they are worn beyond the wear limit. The wear limit clearance range is 0.76 mm (0.03 in.) minimum and 1.52 mm (0.06 in.) maximum. See A in Figure 13.

4000 YRM 1405 a. If either upper bearing is worn to less than 2.5 mm (0.1 in.) thickness, replace upper bearings by driving the upper bearings from the inner frame. See Figure 14. To install new upper bearing, align the pins on the bottom side of bearing to notches on top carriage bar and slide into place on top carriage. See Figure 14. b. If either lower bearing is worn to less than 2.5 mm (0.1 in.) thickness, replace lower bearings by prying the lower bearings from the inner frame. See Figure 14. To install new lower bearing, align the circular pins on backside of lower bearing to holes on lower carriage bar and tap bearing into place on lower carriage bar using a rubber or brass hammer. See Figure 14.

WARNING Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM. B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.) MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM. Figure 13. Lower Mounting Hooks Wear Limit and Clearance Adjustment, Two and Three-Stage FFL Mast and Two-Stage LFL Mast

WARNING Improper welding procedures can damage the structure of the mast or cause incorrect function of the mast. Consult your Yale lift truck dealer for more information before welding on the mast. 2. Clean and inspect the carriage bars for damage and smoothness. Ensure the carriage bars are parallel and the ends are flush. If carriage bars have any protruding welds or damaged notches, repair by grinding, filing, or welding. 3. Clean the bearing areas. Inspect the sideshift bearings for wear as follows:

4. Inspect the sideshift cylinder. Replace the entire cylinder assembly if a cylinder rod is bent or scored or if there is damage on the outside of the cylinder shell that could impair performance or cause leaks under pressure. See Figure 12 and Figure 10. Clean the retainers, glands, and cylinder rods with cleaning solvent. 5. Inspect load rollers for wear and damage. If load rollers must be replaced, make a note of the location and number of the shims to ensure correct installation.

Assemble NOTE: Perform Step 1 and Step 2 on lift trucks equipped with two and three-stage FFL mast and two-stage LFL mast. 1. Assemble the sideshift cylinder as follows (see Figure 12): NOTE: If new retainers that are already assembled with seals and O-rings are being installed, proceed to Step b. a. Lubricate new O-rings and seals with clean hydraulic oil. Install the seals and O-rings into the

4000 YRM 1405

Carriages Repair

retainer grooves. Form the seals and O-rings into a "kidney" shape to ease placement into the groove. Note the direction of the seals. Pressure seals are installed with the lip toward the pressure side of the cylinder. b. Apply a film of hydraulic oil to the inside of the retainers. c. Clamp one end of the cylinder shell in a vise between the hydraulic fitting and the end. d. Screw the retainer into the cylinder. Tighten the retainer to 325 ±30 N•m (240 ±25 lbf ft).

Slide the retainer onto the cylinder rod. Screw the retainer into the cylinder. Tighten the retainer to 325 ±30 N•m (240 ±25 lbf ft).

NOTE: The pin, located on the top left side of the cylinder, looking from the front of the carriage, is for alignment purposes and to prevent the cylinder from rolling to the front or to the back. See Figure 9. 2. Install the sideshift cylinder onto the carriage with the pin in the up position. Install two clevis pins and two hairpins to secure sideshift cylinder to carriage.

e. Clamp the other end of the cylinder shell in a vise between the hydraulic fitting and the end.

NOTE: INTEGRAL SIDESHIFT CARRIAGE FOR TWO AND THREE-STAGE FFL MAST AND TWO-STAGE LFL MAST SHOWN. MEASUREMENT OF BEARINGS AND MINIMUM THICKNESS OF BEARINGS IS THE SAME ON FOUR-STAGE FFL MAST. ON FOUR-STAGE FFL MAST, GREASE IS APPLIED ON SAME SIDE OF LOWER BEARINGS AS SHOWN IN FIGURE 14. ALSO, SEE FIGURE 10. A. MINIMUM THICKNESS, 2.5 mm (0.1 in.) 1. LOWER BEARINGS 2. CARRIAGE BARS

3. UPPER BEARINGS

*BOLD ARROWS INDICATE WHICH SIDE TO APPLY GREASE. Figure 14. Checking Upper and Lower Bearings

Carriages Repair

4000 YRM 1405

NOTE: Perform Step 3 on lift trucks equipped with fourstage FFL mast.

lower hook clearance requires the upper bearings be fully seated.

3. Assemble the sideshift cylinder as follows (see Figure 10):

5. Apply a 1 mm (0.040 in.) layer of multipurpose grease to upper and lower bearing surfaces. Install the upper and lower bearings onto the inner frame. Bearings snap into place. See Figure 14.

a. Lubricate new O-rings with clean hydraulic oil. Install O-rings on threaded side of gland. NOTE: Form the seals and wipers into a "kidney" shape to ease placement into the groove. Note the direction of the seals and wipers. Pressure seals are installed with the lip toward the pressure side of the cylinder. b. Lubricate new seals and wipers with clean hydraulic oil. Install seals into second slot from non-threaded side of gland. Install wipers into first slot from non-threaded side of gland.

CAUTION To prevent damage to cylinder rod, DO NOT install assembled gland over tapered end of cylinder rod. c. Apply two drops of Loctite™ 277 on cylinder block thread. See Figure 10. Slide assembled gland over rounded end of cylinder rod and Install gland into cylinder block and tighten by hand until fully seated in cylinder block. d. Check gap between gland and cylinder block. Gap must not exceed 0.1 mm (.004 in.). If gap is not correct, inspect gland and replace if worn or damaged. See Parts Manual. e. Tighten gland 217 N•m (160 lbf ft). 4. If lube fittings were removed, install new lube fittings into outer frame. See Figure 9 and Figure 10. NOTE: Use a wood block or a plastic hammer to fully seat the upper bearings onto the inner frame. Proper

Install 1. Use a crane with a capacity of at least 450 kg (992 lb) to install the outer frame on the inner frame. NOTE: Perform Step 2 for lift trucks equipped with two and three-stage FFL mast and two-stage LFL mast. 2. Install the lower mounting hooks using four capscrews. Tighten to 165 ±15 N•m (120 ±12 lbf ft). For proper sideshift operation, make sure there is 0.76 to 1.52 mm (0.03 to 0.06 in.) clearance between the bottom of the hooks and the outer frame. See B in Figure 13. NOTE: Perform Step 3 for lift trucks equipped with fourstage FFL mast. 3. Apply Loctite™ 243 to capscrew holes on bottom of outer frame. Install lower retainers to bottom of outer frame using capscrews. See Figure 10. Tighten capscrews to 60 N•m (44 lbf ft). 4. Connect the hydraulic lines, as noted during removal, to the sideshift cylinder. 5. Install the backrest on the sideshift carriage. See Figure 6. Tighten the capscrews to 195 N•m (144 lbf ft). 6. Install the forks. See the section Fork Repair for the procedures.

4000 YRM 1405

Two-Stage Mast With Limited Free-Lift Repair

Two-Stage Mast With Limited Free-Lift Repair REMOVE WARNING The mast is heavy. The mast can weigh approximately 907 kg (2000 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. Serious injury can occur if the mast falls.

CAUTION Make sure all the mast weldments are fastened together. Make sure the safety chains will not damage the sheaves, tubing, or other parts of the mast. NOTE: If the mast needs to be disassembled, remove the forks and carriage. See the sections Fork Repair and Carriages Repair for procedures. If only the main lift cylinders or tilt cylinders need to be repaired, the mast does not need to be removed from the lift truck. See the section Cylinder Repair 2100 YRM 1382 for procedures. For header hose installation and adjustment, see the section Header Hose Installation and Adjustment. 1. Fully lower all mast weldments. Tilt the mast fully forward. Connect a crane or lifting device, with a capacity of at least 907 kg (2000 lb), to all top crossmembers of the mast weldments using chains to support the mast in an upright position when the tilt cylinders are disconnected. See the section Safety Procedures When Working Near Mast.

WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system has cooled. Completely lower forks to relieve hydraulic pressure before disconnecting any hoses.

CAUTION Protect the hydraulic system from dirt and contaminants when disconnecting hydraulic hoses from the mast. If hydraulic system becomes contaminated, damage to hydraulic system can occur.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 2. Position a drip pan with a capacity of 21 liter (22.5 qt) under the area of the hydraulic fittings. 3.

ERP16-20VF (ERP30-40VF) (A955) and ERP1520VT (ERP030-040VT) (G807) Models Only - Remove the floor mat. Lift the floor plate up enough to disconnect the electrical connectors from the accelerator pedal or Foot Directional Control pedal, and remove floor plate with accelerator pedal or Foot Directional Control still attached. See Figure 15.

4. ESC030-40AC (B883) Models Only - Remove the hydraulic compartment cover from the lift truck to access the mast hose connections. NOTE: Before disconnecting any hydraulic hoses, be sure to tag each hose with a letter: A and B for three function mast and A, B, C, and D for four function mast, to aid in reconnecting when installing the mast onto the lift truck. See Figure 18. 5. Before loosening or removing hose clamps, mark hoses using a paint pen or other permanent marking device. The marks are used to reinstall hoses in the correct position. See Figure 16. 6. Loosen hose clamp, located just below the brake pedal, so that hoses are able to move within the clamp without stretching. See Figure 16.

Two-Stage Mast With Limited Free-Lift Repair

Figure 15. Floor Plate and Accelerator Pedal, Remove

4000 YRM 1405

Two-Stage Mast With Limited Free-Lift Repair Legend for Figure 15

NOTE: FLOOR MAT REMOVED FOR CLARITY. STANDARD ACCELERATOR PEDAL IS SHOWN. PROCEDURES TO REMOVE FLOOR PLATE WITH A FOOT DIRECTIONAL CONTROL PEDAL ARE THE SAME. MODELS ERP1620VF (ERP30-40VF) (A955) AND ERP15-20VT (ERP030-040VT) (G807) ONLY. A. TOP VIEW

B. BOTTOM VIEW

1. 2. 3. 4.

5. 6. 7. 8.

CAPSCREW ACCELERATOR PEDAL FLOOR PLATE PEDAL BASE

ACCELERATOR PEDAL MOUNTING PLATE ACCELERATOR PEDAL POSITION SENSOR ELECTRICAL CONNECTORS NUTS

A. MARK HOSES HERE TO ENSURE HOSES ARE IN SAME POSITION WHEN TIGHTENING CLAMP. 1. HOSE CLAMP (LOWER CROSSMEMBER) 2. CAPSCREW 3. LEFT MAIN LIFT CYLINDER

4. RIGHT MAIN LIFT CYLINDER 5. HOSE CLAMP (BELOW BRAKE PEDAL)

Figure 16. Hose Marking

Two-Stage Mast With Limited Free-Lift Repair

WARNING Use a driver, NOT your fingers, to push the anchor pins from the clevises on the tilt cylinders. The cylinder or mast can move and cause serious injury.

1. 2. 3. 4.

TILT CYLINDER ROD END TILT CYLINDER SHELL SPECIAL WASHER LOCK WASHER EXTERNAL TOOTH

4000 YRM 1405 7. Remove the capscrew, special washer, lockwasher external tooth, and rod end pin from the tilt cylinder rod ends on the outer mast. Remove tilt cylinder rod ends from outer mast. See Figure 17.

5. CAPSCREW 6. GREASE FITTING 7. ROD END PIN

Figure 17. Tilt Cylinder Mounting

4000 YRM 1405

Two-Stage Mast With Limited Free-Lift Repair

8. Use lifting device and tilt the mast forward until there is enough space for access to the third and fourth function (if equipped) hose clamp and main lift supply hose connections. 9. Before loosening or removing hose clamps, mark hoses with a paint pen or other permanent marking device, so that hoses can be reinstalled in the correct position. See Figure 16. 10. Disconnect the third and fourth (if equipped) function hoses. See Figure 18. Remove the hose clamps from the lower crossmember. See Figure 16. 11. Disconnect the main lift supply hose. ure 18.

See Fig-

12. Move disconnected mast hoses underneath the mast. 13. Use the lifting device and move mast back into vertical position. NOTE: Make a note of each shim arrangement. The shim arrangement will be approximately the same during assembly. 14. Remove the bolts that hold the retainer caps to the mast mount stubshafts. Remove the shims and bushings. See Figure 20. NOTE: When placing mast on wooden beams, do not lay mast with main lift cylinders resting on wooden beams. 15. Use lifting device or crane to lift mast assembly from lift truck. Position the outer mast across wooden beams on the floor with the carriage side up. NOTE: BACK VIEW OF MAST SHOWN. A. HEADER HOSE B. HEADER HOSE

C. HEADER HOSE D. HEADER HOSE

1. FOURTH FUNCTION HOSE 2. LIFT CHAIN 3. CHAIN ANCHOR 4. THIRD FUNCTION HOSES

5. MAIN LIFT SUPPLY HOSE 6. LOWERING CONTROL VALVE 7. HOSE CONNECTIONS

Figure 18. Mast Hydraulic Hose Removal

Two-Stage Mast With Limited Free-Lift Repair

Figure 19. Two-Stage, Limited Free-Lift (LFL) Mast

4000 YRM 1405

Two-Stage Mast With Limited Free-Lift Repair Legend for Figure 19

A. HOSE SHEAVE ASSEMBLY

B. CHAIN SHEAVE ASSEMBLY

1. 2. 3. 4. 5. 6.

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

7. 8. 9. 10. 11. 12.

SNAP RING SHIM LOAD ROLLER INNER MAST LOWERING CONTROL VALVE LOWERING CONTROL VALVE MOUNTING BRACKET LOWERING CONTROL VALVE HOUSING SPRING AND LOWERING CONTROL VALVE WASHER RIGHT MAIN LIFT CYLINDER NUT WASHER SPACER

CAPSCREW OUTER MAST CHAIN ANCHOR COTTER PIN CHAIN ANCHOR PIN O-RING STRIP BEARING CHAIN SHEAVE BEARING LEFT MAIN LIFT CYLINDER HOSE GUARD STUBSHAFT HOSE SHEAVE SPECIAL WASHER

CAUTION Protect the hydraulic system from dirt and contaminants when servicing the hydraulic system. NOTE: If only the lift cylinders need to be removed and repaired, see Cylinder Repair 2100 YRM 1382 for procedures. For header hose installation and adjustment, see the section Header Hose Installation and Adjustment. 1. Clean the area around the hydraulic fittings for the lift cylinders. Remove the cylinder restraint brackets at the top of the outer mast. Disconnect the fittings at the lift cylinders and put caps on the open lines. See Figure 19. 2. Remove the header hoses, if equipped. 1. 2. 3. 4.

RETAINER CAP BOLTS SHIM BUSHING

5. MAST MOUNTING STUBSHAFT 6. GREASE FITTING

Figure 20. Mast Mounting

DISASSEMBLE WARNING Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil. Thoroughly wash oil from exposed areas of skin as soon as possible.

The hydraulic oil is hot at normal operating temperatures. Be careful when draining the oil.

Two-Stage Mast With Limited Free-Lift Repair

4000 YRM 1405 See Figure 22. Slide the inner mast weldment out of the outer mast weldment until the mast stub shafts of the inner mast weldment are in the notches of the outer channels. Remove the inner mast weldment from the outer mast weldment.

WARNING The mast weldments can slide when the mast is moved. A weldment that slides can cause serious injury. 4. Slide the inner mast weldment from the outer mast weldment approximately 30 cm (12 in.) to disengage the main lift cylinders from the inner mast weldment. Remove the main lift cylinders from the outer mast weldment.

10. Remove the hose and chain sheaves from inner mast and disassemble them as necessary for cleaning and repair. See Figure 19.

5. Remove the lowering control valve housing for the lowering control valve from the outer mast. NOTE: Make a note of each shim arrangement on load rollers. The shim arrangement will be approximately the same during assembly. 6. Remove the snap rings, shims, and load rollers from the bottom of the inner mast. See Figure 19.

WARNING Be careful when removing or installing snap rings on the load rollers. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection when removing and installing snap rings onto load rollers. 7. Remove snap rings, shims, and load rollers from top of outer mast. See Figure 19. 8. Remove strip bearings from top of outer mast. See Figure 21.

1. 2. 3. 4.

STRIP BEARING SHIMS TOP OF OUTER MAST O-RING Figure 21. Strip Bearings

WARNING The mast is heavy and can weigh approximately 907 kg (2000 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. NOTE: If the outer mast is being replaced, copy the part number and date code information from the old channel and stamp that information on the channel of the new outer mast with the letter R at the end to indicate that it has been replaced. 9. Slide the inner mast weldment halfway out of the top of the outer mast weldment. Connect a crane [the capacity of the crane must be at least 907 kg (2000 lb)] to the center of the inner mast weldment.

Figure 22. Mast Disassembly

4000 YRM 1405

Two-Stage Mast With Limited Free-Lift Repair

CLEAN AND INSPECT CAUTION DO NOT use steam or high-pressure water to clean the load rollers or the lift chains. Steam and highpressure water can remove the lubrication from the bearings in the load rollers. Water in the bearings of the sheaves and the link pins of chains can also shorten the service life of these parts. 1. Inspect chain sheaves and load rollers for wear or damage. DO NOT use steam to clean lift chain sheaves or load rollers. The bearings in the sheaves and load rollers are sealed and lubricated.

WARNING Cleaning solvents may be flammable and toxic and can cause severe skin irritation. When using commercial cleaning solvents, always comply with solvent manufacturer’s recommended safety precautions.

2. Clean the lift chains by soaking in solvent for 30 minutes to remove all dirt and grease. Hang lift chains up and remove solvent using compressed air.

WARNING Never replace only the worn section of a chain. Replace the complete chain. Never replace only one chain of a chain pair. Replace both chains. Damage to the lift truck and serious injury can occur if lift chains are not replaced correctly. NOTE: The chains must be inspected in the area of chain that passes over the chain sheave during the first portion of a lift. These links will show maximum wear. 3. Inspect the lift chains for wear and damage. A lift chain becomes longer when it is worn. If a chain is 3% longer than a new lift chain, the lift chain must be replaced. 4. If a chain scale is available, check lift chains as shown in Figure 23. If a chain scale is not available measure 20 links of chain. Measure from the center of a pin to the center of another pin 20 pitches away. Compare the length with the chart in Figure 23. Replace chain if the length of 20 links of the worn section is more than the maximum wear limit.

Figure 23. Lift Chains Check

Two-Stage Mast With Limited Free-Lift Repair

4000 YRM 1405

Legend for Figure 23 NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE. Pitch

12.7 15.9 19.1 25.4 1. 2. 3. 4.

mm mm mm mm

(0.5 (0.6 (0.8 (1.0

Total length of 20 links (pitch) of new chain in.) in.) in.) in.)

254.0 317.5 381.0 508.0

mm mm mm mm

WORN PIN CRACKS EDGE WEAR HOLE WEAR

5. Lubricate lift chains by soaking them in SAE 30 engine oil for 30 minutes. Hang chains over a drip pan for one hour to remove excess oil. 6. Inspect the chain anchors and chain anchor pins. Replace any parts that are worn or damaged.

WARNING Steam can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose your skin to steam. 7. Clean the mast weldments with steam or solvent.

WARNING Improper welding procedures can damage the structure of the mast or cause incorrect function of the mast which can result in serious injury to personnel. Consult your Yale lift truck dealer for more information before welding on the mast. 8. Inspect the sliding surfaces for wear or damage. Inspect the load roller contact surfaces for wear or damage. Inspect all welds for cracks. 9. Remove the bushings and shims from the stub shafts. See Figure 20. Inspect the bushings, shims

(10.0 (12.5 (15.0 (20.0 5. 6. 7. 8.

Wear Limit The maximum length of 20 links

in.) in.) in.) in.)

261.6 327.0 392.4 523.3

mm mm mm mm

(10.3 (12.9 (15.4 (20.6

in.) in.) in.) in.)

LOOSE LEAVES DAMAGED PIN RUST CHAIN WEAR SCALE and retainer caps for wear or damage. See the Parts Manual if any part needs to be replaced.

ASSEMBLE NOTE: When the mast has header hoses installed, see the procedures in the section Header Hose Installation and Adjustment. 1. Install snap rings, chain sheave and bearing onto stubshaft on top of inner mast. Apply thin coat of multipurpose grease with 2 to 4% molybdenum disulfide to hose sheave stubshafts. Install special washers, spacer, hose sheave, stubshaft weldment, washer, and capscrew. Tighten capscrew to 66 N•m (49 lbf ft). See Figure 19.

WARNING The mast is heavy. The mast can weigh approximately 907 kg (2000 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. 2. Connect a lifting device to the center of inner mast (see Figure 22). Fit the stub shafts through notches in the outer mast. Slide inner mast into the outer mast so stub shafts are seen at the top and bottom of the weldments. See Figure 19. NOTE: The shims for the load rollers keep the weldments parallel and provide correct clearance. During assembly, the location of the shims will be approximately the same as they were before disassembly. Check clearance and adjust shims for wear or changes

4000 YRM 1405 because of repairs. Strip bearings are also adjusted by using shims. 3. Install the strip bearings, O-rings, and the shims to top of outer mast. (see Figure 21.) Apply thin coat of multipurpose grease with 2 to 4% molybdenum disulfide to bearing surface. Check the clearance of the strip bearings as described in Mast Adjustments. 4. Install the load rollers, snap rings, and shims on both top of outer mast and bottom of inner mast. Check the clearance of the load rollers and strip bearings as described in Mast Adjustments. 5. Install lowering control valve and lowering control valve housing to the outer mast. Tighten nut to 18 N•m (159 lbf in). 6. To install the main lift cylinders, push the inner mast to engage the rods of the lift cylinders. Install shims, washers, and snap rings to top of main lift cylinders. 7. Install the capscrew, washers, spacer, and nut at the mount near the top of each main lift cylinder. Tighten capscrew to 40 N•m (29.5 lbf ft). Install the snap rings, washers, and shims from the top of each main lift cylinder. Connect the main lift chains at the chain anchors. See Figure 19.

INSTALL 1. Lubricate the bushings with chassis lube and install them onto the stub shafts at the bottom of the outer mast weldment. See Figure 20.

WARNING The mast is heavy. The mast can weigh approximately 907 kg (2000 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. Serious injury can occur if the mast falls. 2. Connect a lifting device to the top of the mast using chains. Make sure all mast uprights are fastened together. Make sure chains will not damaged chain sheaves, tubing, or other parts of the mast. 3.

ERP16-20VF (ERP30-40VF) (A955) and ERP1520VT (ERP030-040VT) (G807) Models Only - Use the lifting device and install the mast into the transmission housing mounts. Apply Loctite™ #242 adhesive sealant to bolt threads. Install the bolts, shims and retainer caps. Tighten the bolts in a diametric pattern to 24 N•m (18 lbf ft).

Two-Stage Mast With Limited Free-Lift Repair 4. ESC030-40AC (B883) Models Only - Use the lifting device and install the mast into the transmission housing mounts. Apply Loctite™ #290 adhesive sealant to bolt threads. Install the bolts, shims and retainer caps. Tighten the bolts in a diametric pattern to 35 N•m (26 lbf ft). NOTE: Use lifting device and tilt mast forward until there is enough space for access to the third, fourth and main lift supply hose connections. 5. Connect the main lift supply hose. See Figure 18. 6. Connect the third and fourth (if equipped) function hoses. Install hose clamps to lower crossmember. Be sure to match clamps to marks on hoses made during removal. See Figure 16. Tighten clamp socket head capscrews to 11 N•m (97 lbf in).

WARNING Use a pry bar, NOT your fingers, to align the tilt cylinder clevises with the outer mast. The tilt cylinder or mast can shift and cause serious injury. 7. Apply multipurpose grease with 2 to 4% molybdenum disulfide to rod end pin and connect tilt cylinders to mast using rod end pin, capscrew, special washer, and lockwasher external tooth. Tighten capscrews to 38 N•m (28 lbf ft). See Figure 17. 8. Make sure marks on hoses and edge of clamp match up as shown in Figure 16. Tighten hose clamp capscrews to 11 N•m (97 lbf in). 9.

ERP16-20VF (ERP30-40VF) (A955) and ERP15-20VT (ERP030-040VT) (G807) Models Only - Connect the accelerator pedal or Foot Directional Control pedal, and install floor plate and floor mat. See Figure 15.

Two-Stage Mast With Limited Free-Lift Repair NOTE: Before checking for mast side kicking, the mast must be fully assembled to include the carriage, forks, load backrest and any attachments if the lift truck is equipped with one. 13. Raise the mast, without a load to its full height and check for side kicking. Mast side kicking is where the mast, without a load, moves either to the right or left as it is being raised. If the mast is side kicking, see the Mast Adjustments section for procedures to correct mast side kicking. 14. Lubricate the sliding surfaces and load roller surfaces along the full length of the channels as shown in Figure 24. Apply lubricant only to surfaces indicated in Figure 24.

4000 YRM 1405

HEADER HOSE INSTALLATION AND ADJUSTMENT Install WARNING Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil. Thoroughly wash oil from exposed areas of skin as soon as possible.

WARNING Never check for leaks by putting hands on hydraulic lines or components under pressure. Hydraulic oil under pressure can be injected into the skin.

WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast in this section.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. Before installing the header hoses, make sure you know the lift height of the mast. The tension on the header hoses is adjusted according to lift height. The lift height is on the Nameplate of the lift truck and on the right side of the outer mast. NOTE: This procedure is for the four-function option. The three-function option will have hoses A and B only.

A. LOWER LOAD ROLLERS B. UPPER LOAD ROLLERS 1. LUBRICATE STRIP BEARING SURFACES 2. LUBRICATE LOAD ROLLER SURFACES 3. LOAD ROLLER Figure 24. Mast Lubrication

Legend for Figure 25 NOTE: REAR VIEW SHOWN. PARTS OF THE MAST AND CARRIAGE OMITTED FOR CLARITY. A. HOSE B. HOSE

C. HOSE D. HOSE

4000 YRM 1405

Two-Stage Mast With Limited Free-Lift Repair

Figure 25. Header Hose Alignment for Two-Stage Limited Free-Lift Mast

Two-Stage Mast With Limited Free-Lift Repair 2. Clamp the end of the hose (the smaller fitting) that attaches to the carriage in a vise (DO NOT clamp on the threads), and pull on the other end until the hose is straight. DO NOT apply enough force to stretch the hose. See Figure 26. NOTE: Dimension E is determined by the height of outer mast channel from the ground and the length

4000 YRM 1405 of outer mast channel. This mark will be used to pretension the header hoses during installation. See Figure 26 and Table 2. 3. Place a mark on all the hoses at dimension E. All measurements are made from the carriage end of the hose (the smaller fitting). See Figure 27.

Figure 26. Header Hose Measurement for Two-Stage Limited Free-Lift Mast

4000 YRM 1405

Two-Stage Mast With Limited Free-Lift Repair Legend for Figure 26

1. GROUND LEVEL 2. HOSE 3. VISE

4. TOP OUTER CHANNEL 5. BOTTOM OUTER CHANNEL

Table 2. Two-Stage Limited Free-Lift (LFL) Hose Dimensions Channel Length (Reference)

Lift Height

Dimension "E"

in.

3392

133.5

2090

2357

92.8

3892

153.2

2440

2702

106.4

4392

172.9

2690

2948

116.1

4892

192.6

3040

3293

129.6

4. Lift carriage off the ground approximately 76 mm (3 in.). Place blocks under carriage for support. 5. Install carriage brackets to carriage. Tighten capscrews to 18 N•m (13 lbf ft). See Figure 27. 6. Install hoses to the carriage brackets with the clamps and tighten capscrews to 18 N•m (13 lbf ft). See Figure 27. 7. Apply a thin coat of multipurpose grease with molybdenum disulfide to hose sheave stubshafts before installing hose sheaves. Place the hoses at the location of the hose sheave. 8. The sheave(s) and stub shafts must be assembled, and the hose(s) must be routed onto the sheave(s) before the hose(s) are attached to the mast. Tighten the hose clamp hardware to 8 N•m

(71 lbf in) and the sheave assembly capscrews to 66 N•m (49 lbf ft). See Figure 27. Install clamps to main lift cylinders. Tighten capscrews and nuts to 25 N•m (221 lbf in). 9. Put the clamps over the hoses and attach the clamps to the upper brackets. DO NOT tighten the hardware. NOTE: To make the alignment of dimension E easier, use a crane with a capacity of at least 907.2 kg (2000 lb) to raise the carriage high enough to install a safety chain. See Figure 28. 10. Align mark E at the bottom of the clamps. Tighten the hardware to 8 N•m (71 lbf in). Refer to Figure 27.

Two-Stage Mast With Limited Free-Lift Repair

Figure 27. Header Hoses for Two-Stage Limited Free-Lift Mast

4000 YRM 1405

Two-Stage Mast With Limited Free-Lift Repair Legend for Figure 27

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP 1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15.

SPECIAL WASHER SPACER HOSE SHEAVE STUBSHAFT LOCKWASHER CAPSCREW BAR SOCKET HEAD CAPSCREWS

1. HOOK

NUT HOSE BRACKET CLAMP HOSES CARRIAGE CARRIAGE BRACKET CARRIAGE BRACKET MOUNTING CAPSCREW

2. SHACKLE Figure 28. Chaining the Carriage (LFL)

11. Connect the header hoses to the truck hoses.

Adjust

12. Use the rubber clamps and hose clamps to attach the hoses to the main lift cylinders and just below the middle crossmember on the outer mast. DO NOT allow the hoses to stretch or fold while tilting the mast fully forward and backward.

When properly adjusted, the hoses will not be so tight that they compress when they pass over the sheaves, nor will they be so loose that they touch the load backrest or any crossmember that is next to a sheave.

13. With no load on the forks, check the header hose adjustment by operating the mast through the full lift cycle two times.

1. Cap off hoses when attachments have been removed. 2. Check that hoses and cables are routed properly.

Two-Stage Mast With Full Free-Lift Repair

4000 YRM 1405 push the hoses up (if too tight), half the width of the clamp 15.0 mm (0.6 in.). Retighten the hardware to 8 N•m (71 lbf in).

3. Slowly raise the main cylinders to take up slack in the lift chains. 4. Tighten strap clamps at the bracket weldment. 5. Cycle the mast a few times to ensure proper tracking of hoses. 6. Secure hose assemblies to main lift cylinders with hose clamp and screw clamp. 7. If the tension of the hoses is incorrect, loosen the clamps and pull the hoses down (if too loose) or

8. With no load on the forks, check the header hose adjustment by operating the mast through the full lift cycle two times. When properly adjusted, the hoses will not be so tight that they compress when they pass over the sheaves nor will they be so loose that they touch the load backrest or any crossmember that is next to a sheave. If necessary, repeat until the hoses are properly adjusted.

Two-Stage Mast With Full Free-Lift Repair REMOVE WARNING The mast is heavy. The mast can weigh approximately 907 kg (2000 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. Serious injury can occur if the mast falls.

CAUTION CAUTION Make sure all the mast weldments are fastened together. Make sure the safety chains will not damage the sheaves, tubing, or other parts of the mast. NOTE: If the mast needs to be disassembled, remove the forks and carriage. See the sections Fork Repair and Carriages Repair for procedures. If only the main lift cylinders, tilt cylinders, or free-lift cylinder needs to be repaired, the mast does not need to be removed from the lift truck. See the section Cylinder Repair 2100 YRM 1382 for procedures. For header hose installation and adjustment, see the section Header Hose Installation and Adjustment. 1. Fully lower all mast weldments. Tilt the mast fully forward. Connect a crane with a capacity of at least 907 kg (2000 lb) to all top crossmembers of the mast weldments using chains to support the mast in an upright position when the tilt cylinders are disconnected. See the section Safety Procedures When Working Near Mast.

Protect the hydraulic system from dirt and contaminants when disconnecting hydraulic hoses from the mast. If hydraulic system becomes contaminated, damage to hydraulic system can occur.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 2. Position a drip pan with a capacity of 21 liter (22.5 qt) under the area of the hydraulic fittings. 3.

4000 YRM 1405

Two-Stage Mast With Full Free-Lift Repair

Figure 29. Floor Plate and Accelerator Pedal, Remove

Two-Stage Mast With Full Free-Lift Repair

4000 YRM 1405 Legend for Figure 29

B. BOTTOM VIEW

1. 2. 3. 4.

5. 6. 7. 8.

CAPSCREW ACCELERATOR PEDAL FLOOR PLATE PEDAL BASE

4. ESC030-40AC (B883) Models Only - Remove the hydraulic compartment cover from the lift truck to access the mast hose connections. NOTE: Before disconnecting any hydraulic hoses, be sure to tag each hose with a letter: A and B for three function mast and A, B, C, and D for four function mast, to aid in reconnecting when installing the mast onto the lift truck. See Figure 32. 5. Before loosening or removing hose clamps, mark hoses using a paint pen or other permanent marking device. The marks are used to reinstall hoses in the correct position. See Figure 30. 6. Loosen hose clamp, located just below the brake pedal, so that hoses are able to move within the clamp. See Figure 30.

WARNING Use a driver, NOT your fingers, to push the anchor pins from the clevises on the tilt cylinders. The cylinder or mast can move and cause serious injury. 7. Remove the capscrew, special washer, external tooth lockwasher, and rod end pin from the tilt

ACCELERATOR PEDAL MOUNTING PLATE ACCELERATOR PEDAL POSITION SENSOR ELECTRICAL CONNECTORS NUTS cylinder rod ends on the outer mast. Remove tilt cylinder rod ends from outer mast. See Figure 31.

8. Use lifting device and tilt the mast forward until there is enough space for access to the third and fourth function (if equipped) header hose clamps and main lift supply hose connections. 9. Before loosening or removing hose clamps, mark hoses using a paint pen or other permanent marking device. The marks are used to reinstall hoses in the correct position. See Figure 30. 10. Disconnect the third and fourth (if equipped) function hoses. See Figure 32. Remove the hose clamps from the lower crossmember. See Figure 30. 11. Disconnect the main lift supply hose. ure 32.

See Fig-

12. Move disconnected mast hoses underneath the mast. 13. Use the lifting device and move mast back into vertical position.

4000 YRM 1405

Two-Stage Mast With Full Free-Lift Repair

A. MARK HOSES HERE TO ENSURE HOSES AND CLAMP ARE IN SAME POSITION WHEN TIGHTENING CLAMP. 1. HOSE CLAMP (LOWER CROSSMEMBER) 2. CAPSCREW 3. LEFT MAIN LIFT CYLINDER

4. RIGHT MAIN LIFT CYLINDER 5. HOSE CLAMP (BELOW BRAKE PEDAL)

Figure 30. Hose Marking

Two-Stage Mast With Full Free-Lift Repair

1. 2. 3. 4.

TILT CYLINDER ROD END TILT CYLINDER SHELL SPECIAL WASHER LOCK WASHER EXTERNAL TOOTH

4000 YRM 1405

5. CAPSCREW 6. GREASE FITTING 7. ROD END PIN

Figure 31. Tilt Cylinder Mounting

4000 YRM 1405

Two-Stage Mast With Full Free-Lift Repair Legend for Figure 32 NOTE: BACK VIEW OF MAST SHOWN. A. HEADER HOSE B. HEADER HOSE

C. HEADER HOSE D. HEADER HOSE

1. FOURTH FUNCTION HOSES 2. THIRD FUNCTION HOSES 3. LIFT CHAIN 4. CHAIN ANCHOR

5. FULL FREE-LIFT SUPPLY TUBE 6. MAIN LIFT SUPPLY HOSE 7. LOWERING CONTROL VALVE

Figure 32. Mast Hydraulic Hose Removal

Two-Stage Mast With Full Free-Lift Repair

4000 YRM 1405

NOTE: REAR VIEW FROM RIGHT SIDE SHOWN. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

CAPSCREW WASHER NUT FREE-LIFT CYLINDER BRACKET CHAIN GUARD BRACKET CROSSHEAD FREE-LIFT CHAIN FREE-LIFT CYLINDER VELOCITY FUSE FREE-LIFT SUPPLY TUBE SNAP RING SHIM LOAD ROLLER INNER MAST

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

LOWER CONTROL VALVE HOSE LOWERING CONTROL VALVE LOWERING CONTROL VALVE HOUSING NUT LOWERING CONTROL VALVE MOUNTING BRACKET RIGHT MAIN LIFT CYLINDER LEFT MAIN LIFT CYLINDER STRIP BEARING O-RING SHIM(S) SPACER OUTER MAST HYDRAULIC FITTING CHAIN ANCHOR

Figure 33. Two-Stage, Full Free-Lift (FFL) Mast

4000 YRM 1405

Two-Stage Mast With Full Free-Lift Repair

NOTE: Make a note of each shim arrangement. The shim arrangement will be approximately the same during assembly. 14. Remove the bolts that hold the retainer caps to the mast mount stubshafts. Remove the shims and bushings. See Figure 34. NOTE: When placing mast on wooden beams, do not lay mast with main lift cylinders resting on wooden beams. 15. Use lifting device or crane to lift mast assembly from lift truck. Position the outer mast across wooden beams on the floor with the carriage side up.

NOTE: If only the lift cylinders need to be removed and repaired, see Cylinder Repair 2100 YRM 1382 for procedures. For header hose installation and adjustment, see the section Header Hose Installation and Adjustment for procedures. 1. Clean the area around the hydraulic fittings for the lift cylinders. Disconnect the fittings at the main lift cylinders and put caps on the open lines. See Figure 33. 2. Disconnect and remove the chain and header hoses from the crosshead. Remove the free-lift cylinder brackets and disconnect the free-lift supply tube for the free-lift cylinder. See Figure 33. Remove free-lift cylinder.

1. 2. 3. 4.

RETAINER CAP BOLTS SHIM BUSHING

5. MAST MOUNTING STUBSHAFT 6. GREASE FITTING

Figure 34. Mast Mounting

CAUTION Protect the hydraulic system from dirt and contaminants when servicing the hydraulic system.

4. Disconnect the FFL supply tube and remove the hydraulic fitting from the top of the right main lift cylinder. See Figure 35. Remove the snap rings, washers, and shims from the top of the right main lift cylinder.

WARNING The mast weldments can slide when the mast is moved. A weldment that slides can cause serious injury. 5. Slide the inner mast weldment from the outer mast weldment approximately 30 cm (12 in.) to disengage the main lift cylinders from the inner mast weldment. Remove the spacers, nuts, and bolts at the bottom mounts for the main lift cylinders on the outer mast. Remove the main lift cylinders from the outer mast weldment. 6. Remove the lowering control valve housing for the lowering control valve (see Figure 35) from the outer mast.

Two-Stage Mast With Full Free-Lift Repair

Figure 35. Main Lift Cylinders and Lowering Control Valve

4000 YRM 1405

Two-Stage Mast With Full Free-Lift Repair Legend for Figure 35

1. 2. 3. 4. 5. 6. 7. 8. 9.

LEFT MAIN LIFT CYLINDER RIGHT MAIN LIFT CYLINDER HYDRAULIC FITTING SNAP RING WASHER SHIMS CAPSCREW SPACER NUT

WARNING Be careful when removing or installing snap rings on the load rollers. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection when removing and installing snap rings onto load rollers. NOTE: Make a note of each shim on load rollers. The shim arrangement will be approximately the same during assembly. 7. Remove snap rings, shims and load rollers from bottom of inner mast and top of outer mast. See Figure 33. 8. Remove strip bearings from top of outer mast.

10. 11. 12. 13. 14. 15. 16. 17.

FILL SCREW SEAL LOWERING CONTROL VALVE LOWERING CONTROL VALVE HOUSING HYDRAULIC FITTING HOSE ASSEMBLY SPRING WASHER

WARNING The mast is heavy. The mast can weigh approximately 907 kg (2000 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. NOTE: If the outer mast is being replaced, copy the part number and date code information from the old channel and stamp that information on the channel of the new outer mast with the letter R at the end to indicate that it has been replaced. 9. Slide the inner mast half way out of the top of the outer mast. Connect a lifting device to the center of the inner mast. See Figure 37. 10. Slide the inner mast out of the outer mast until the mast stub shafts of the inner mast are in the notches of the outer channels. Remove the inner mast from the outer mast. 11. Remove the hose and chain sheaves from mast, and the fourth function mini rollers (if equipped), and disassemble them as necessary for cleaning and repair. See Figure 33 and Figure 38.

1. 2. 3. 4.

STRIP BEARING SHIMS TOP OF OUTER MAST O-RING

Figure 37. Mast Disassembly

Figure 36. Strip Bearings

Two-Stage Mast With Full Free-Lift Repair

1. 2. 3. 4.

CAPSCREW LEFT HEADER HOSE ROLLER BRACKET MINI ROLLERS SPACER

4000 YRM 1405

5. 6. 7. 8.

NUT FREE-LIFT CYLINDER FREE-LIFT CHAIN RIGHT HEADER HOSE ROLLER BRACKET

Figure 38. Fourth Function Mini Rollers Removal

CLEAN AND INSPECT CAUTION DO NOT use steam or high-pressure water to clean the load rollers or the lift chains. Steam and highpressure water can remove the lubrication from the bearings in the load rollers. Water in the bearings of the sheaves and the link pins of chains can also shorten the service life of these parts. 1. Inspect chain and hose sheaves and load rollers for wear or damage. DO NOT use steam to clean chain and hose sheaves or load rollers. The bearings in the sheaves and load rollers are sealed and lubricated.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 2. Clean the lift chain by soaking in solvent for 30 minutes to remove all dirt and grease. Hang lift chain up and remove solvent using compressed air.

4000 YRM 1405

Two-Stage Mast With Full Free-Lift Repair

Never replace only the worn section of a chain. Replace the complete chain. Never replace only one chain of a chain pair. Replace both chains. Damage to the lift truck and serious injury can occur if lift chains are not replaced correctly.

4. If a chain scale is available, check lift chains as shown in Figure 39. If a chain scale is not available measure 20 links of chain. Measure from the center of a pin to the center of another pin 20 pitches away. Compare the length with the chart in Figure 39. Replace chain if the length of 20 links of the worn section is more than the maximum wear limit.

NOTE: The chain must be inspected in the area of chain that passes over the chain sheave during the first portion of a lift. These links will show maximum wear.

5. Lubricate lift chain by soaking it in SAE 30 engine oil for 30 minutes. Hang chain over a drip pan for one hour to remove excess oil.

3. Inspect the lift chains for wear and damage. A lift chain becomes longer when it is worn. If a chain is 3% longer than a new lift chain, the lift chain must be replaced.

6. Inspect the chain anchor and pin. Replace any parts that are worn or damaged.

WARNING

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE. Pitch

12.7 15.9 19.1 25.4 1. 2. 3. 4.

mm mm mm mm

WORN PIN CRACKS EDGE WEAR HOLE WEAR

(0.5 (0.6 (0.8 (1.0

Total length of 20 links (pitch) of new chain in.) in.) in.) in.)

254.0 317.5 381.0 508.0

mm mm mm mm

(10.0 (12.5 (15.0 (20.0 5. 6. 7. 8.

in.) in.) in.) in.)

Wear Limit The maximum length of 20 links 261.6 327.0 392.4 523.3

mm mm mm mm

(10.3 (12.9 (15.4 (20.6

in.) in.) in.) in.)

LOOSE LEAVES DAMAGED PIN RUST CHAIN WEAR SCALE

Figure 39. Lift Chains Check

Two-Stage Mast With Full Free-Lift Repair

WARNING Steam can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose your skin to steam. 7. Clean the mast weldments with steam or solvent.

WARNING Improper welding procedures can damage the structure of the mast or cause incorrect function of the mast which can result in serious injury to personnel. Contact Resident Service Engineering through the Contact Management System before welding on the mast. 8. Inspect the sliding surfaces for wear or damage. Inspect the load roller contact surfaces for wear or damage. Inspect all welds for cracks. 9. Remove the bushings and shims from the stub shafts. Inspect the bushings, shims and retainer caps for wear or damage. See the Parts Manual if any part needs to be replaced. 10. If lift truck is equipped with a four function mast, Inspect header hose roller brackets and mini rollers, for wear and damage. See Figure 38. Replace any parts that are worn or damaged. If the fourth function mini rollers need to be lubricated, see the section Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15-20VT (ERP030-040VT) (G807), Periodic Maintenance 8000 YRM 1373 for lift truck models ERP16-20VF (ERP30-40VF) (A955), or Periodic Maintenance 8000 YRM 1418 for lift truck models ESC030-40AC (B883) for lubrication procedures.

ASSEMBLE 1. Install the hose and chain sheaves to free-lift cylinder crosshead. If mast is equipped with a fourth function, install the fourth function mini rollers and header hose brackets to free-lift cylinder crosshead using capscrews, spacers, and nuts. See Figure 38.

4000 YRM 1405

WARNING The mast is heavy. The mast can weigh approximately 907 kg (2000 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. NOTE: For header hose installation and adjustment procedures, see the section Header Hose Installation and Adjustment. 2. Connect a lifting device to the center of inner mast (see Figure 37). Fit stubshafts through notches in the outer mast. Slide inner mast into the outer mast so stub shafts are seen at the top and bottom of the weldments. See Figure 33. NOTE: The shims for the load rollers keep the weldments parallel and provide correct clearance. During assembly, the location of the shims will be approximately the same as they were before disassembly. Check clearance and adjust shims for wear or for changes because of repairs. Strip bearings are also adjusted by using shims. See the section Mast Adjustments for the instructions to make the necessary adjustments. 3. Apply multipurpose grease with 2-4% molybdenum disulfide to strip bearing surface. Install the strip bearings, shims, and O-rings to top of outer mast (see Figure 36). Check the clearance of the strip bearing as described in Mast Adjustments. 4. Install the load rollers, shims, and snap rings to bottom of inner mast and top of outer mast. Check the clearance of the load rollers and strip bearings as described in the section Mast Adjustments. 5. Install main lift cylinders in mounts on bottom of outer mast. Install shims, washers, and snap ring at the top of right main lift cylinder. See Figure 33 and Figure 35. 6. Install shims at the top of the left main lift cylinder. Push the inner mast to engage the rods of the main lift cylinders. Check the clearance at the top of the main lift cylinder mounts. Add or remove shims at the left main lift cylinder until it is even with the right main lift cylinder. Install washer and snap ring at the top of left main lift cylinder. Install the hydraulic fitting on the right main lift cylinder. See Figure 33 and Figure 35. 7. Install spacers, nuts, and bolts at the bottom mounts for the main lift cylinders. Tighten bolts to 40 N•m (30 lbf ft).

4000 YRM 1405 8. Install the lowering control valve housing and lowering control valve to outer mast. Tighten capscrews and nuts to 18 N•m (159 lbf in). Install the washer and spring to left hydraulic fitting (see Figure 35). Connect left and right hydraulic fittings to bottom of main lift cylinders. 9. Install the free-lift cylinder in the mounts on the inner mast. Install the free-lift cylinder guard brackets for the cylinder and tighten the capscrews to 53 N•m (39 lbf ft). See Figure 33. 10. Connect the free-lift supply tube. Connect the freelift chains to chain anchors at he crosshead. Attach a wire between the end of the lift chain and the bottom of the mast to control the lift chain during installation.

INSTALL 1. Lubricate the bushings with chassis lube and install them onto the stub shafts at the bottom of the outer mast weldment. See Figure 34.

WARNING The mast is heavy. The mast can weigh approximately 907 kg (2000 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. Serious injury can occur if the mast falls. 2. Connect a lifting device to the top of the mast using chains. Make sure all mast uprights are fastened together. Make sure lift chain will not damaged chain sheaves, tubing, or other parts of the mast. 3.

Two-Stage Mast With Full Free-Lift Repair 6. Connect the main lift supply hose. See Figure 32. 7. Connect the third and fourth (if equipped) hoses. Install hose clamps to lower crossmember. Be sure to match clamps to marks on hoses made during removal. See Figure 30. Tighten clamp socket head capscrews to 11 N•m (97 lbf in).

WARNING Use a pry bar, NOT your fingers, to align the tilt cylinder clevises with the outer mast. The tilt cylinder or mast can shift and cause serious injury. 8. Apply multipurpose grease with 2-4% molybdenum disulfide to rod end pin and connect tilt cylinders to mast using rod end pin, capscrew, special washer, and external tooth lockwasher. Tighten capscrews to 38 N•m (28 lbf ft). See Figure 33. 9.

ERP16-20VF (ERP30-40VF) (A955) and ERP15-20VT (ERP030-040VT) (G807) Models Only - Connect the accelerator pedal or the Foot Directional Control pedal, and install floor plate and floor mat. See Figure 29.

10. ESC030-40AC (B883) Models Only - Install the hydraulic compartment cover to the lift truck as removed. 11. Install the carriage as described in Carriages Repair and install the forks as shown in the section Fork Repair. 12. Check the tilt cylinder adjustment. See the section Cylinder Repair 2100 YRM 1382 for procedures. Operate the mast and check for leaks and check to ensure mast is operating correctly. Check lift chains as described in the section Lift Chains Adjustment. NOTE: Before checking for mast side kicking, the mast must be fully assembled to include the carriage, forks, load backrest and any attachments if the lift truck is equipped with one. 13. Raise the mast, without a load to its full height and check for side kicking. Mast side kicking is where the mast, without a load, moves either to the right or left as it is being raised. If the mast is side kicking, see the Mast Adjustments section for procedures to correct mast side kicking. 14. Lubricate the sliding surfaces and load roller surfaces along the full length of the channels as shown in Figure 40. Apply lubricant only to surfaces indicated in Figure 40.

Two-Stage Mast With Full Free-Lift Repair

4000 YRM 1405

WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast in this section.

WARNING Never check for leaks by putting hands on hydraulic lines or components under pressure. Hydraulic oil under pressure can be injected into the skin.

NOTE: The carriage height must be correct before the header hoses can be adjusted. See Lift Chains Adjustment for the carriage adjustment procedure. 1. Mark each hose with a single letter: A, B, C, and D. See Figure 41 and Figure 42. NOTE: Dimensions E and G is determined by the height of outer mast channel from the ground and the length of outer mast channel. These marks will be used to pretension the header hoses during installation. See Figure 43, Table 3, and Table 4. 2. Clamp the end of the hose (the smaller fitting) that attaches to the carriage in a vise (DO NOT clamp on the threads), and pull on the other end until the hose is straight. DO NOT apply enough force to stretch the hose. See Figure 43. 3. Place a mark on all the hoses at dimensions E and G. All measurements are made from the carriage end of the hose (the smaller fitting). See Figure 43.

4000 YRM 1405

Two-Stage Mast With Full Free-Lift Repair

Figure 41. Header Hose Alignment for Two-Stage Full Free-Lift Mast

Two-Stage Mast With Full Free-Lift Repair

4000 YRM 1405 Legend for Figure 41

NOTE: REAR VIEW SHOWN. PARTS OF THE MAST AND CARRIAGE OMITTED FOR CLARITY. FOUR FUNCTION MAST SHOWN. A. HEADER HOSE B. HEADER HOSE

C. HEADER HOSE D. HEADER HOSE

NOTE: VIEW FROM FRONT OF MAST SHOWN. A. HEADER HOSE B. HEADER HOSE C. HEADER HOSE

D. HEADER HOSE E. THREE AND FOUR FUNCTION SHOWN F. THREE FUNCTION ONLY SHOWN

1. CAPSCREW 2. NUT 3. SPACER

4. BRACKET 5. HOSE SHEAVE

Figure 42. Header Hose Alignment, Free-Lift Cylinder, for Two-Stage Full Free-Lift Mast

4000 YRM 1405

Two-Stage Mast With Full Free-Lift Repair

Figure 43. Header Hose Measurement For Two-Stage Full Free-Lift Mast

Two-Stage Mast With Full Free-Lift Repair

4000 YRM 1405 Legend for Figure 43

1. GROUND LEVEL 2. HOSE 3. VISE

4. TOP OUTER CHANNEL 5. BOTTOM OUTER CHANNEL

Table 3. Two-Stage Full Free-Lift (FFL) Hose Dimensions, Three Function Mast

Lift Height

Channel Length (Reference)

Dimension "E"

Dimension "G" Hose A

Dimension "G" Hose B

in.

3178

125.1

1990

1391

54.7

3074

121.0

2954

116.2

3678

144.8

2240

1638

64.4

3571

140.5

3450

135.8

4298

169.2

2590

1982

78.0

4265

167.9

4145

163.1

Table 4. Two-Stage Full Free-Lift (FFL) Hose Dimensions, Four Function Mast

Lift Height

Channel Length (Reference)

Dimension "E"

Dimension "G" Hose C

Dimension "G" Hose D

in.

3178

125.1

1990

251

9.9

1934

76.1

1814

71.4

3678

144.8

2240

300

11.8

2233

87.9

2113

83.2

4298

169.2

2590

251

9.9

2534

99.7

2414

95.0

NOTE: When determining hose dimensions for four function mast, also include information found in Table 3. 4. Install bracket (item #21 in Figure 44) onto free-lift cylinder with clamp. 5. Install channel on free-lift cylinder and left main lift cylinder with clamps. See Figure 44. 6. Install brackets to carriage with capscrew. Tighten capscrews to 19 N•m (168 lbf in). Attach the hoses and fittings to the carriage bracket with clamps and nuts. See Figure 45.

7. Chain the carriage up so that there is slack on the free-lift chain. See Figure 46. Remove free-lift chain guard from free-lift cylinder crosshead. NOTE: Add a thin coat of multipurpose grease to shaft before installing hose sheaves. 8. Install hose sheaves onto crosshead using crosshead pin. install hoses onto hose sheaves. Install free-lift chain guard to free-lift cylinder crosshead. See Figure 42.

4000 YRM 1405

Two-Stage Mast With Full Free-Lift Repair

Figure 44. Header Hoses for Two-Stage Full Free-Lift Mast

Two-Stage Mast With Full Free-Lift Repair

4000 YRM 1405 Legend for Figure 44

A. ALIGN MARK G AT TOP OF THIS CLAMP.

B. ALIGN MARK E AT BOTTOM OF THIS CLAMP.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

CHANNEL CAPSCREW NUT BRACKET CHAIN ANCHOR STRAP CLAMP LEFT MAIN LIFT CYLINDER CLAMP FITTING TUBE CLAMP ASSEMBLY

HOSE GUARD SPACER CHAIN HEADER HOSES COWL HOSES RIGHT MAIN LIFT CYLINDER FULL FREE-LIFT CYLINDER FULL FREE-LIFT BRACKET CHAIN SHEAVE BRACKET HOSE SHEAVES Legend for Figure 45

NOTE: COMPONENTS OMITTED FOR CLARITY. 1. 2. 3. 4. 5.

CARRIAGE BRACKETS CAPSCREW FITTING NUT CHAIN ANCHOR

Figure 45. Hose Attachment To Carriage

Figure 46. Chaining the Carriage (FFL)

4000 YRM 1405

Two-Stage Mast With Full Free-Lift Repair Legend for Figure 46

1. HOOK

2. SHACKLE

NOTE: To make the alignment of dimension E easier, use a crane with a capacity at least 907.2 kg (2000 lb) to raise the carriage high enough to install a safety chain. See Figure 46.

5. Cycle the mast a few times to ensure proper tracking of hoses.

9. Align mark E at the bottom of the clamp. Tighten the hardware to 9 N•m (80 lbf in). 10. Apply a spray lubricant on the hoses in the area that will contact the channels. Make sure the hoses are properly aligned in the channels. Put the clamps over the hoses and attach the clamps to the channels. Tighten the hardware to 8 N•m (71 lbf in). 11. Connect the header hoses (C and D) to the cowl hoses. Connect the header hoses (A and B) to the tubes. See Figure 44 and Figure 41. 12. Use the rubber clamps and strap clamps to attach the hoses to the main lift cylinders. DO NOT allow the cowl hoses to stretch or fold while tilting the mast fully forward and backward.

Adjust When properly adjusted, the hoses will not be so tight that they compress when they pass over the sheaves, nor will they be so loose that they touch the load backrest or any crossmember that is next to a sheave. 1. Cap off hoses when attachments have been removed. 2. Check that hoses and cables are routed properly. 3. Slowly raise the free-lift and main cylinders to take up slack in the lift chains.

6. Secure hose assemblies to main lift cylinders with hose clamp and screw clamp. NOTE: If the hose tension between the carriage and the clamp at the free-lift bracket is correct, go to Step 7. If the hose tension between the carriage and the clamp at the free-lift bracket is incorrect, loosen the clamps and pull (if the hoses are loose) or push (if the hoses are tight) on the hoses so they move 15.0 mm (0.6 in.) side to side. Tighten the hardware to 8 N•m (71 lbf in). NOTE: If the hose tension between the clamp at the upper bracket and the clamp at the free-lift bracket is correct, go to Step 8. 7. If the tension of the hoses is incorrect, loosen the clamps and pull the hoses down (if too loose) or push the hoses up (if too tight) so they can move 15.0 mm (0.6 in.) side to side. Retighten the hardware to 9 N•m (80 lbf in). 8. With no load on the forks, check the header hose adjustment by operating the mast through the full lift cycle two times. When properly adjusted, the hoses will not be so tight that they compress when they pass over the sheaves nor will they be so loose that they touch the load backrest or any crossmember that is next to a sheave. If necessary, repeat until the hoses are properly adjusted. See Table 3 and Table 4.

4. Tighten strap clamps at the bracket weldment.

Three-Stage Mast With Full Free-Lift Repair

4000 YRM 1405

Three-Stage Mast With Full Free-Lift Repair REMOVE

CAUTION

Protect the hydraulic system from dirt and contaminants when disconnecting hydraulic hoses from the mast. If hydraulic system becomes contaminated, damage to hydraulic system can occur.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

CAUTION Make sure all the mast weldments are fastened together. Make sure the safety chains will not damage the sheaves, tubing, or other parts of the mast. NOTE: If the mast needs to be disassembled, remove the forks and carriage. See the sections Fork Repair and Carriages Repair for procedures. If only the main lift cylinders, tilt cylinders, or free-lift cylinder need to be repaired, the mast does not need to be removed from the lift truck. See the section Cylinder Repair 2100 YRM 1382 for procedures. For header hose installation and adjustment procedures, see the section Header Hose Installation and Adjustment. 1. Fully lower all mast weldments. Tilt the mast fully forward. Connect a crane with a capacity of at least 907 kg (2000 lb) to all top crossmembers of the mast weldments using chains to support the mast in an upright position when the tilt cylinders are disconnected. See the section Safety Procedures When Working Near Mast.

2. Position a drip pan with a capacity of 21 liter (22.5 qt) under the area of the hydraulic fittings. 3.

4. ESC030-40AC (B883) Models Only - Remove the hydraulic compartment cover from the lift truck to access the mast hose connections. NOTE: Before disconnecting any hydraulic hoses, be sure to tag each hose with a letter: A and B for three function mast and A, B, C, and D for four function mast, to aid in reconnecting when installing the mast onto the lift truck. See Figure 50. 5. Before loosening or removing hose clamps, mark hoses using a paint pen or other permanent marking device. The marks are used to reinstall hoses in the correct position. See Figure 48. 6. Loosen hose clamp, located just below the brake pedal, so that hoses are able to move within the clamp without stretching. See Figure 48.

Legend for Figure 47 NOTE: FLOOR MAT REMOVED FOR CLARITY. STANDARD ACCELERATOR PEDAL IS SHOWN. PROCEDURES TO REMOVE FLOOR PLATE WITH A FOOT DIRECTIONAL CONTROL PEDAL ARE THE SAME. MODELSERP1620VF (ERP30-40VF) (A955) AND ERP15-20VT (ERP030-040VT) (G807) ONLY. A. TOP VIEW

B. BOTTOM VIEW

1. 2. 3. 4.

5. 6. 7. 8.

CAPSCREW ACCELERATOR PEDAL FLOOR PLATE PEDAL BASE

ACCELERATOR PEDAL MOUNTING PLATE ACCELERATOR PEDAL POSITION SENSOR ELECTRICAL CONNECTORS NUTS

4000 YRM 1405

Three-Stage Mast With Full Free-Lift Repair

Figure 47. Floor Plate and Accelerator Pedal, Remove

Three-Stage Mast With Full Free-Lift Repair

4000 YRM 1405

A. MARK HOSES HERE TO ENSURE HOSES AND CLAMP ARE IN SAME POSITION WHEN TIGHTENING CLAMP. 1. HOSE CLAMP 2. CAPSCREW

3. LEFT MAIN LIFT CYLINDER 4. RIGHT MAIN LIFT CYLINDER Figure 48. Hose Marking

4000 YRM 1405

Three-Stage Mast With Full Free-Lift Repair

NOTE: TWO-STAGE FFL MAST SHOWN. TILT CYLINDER ARRANGEMENT IS THE SAME ON TWO-STAGE LFL AND THREE-STAGE FFL MASTS. 1. 2. 3. 4.

TILT CYLINDER ROD END TILT CYLINDER SHELL SPECIAL WASHER LOCK WASHER EXTERNAL TOOTH

5. CAPSCREW 6. GREASE FITTING 7. ROD END PIN

Figure 49. Tilt Cylinder Mounting 10. Disconnect the third and fourth (if equipped) function hoses. See Figure 50. Remove the hose clamps from the lower crossmember. See Figure 48.

11. Disconnect the main lift supply hose. ure 50.

See Fig-

12. Move disconnected hoses underneath the mast.

Three-Stage Mast With Full Free-Lift Repair

Figure 50. Mast Hydraulic Hose Removal

4000 YRM 1405

Three-Stage Mast With Full Free-Lift Repair Legend for Figure 50

NOTE: BACK VIEW OF MAST SHOWN. A. HEADER HOSE B. HEADER HOSE

C. HEADER HOSE D. HEADER HOSE

1. 2. 3. 4.

5. THIRD FUNCTION HOSES 6. MAIN LIFT SUPPLY HOSE 7. LOWERING CONTROL VALVE

FOURTH FUNCTION HOSES LIFT CHAIN CHAIN ANCHOR FREE-LIFT SUPPLY TUBE

13. Use the lifting device and move mast into vertical position. NOTE: Make a note of each shim arrangement. The shim arrangement will be approximately the same during assembly. 14. Remove the bolts that hold the retainer caps to the mast mount stubshafts. Remove the shims and bushings. See Figure 51. NOTE: When placing mast on wooden beams, do not lay mast with main lift cylinders resting on wooden beams. 15. Use lifting device or crane to lift mast assembly from lift truck. Position the outer mast across wooden beams on the floor with the carriage side up.

CAUTION Protect the hydraulic system from dirt and contaminants when servicing the hydraulic system. NOTE: If only the main lift cylinders, tilt cylinders, or free-lift cylinder need to be repaired, the mast does not need to be removed from the lift truck. See the section Cylinder Repair 2100 YRM 1382 for procedures. For header hose installation and adjustment procedures, see the section Header Hose Installation and Adjustment. 1. Clean the area around the hydraulic fittings for the main lift cylinders. Disconnect the fittings at the main lift cylinders and put caps on the open lines. Disconnect the free-lift chains from the chain anchor. See Figure 52. 2. Remove the header hoses.

1. 2. 3. 4.

RETAINER CAP BOLTS SHIM BUSHING

5. MAST MOUNTING STUBSHAFT 6. GREASE FITTING

3. Disconnect and remove the free-lift supply tube. Remove the free-lift cylinder guard brackets. Remove free-lift cylinder from mast. If lift truck is equipped with a four function mast, remove header hose roller brackets and mini rollers (see Figure 53) and remove the hose and chain sheaves from free-lift cylinder and disassemble them as necessary for cleaning, inspection, and repair.

Figure 51. Mast Mounting

Three-Stage Mast With Full Free-Lift Repair

Figure 52. Three-Stage, Full Free-Lift (FFL) Mast

4000 YRM 1405

Three-Stage Mast With Full Free-Lift Repair Legend for Figure 52

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

OUTER MAST LOAD ROLLER SHIM SNAP RING WASHER RIGHT MAIN LIFT CYLINDER COTTER PIN CHAIN ANCHOR PIN NUT SPACER LEFT MAIN LIFT CYLINDER CAPSCREW STRIP BEARING BALL BEARING CHAIN SHEAVE HOSE SHEAVE STUBSHAFT BAR

1. 2. 3. 4.

CAPSCREW LEFT HEADER HOSE ROLLER BRACKET MINI ROLLERS SPACER

24. 25. 26. 27. 28. 29. 30. 31. 32. 33.

INTERMEDIATE MAST FREE-LIFT SUPPLY TUBE LOWERING CONTROL VALVE LOWERING CONTROL VALVE SPRING AND WASHER LOWERING CONTROL VALVE MOUNTING BRACKET BOTTOM CROSSMEMBER CHAIN ANCHOR MIDDLE CROSSMEMBER CROSSHEAD PIN FREE-LIFT CYLINDER GUARD BRACKET CHAIN GUARD HOSE BRACKET FREE-LIFT CHAIN FREE-LIFT CYLINDER INNER MAST

5. 6. 7. 8.

NUT FREE-LIFT CYLINDER FREE-LIFT CHAIN RIGHT HEADER HOSE ROLLER BRACKET

19. 20. 21. 22. 23.

Figure 53. Fourth Function Mini Rollers Removal

Three-Stage Mast With Full Free-Lift Repair

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. 4. Disconnect the main lift chains from the chain anchors near the top of the main lift cylinders. Disconnect the other end of the main lift chains at the bottom of the inner mast. Push the inner mast towards the bottom of the mast assembly until the bottom load rollers can be seen. 5. Remove the lowering control valve housing for the lowering control valve from the outer mast. 6. Remove strip bearings from top of intermediate mast. See Figure 54.

4000 YRM 1405 rollers, shims, and snap rings at the top of the intermediate mast. Make note of each shim arrangement and load roller location. The shim arrangement will be approximately the same during assembly. See Figure 52.

WARNING The mast is heavy and can weigh approximately 907 kg (2000 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. 8. Slide the inner mast halfway out of the top of the intermediate mast. Connect a crane with a capacity of at least 907 kg (2000 lb) to the center of the inner mast. See Figure 55. Slide the inner mast out of the intermediate mast until the stubshafts are in the notches of the intermediate mast. Remove the inner mast from the intermediate mast.

WARNING Be careful when removing or installing snap rings on the load rollers. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection when removing and installing snap rings onto load rollers. 9. Remove snap rings, shims, and washers from the top of the main lift cylinders. See Figure 52. 10. Remove the nut, capscrew, washer, and spacer at the mount near the top of each main lift cylinder. See Figure 52.

1. 2. 3. 4.

STRIP BEARING SHIMS TOP OF OUTER MAST O-RING Figure 54. Strip Bearings

WARNING The mast weldments can slide when the mast is moved. A weldment that slides can cause serious injury. 7. Remove the load rollers, shims, and snap rings at the bottom of the inner mast. Remove the load

Figure 55. Mast Disassembly

4000 YRM 1405 11. Push the intermediate mast to disengage the main lift cylinders. Remove main lift cylinders. NOTE: If the outer mast is being replaced, copy the part number and date code information from the old channel and stamp that information on the channel of the new outer mast with the letter R at the end to indicate that it has been replaced. 12. Slide the intermediate mast halfway out of the top of the outer mast. Connect a crane [the capacity of the crane must be at least 907 kg (2000 lb)] to the center of the intermediate mast weldment. See Figure 55. Slide the intermediate mast weldment out of the outer mast weldment until the mast stubshafts of the inner mast weldment are in the notches of the outer channels. Remove the intermediate mast weldment from the outer mast weldment. 13. Remove the hose and chain sheaves from intermediate mast and disassemble them as necessary for cleaning and repair. See Figure 52.

Three-Stage Mast With Full Free-Lift Repair

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 2. Clean the lift chains by soaking in solvent for 30 minutes to remove all dirt and grease. Hang lift chains up and remove solvent using compressed air.

WARNING Never replace only the worn section of a chain. Replace the complete chain. Never replace only one chain of a chain pair. Replace both chains. Damage to the lift truck and serious injury can occur if lift chains are not replaced correctly. NOTE: The chains must be inspected in the area of chain that passes over the chain sheave during the first portion of a lift. These links will show maximum wear. 3. Inspect the lift chains for wear and damage. A lift chain becomes longer when it is worn. If a chain is 3% longer than a new lift chain, the lift chain must be replaced. 4. If a chain scale is available, check lift chains as shown in Figure 56. If a chain scale is not available measure 20 links of chain. Measure from the center of a pin to the center of another pin 20 pitches away. Compare the length with the chart in Figure 56. Replace chain if the length of 20 links of the worn section is more than the maximum wear limit. 5. Lubricate lift chains by soaking them in SAE 30 engine oil for 30 minutes. Hang chains over a drip pan for one hour to remove excess oil. 6. Inspect the chain anchors and pins. Replace any parts that are worn or damaged.

Three-Stage Mast With Full Free-Lift Repair

4000 YRM 1405

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE. Pitch

12.7 15.9 19.1 25.4 1. 2. 3. 4.

mm mm mm mm

(0.5 (0.6 (0.8 (1.0

Total length of 20 links (pitch) of new chain in.) in.) in.) in.)

254.0 317.5 381.0 508.0

mm mm mm mm

WORN PIN CRACKS EDGE WEAR HOLE WEAR

(10.0 (12.5 (15.0 (20.0 5. 6. 7. 8.

Wear Limit The maximum length of 20 links

in.) in.) in.) in.)

261.6 327.0 392.4 523.3

mm mm mm mm

(10.3 (12.9 (15.4 (20.6

in.) in.) in.) in.)

LOOSE LEAVES DAMAGED PIN RUST CHAIN WEAR SCALE

Figure 56. Lift Chains Check

WARNING Steam can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose your skin to steam. 7. Clean the mast weldments with steam or solvent.

4000 YRM 1405

Three-Stage Mast With Full Free-Lift Repair strip bearings and the shims on the channels of the outer mast. See Figure 57. Check the clearance of the strip bearings as described in Mast Adjustments.

and retainer caps for wear or damage. See the Parts Manual if any part needs to be replaced. 10. If lift truck is equipped with a four function mast, Inspect header hose roller brackets and mini rollers, for wear and damage. See Figure 53. Replace any parts that are worn or damaged. If the fourth function mini rollers need to be lubricated, see the section Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15-20VT (ERP030-040VT) (G807), Periodic Maintenance 8000 YRM 1373 for lift truck models ERP16-20VF (ERP30-40VF) (A955), or Periodic Maintenance 8000 YRM 1418 for lift truck models ESC030-40AC (B883) for lubrication procedures.

ASSEMBLE WARNING The mast is heavy. The mast can weigh approximately 907 kg (2000 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. Serious injury can occur if mast falls. NOTE: The shims for the load rollers keep the weldments parallel and provide correct clearance. During assembly, the shim arrangement will be approximately the same as before disassembly. Check the clearance and adjust the shims for wear or for changes caused by repairs. The strip bearings are also adjusted by using shims. See the section Mast Adjustments for the adjustment procedures.

4. Install the load rollers and the shims on the outer mast and at the bottom of the intermediate mast. Before doing Step 5, adjust the intermediate mast and check the clearance of the load rollers as described in Mast Adjustments. NOTE: The clearance check and adjustment in Step 5 is only and initial setup. The final check and adjustment is done after the mast is installed on the lift truck. 5. Install the main lift cylinders. Push the intermediate mast to engage the main lift cylinders. Check the clearance at the top of the main lift cylinder mounts. Add or remove shims at the top of the cylinder rods until they are even. Install the snap rings and washers at the top of the main lift cylinders. See Figure 52. 6. Install the lowering control valve housing and lowering control valve to outer mast. Tighten nut to 18 N•m (159 lbf in). Connect the hydraulic lines and fittings between the housing and main lift cylinders.

NOTE: When the mast has header hoses installed, see the procedures in the section Header Hose Installation and Adjustment. 1. Install the hose and chain sheaves to intermediate mast. 2. Put the outer mast on the floor with the carriage side up. Connect a crane with a capacity of at least 907 kg (2000 lb) to the center of the intermediate mast weldment. Fit the lower stub shafts of the intermediate mast into the notches in the top of the outer mast. Slide the intermediate mast into the outer mast so that the stub shafts are seen at the top and bottom of both weldments. NOTE: The load rollers must be in place before strip bearing can be shimmed.

1. 2. 3. 4.

STRIP BEARING SHIM TOP OF OUTER MAST O-RING Figure 57. Strip Bearings

3. Apply multipurpose grease with 2 to 4% molybdenum disulfide to the bearing surfaces and install the

Three-Stage Mast With Full Free-Lift Repair 7. Install the snap rings, washers, nuts, and capscrews at the mounts for the main lift cylinders. Tighten capscrews to 53 N•m (39 lbf ft). 8. Connect a crane with a capacity of at least 907 kg (2000 lb) to the center of the inner mast weldment. Slide inner mast into intermediate mast so the stubshafts are seen at the top and bottom. NOTE: The load rollers must be in place before strip bearings can be shimmed. 9. Install the strip bearings and the shims on the channels of the intermediate mast. Apply thin coat of multipurpose grease with 2 to 4% molybdenum disulfide to bearing surface. Install the load rollers and the shims on the intermediate and inner masts. Before doing Step 10, adjust the inner mast as described in Mast Adjustments. 10. Connect the main lift chains to the chain anchors at the main lift cylinder mounts. Put lift chains over the chain sheaves and connect them to the anchors at the bottom of the inner mast. NOTE: The nuts for the free-lift cylinder guard are installed on the bracket side of the free-lift cylinder. 11. Install the free-lift cylinder in the mounts on the inner mast. Install the free-lift cylinder guards for the free-lift cylinder. Tighten capscrews and nuts to 53 N•m (39 lbf ft). 12. Install the hose sheaves for the free-lift cylinder. Tighten capscrew for hose sheave to 66 N•m (49 lbf ft). If mast is equipped with a fourth function, install mini rollers and header hose roller brackets to free-lift cylinder. See Figure 53. Install the hydraulic hose and free-lift supply tube. 13. Connect the free-lift chains to the chain anchors at the crosshead. Attach a wire between the end of the lift chain and the bottom of the mast to control the lift chain during mast installation.

INSTALL 1. Lubricate the bushings with chassis lube and install them onto the stub shafts at the bottom of the outer mast weldment. See Figure 51.

4000 YRM 1405

WARNING The mast is heavy. The mast can weigh approximately 907 kg (2000 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. Serious injury can occur if the mast falls. 2. Connect a lifting device to the top of the mast using chains. Make sure all mast uprights are fastened together. Make sure chains will not damage chain sheaves, tubing, or other parts of the mast. 3.

4. ESC030-40AC (B883) Models Only - Use the lifting device and install the mast into the transmission housing mounts. Apply Loctite™ #290 adhesive sealant to bolt threads. Install the bolts, shims and retainer caps. Tighten the bolts in a diametric pattern to 35 N•m (26 lbf ft). 5. Use lifting device and tilt mast forward until there is enough space for access to the third, fourth, and main lift supply hose connections. 6. Connect the third and fourth (if equipped) hoses. Install hose clamps to lower crossmember. Be sure to match clamps to marks on hoses made during removal. See Figure 48. Tighten clamp socket head capscrews to 11 N•m (97 lbf in).

WARNING Use a pry bar, NOT your fingers, to align the tilt cylinder clevises with the outer mast. The tilt cylinder or mast can shift and cause serious injury. 7. Apply multipurpose grease with 2 to 4% molybdenum disulfide to rod end pin and connect tilt cylinders to mast using rod end pin, capscrew, special washer, and external tooth lockwasher. Tighten capscrews to 38 N•m (28 lbf ft). See Figure 49.

4000 YRM 1405 8.

ERP16-20VF (ERP30-40VF) (A955) and ERP1520VT (ERP030-040VT) (G807) - Connect the accelerator pedal or Foot Directional Control pedal, and install floor plate and floor mat. See Figure 48.

9. ESC030-40AC (B883) Models Only - Install the hydraulic compartment cover to the lift truck as removed. 10. Install the carriage as described in Carriages Repair and install the forks as shown in the section Fork Repair. 11. Check the tilt cylinder adjustment. See the section Cylinder Repair 2100 YRM 1382 for procedures. Operate the mast and check for leaks and to ensure mast is operating correctly. Check lift chains as described in the section Lift Chains Adjustment.

Three-Stage Mast With Full Free-Lift Repair Legend for Figure 58 A. LOWER LOAD ROLLERS B. UPPER LOAD ROLLERS 1. LUBRICATE STRIP BEARING SURFACES 2. LUBRICATE LOAD ROLLER SURFACES 3. LOAD ROLLER 13. Lubricate the sliding surfaces and load roller surfaces along the full length of the channels as shown in Figure 58. Apply lubricant only to surfaces indicated in Figure 58.

HEADER HOSE INSTALLATION AND ADJUSTMENT Install WARNING

NOTE: Before checking for mast side kicking, the mast must be fully assembled to include the carriage, forks, load backrest and any attachments if the lift truck is equipped with one.

Before working on or near the mast, see Safety Procedures When Working Near Mast in this section.

12. Raise the mast, without a load to its full height and check for side kicking. Mast side kicking is where the mast, without a load, moves either to the right or left as it is being raised. If the mast is side kicking, see the Mast Adjustments section for procedures to correct mast side kicking.

NOTE: The carriage height must be correct before the header hoses can be adjusted. See Lift Chains Adjustment for the carriage adjustment procedure.

NOTE: This procedure is for the four-function option. The three-function option will have hoses A and B only.

1. Mark each hose with a single letter: A, B, C, and D. See Figure 59 and Figure 60. 2. Dimensions E and G are determined by the height of the outer mast channel from the ground and the length of the outer mast channel. See Figure 61, Table 5, and Table 6 for dimensions E and G.

Figure 58. Mast Lubrication

Three-Stage Mast With Full Free-Lift Repair

Figure 59. Header Hose Alignment for Three-Stage Full Free-Lift Mast

4000 YRM 1405

Three-Stage Mast With Full Free-Lift Repair Legend for Figure 59

A. HEADER HOSE A B. HEADER HOSE B

C. HEADER HOSE C D. HEADER HOSE D

NOTE: FRONT VIEW OF MAST SHOWN. A. HEADER HOSE B. HEADER HOSE C. HEADER HOSE

D. HEADER HOSE E. THREE AND FOUR FUNCTION SHOWN F. THREE FUNCTION ONLY SHOWN

1. CAPSCREW 2. NUT 3. SPACER

4. BRACKET 5. HOSE SHEAVE Figure 60. Header Hose Alignment, Free-Lift Cylinder

Three-Stage Mast With Full Free-Lift Repair

Figure 61. Header Hose Measurement for Three-Stage Full Free-Lift Mast

4000 YRM 1405

Three-Stage Mast With Full Free-Lift Repair Legend for Figure 61

1. GROUND LEVEL 2. BOTTOM OUTER CHANNEL 3. VISE

4. TOP OUTER CHANNEL 5. HOSE

Table 5. Three-Stage Full Free-Lift (FFL) Hose Dimensions, Three Function Mast

Lift Height

Channel Length (Reference)

Dimension "E" Third Function

Dimension "G" Third Function Hose A

Dimension "G" Third Function Hose B

in.

4260

167.7

1840

1244

3440

135

3491

137

4560

179.5

1940

1342

3637

143

3688

145

4860

191.3

2040

1441

3834

151

3885

153

5160

203.1

2190

1588

4130

163

4181

165

5460

215.0

2290

1687

4327

170

4378

172

Table 6. Three-Stage Full Free-Lift (FFL) Hose Dimensions, Four Function Mast

Lift Height

Channel Length (Reference)

Dimension "E" Fourth Function

Dimension "G" Fourth Function Hose C

Dimension "G" Fourth Function Hose D

in.

4260

167.7

1840

202

2450

2398

4560

179.5

1940

202

2548

100

2497

4860

191.3

2040

300

2745

108

2694

106

5160

203.1

2190

251

2844

112

2792

110

5460

215.0

2290

350

3041

120

2989

118

3. Clamp the end of the hose (the smaller fitting) that attaches to the carriage in a vise (DO NOT clamp on the threads), and pull on the other end until the hose is straight. DO NOT apply enough force to stretch the hose. NOTE: These marks will be used to pretension the header hose during installation. 4. Place a mark on all the hoses at dimensions E and G (all measurements are made from the carriage end of the hose [the smaller fitting]). See Figure 61, Table 5, and Table 6.

5. Install hose guides to bottom of inner mast. Tighten capscrews to 48 N•m (35 lbf ft). Apply small amount of multipurpose grease to bottom of hose guide. 6. Install bracket to full free-lift cylinder. Attach bracket with clamp. 7. Install carriage brackets to carriage. Tighten capscrews to 19 N•m (168 lbf in). Install hoses and fittings to carriage brackets. See Figure 62.

Three-Stage Mast With Full Free-Lift Repair

4000 YRM 1405 NOTE: Add a thin coat of multipurpose grease to shaft before installing hose sheaves. 9. Install hose sheaves onto crosshead using crosshead pin. install hoses onto hose sheaves. Install free-lift chain guard to free-lift cylinder crosshead. 10. Attach the hoses to the carriage bracket with clamps. Apply spray lubricant to the surface of the hose guide that contacts the hoses.

1. CARRIAGE BRACKETS 2. CAPSCREW 3. FITTING

4. NUT 5. CHAIN ANCHOR 6. CHAIN

Figure 62. Carriage Brackets and Hose Attachment 8. Chain the carriage up so that there is slack on the free-lift chain. See Figure 63. Remove free-lift chain guard from free-lift cylinder crosshead.

1. HOOK

11. Place the hoses over the top of the free-lift chains and under the hose guides. Attach the hose guides to the lower crossmember and tighten the mounting hardware to 33 N•m (24 lbf ft). Make sure the bracket is between the crossmember and the hose guide. Put the clamps over the hoses and attach the clamps to the free-lift bracket. DO NOT tighten the hardware. See Figure 59 and Figure 60. NOTE: To make the alignment of dimension E easier, use a crane with a capacity of at least 907.2 kg (2000 lb) to raise the carriage high enough to attach a safety chain. See Figure 63.

2. SHACKLE Figure 63. Chaining the Carriage (FFL)

4000 YRM 1405 12. Align the mark for dimension E at the bottom of the clamp to create the proper hose tension. See Figure 64. Tighten the hardware to 8 N•m (71 lbf in). Install the hose guards. Tighten the capscrews that mount the guards to 18 N•m (13 lbf ft). 13. Position the hoses at the hose sheave. The hose sheave and stub shaft must be installed on the hose before they are attached to the mast. Tighten the hardware to 66 N•m (49 lbf ft). 14. Put the clamps over the hoses and attach the clamps to the upper brackets. DO NOT tighten the hardware. NOTE: To make the alignment of dimension G easier, use a crane to raise the inner channel high enough to install a safety chain. 15. Align mark G on hoses A and D at the bottom edge of clamp to create the proper tension. Align mark G on hoses B and C at the top edge of clamp to create the proper tension. Tighten the hardware to 8 N•m (71 lbf in). See Figure 59. 16. Install the clamps. See Figure 64. 17. Connect the header hoses to the cowl hoses. 18. Use the rubber clamps and strap clamps to attach the hoses to the main lift cylinders. Make sure the hoses do not stretch or fold while tilting the mast fully forward and backward.

Three-Stage Mast With Full Free-Lift Repair 2. Check that hoses and cables are routed properly. 3. Slowly raise the free-lift and main cylinders to take up slack in the lift chains. 4. Tighten strap clamps at the bracket weldment. 5. Cycle the mast a few times to ensure proper tracking of hoses. 6. Secure hose assemblies to main lift cylinders with hose clamp and screw clamp. NOTE: If the hose tension between the carriage and the clamp at the free-lift bracket is correct, go to Step 7. If the hose tension between the carriage and the clamp at the free-lift bracket is incorrect, loosen the clamps and pull (if the hoses are loose) or push (if the hoses are tight) on the hoses so they move 15.0 mm (0.6 in.) side to side. Tighten the hardware to 8 N•m (71 lbf in). NOTE: If the hose tension between the clamp at the upper bracket and the clamp at the free-lift bracket is correct, go to Step 8. 7. If the tension of the hoses is incorrect, loosen the clamps and pull the hoses down (if too loose) or push the hoses up (if too tight) so they can move 15.0 mm (0.6 in.) side to side. Retighten the hardware to 8 N•m (71 lbf in). 8. With no load on the forks, check the header hose adjustment by operating the mast through the full lift cycle two times. When properly adjusted, the hoses will not be so tight that they compress when they pass over the sheaves nor will they be so loose that they touch the load backrest or any crossmember that is next to a sheave. If necessary, repeat until the hoses are properly adjusted.

1. Cap off hoses when attachments have been removed.

Three-Stage Mast With Full Free-Lift Repair

Figure 64. Header Hoses for Three-Stage Full Free-Lift (FFL) Mast

4000 YRM 1405

Four-Stage Mast With Full Free-Lift Repair Legend for Figure 64

NOTE: FOUR-FUNCTION MAST SHOWN. A. ALIGN HOSE MARK G AT BOTTOM OF THIS CLAMP

B. ALIGN HOSE MARK E AT BOTTOM OF THIS CLAMP

1. 2. 3. 4.

5. FREE-LIFT CYLINDER 6. FITTING 7. CHAIN SHEAVE

CLAMP HOSE GUARD CHAIN ANCHOR CHAIN

Four-Stage Mast With Full Free-Lift Repair NOTE: The information in this section applies only to lift truck models ERP030-040VT (G807) and ESC03040AC (B883).

REMOVE WARNING The mast is heavy. The mast can weigh approximately 1100 kg (2385 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. Serious injury can occur if the mast falls.

CAUTION Make sure all the mast weldments are fastened together. Make sure the safety chains will not damage the sheaves, tubing, or other parts of the mast. NOTE: If the mast needs to be disassembled, remove the forks and carriage. See the sections Fork Repair and Carriages Repair for procedures. If the free-lift cylinder or tilt cylinders need to be repaired, the mast does not need to be removed from the lift truck. See the section Cylinder Repair 2100 YRM 1382 for procedures. For header hose installation and adjustment procedures, see the section Header Hose Installation and Adjustment. 1. Remove the forks from the mast. Refer to Fork Repair. Fully lower all mast weldments and tilt mast fully forward. 2. Securely attach the chains of an overhead lifting device to the top crossmember of the outer mast. Tighten the chains to remove slack until there is no more than 50 mm (2 in.) of side to side movement. See Figure 65.

1. 2. 3. 4.

ATTACH OVERHEAD LIFTING DEVICE HYDRAULIC SUPPLY HOSE STUB SHAFT LOWERING CONTROL VALVE Figure 65. Mast Removal

Four-Stage Mast With Full Free-Lift Repair

CAUTION Protect the hydraulic system from dirt and contaminants when disconnecting hydraulic hoses from the mast. If hydraulic system becomes contaminated, damage to hydraulic system can occur.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 3. Position a drip pan under the mast to prevent spills when disconnecting the hydraulic fittings. 4. Disconnect and tag lift truck hydraulic supply hose from the lowering control valve. Plug hose end and cap lowering control valve fitting. See Figure 65. NOTE: If the mast will be disassembled, go to Step 5. If mast will not be disassembled, go to Step 6. NOTE: Tag header hoses prior to removal to aid in connecting and installation. 5. Disconnect and remove header hoses and attaching hardware; upper and lower hose guides, hose clamps, hose brackets, and plates. See Figure 66.

4000 YRM 1405 6. Remove free-lift cylinder from mast. See Cylinder Repair 2100 YRM 1382 for procedures.

WARNING Use a driver, NOT your fingers, to push the anchor pins from the clevises on the tilt cylinders. The tilt cylinder or mast can move and cause serious injury. 7. Remove the capscrew, special washer, external tooth lockwasher, and rod end pin from the tilt cylinder rod ends on the outer mast. Remove tilt cylinder rod ends from outer mast. See Figure 67. 8. Remove bolts that hold retainer caps to mast mount stubshafts. See Figure 68.

WARNING DO NOT stand the mast vertically once removed unless it is properly chained to a support device.

WARNING DO NOT stand on or near the mast while it is suspended by an overhead hoist. 9. Slowly lift the mast from the lift truck using the overhead lifting device. Move the mast away from the lift truck and place, horizontally (carriage side facing up) on wooden beams or a pallet. 10. Remove shims and bushings from mast mount stubshafts. See Figure 68.

4000 YRM 1405

Four-Stage Mast With Full Free-Lift Repair

NOTE: SOME MAST COMPONENTS OMITTED FOR CLARITY. COMPONENTS AND HARDWARE FOR A FOUR FUNCTION MAST SHOWN. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

CAPSCREW HOSE CLAMP BAR HOSE CLAMP LOCKWASHER WASHER RESTRAINT RIGHT UPPER HOSE GUIDE LEFT UPPER HOSE GUIDE OUTER MAST RIGHT LOWER HOSE GUIDE

11. 12. 13. 14. 15. 16. 17. 18. 19.

LEFT LOWER HOSE GUIDE OUTER INTERMEDIATE MAST PLATE BLOCK LOWER BRACKET BRACKET NUT FITTING INNER MAST

Figure 66. Header Hoses Attaching Hardware, Remove 79

Four-Stage Mast With Full Free-Lift Repair

4000 YRM 1405 Legend for Figure 68 NOTE: THREE-STAGE FFL MAST SHOWN. FOURSTAGE FFL MAST IS MOUNTED THE SAME WAY. 1. 2. 3. 4.

RETAINER CAP BOLTS SHIM BUSHING

5. MAST MOUNTING STUBSHAFT 6. GREASE FITTING

DISASSEMBLE WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system has cooled. Completely lower forks to relieve hydraulic pressure before disconnecting any hydraulic hoses.

WARNING NOTE: SEVERAL MAST COMPONENTS OMITTED FOR CLARITY. 1. 2. 3. 4. 5. 6. 7.

TILT CYLINDER ROD END TILT CYLINDER SHELL SPECIAL WASHER LOCK WASHER EXTERNAL TOOTH CAPSCREW GREASE FITTING ROD END PIN Figure 67. Tilt Cylinder Mounting

The mast is heavy. The mast can weigh approximately 1100 kg (2385 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. Serious injury can occur if the mast falls.

CAUTION Protect the hydraulic system from dirt and contaminants when disconnecting hydraulic hoses from the mast. If hydraulic system becomes contaminated, damage to the hydraulic system can occur. NOTE: Before disassembling the mast, remove the forks, carriage, and load backrest. See the sections Fork Repair and Carriages Repair for procedures. If the free-lift cylinder or tilt cylinders need to be repaired, the mast does not need to be removed from the lift truck. See the section Cylinder Repair 2100 YRM 1382 for procedures. For header hose installation and adjustment procedures, see the section Header Hose Installation and Adjustment. 1. Remove main lift cylinder from mast. See the section Cylinder Repair 2100 YRM 1382 for procedures. NOTE: Tag chains prior to removal to aid in reassembly. 2. Remove free-lift chain anchors and chains from inner mast crossmember.

Figure 68. Mast Mounting

3. Disconnect free-lift cylinder hose from tube and remove tube assembly. See Figure 69.

4000 YRM 1405

Four-Stage Mast With Full Free-Lift Repair

Figure 69. Four-Stage, Full Free-Lift Mast (FFL)

Four-Stage Mast With Full Free-Lift Repair

4000 YRM 1405 Legend for Figure 69

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

OUTER MAST STRIP BEARING LOAD ROLLER CHAIN ANCHOR COTTER PIN CHAIN ANCHOR PIN NUT SHIM LOCKWASHER CAPSCREW LOWERING CONTROL VALVE MOUNTING BRACKET LOWERING CONTROL VALVE FITTING OUTER INTERMEDIATE MAST BUMPER CLAMP LEFT MAIN LIFT CYLINDER SNAP RING CHAIN SHEAVE

NOTE: Tag chains prior to removal to aid in reassembly. 4. Disconnect lift chains from chain anchors at bottom of inner mast and top of outer intermediate mast. See Figure 69. 5. Push inner mast toward bottom of mast assembly until bottom load rollers are seen. See Figure 70. NOTE: The lower end of inner mast must be raised so that lift chains can clear the inner intermediate mast lower crossmember. 6. Tag and remove inner mast lift chains. 7. Remove strip bearings at top of inner intermediate mast. Remove load rollers at bottom of inner mast. Remove load rollers at top of inner intermediate mast. See Figure 69. Make a note of each shim arrangement and load roller location. The shim arrangements will be approximately the same during assembly. 8. Slide inner mast halfway out of top of inner intermediate mast. Connect crane to center of inner mast. See Figure 70. Slide inner mast out until stub shafts are in notches of inner intermediate mast. Remove inner mast from inner intermediate mast. NOTE: Tag chains prior to removal to aid in reassembly. 9. Disconnect lift chains at bottom of inner intermediate mast and top of outer mast. Remove lift chains and chain anchors. Push inner intermediate mast toward bottom of mast assembly until bottom load rollers are seen. See Figure 70.

20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38.

BRACKET TUBE ASSEMBLY RIGHT MAIN LIFT CYLINDER VALVE STOP DOWEL PAD INNER INTERMEDIATE MAST SHAFT RETAINER HOSES SHEAVE INNER MAST CROSSHEAD BAND SCREW FREE-LIFT CYLINDER SPRING GUIDE SPRING PISTON

10. Remove lower stop from bottom of outer intermediate mast. See Figure 69. 11. Remove strip bearing at top of outer intermediate mast. Remove load rollers at bottom of inner intermediate mast. Remove load rollers at top of outer intermediate mast. Make a note of each shim arrangement and load roller location. The shim arrangements will be approximately the same during assembly. 12. Slide inner intermediate mast halfway out of top of outer intermediate mast. Connect crane to center of inner intermediate mast. See Figure 70. Slide inner intermediate mast out until stub shafts are in notches of outer intermediate mast. Remove inner intermediate mast. 13. Slide outer intermediate mast from bottom of outer mast approximately 30 cm (12 in.). Remove strip bearings at top of outer mast. Remove snap rings and load rollers from both mast weldments. Make a note of each shim arrangement and load roller location. The shim arrangements will be approximately the same during assembly. 14. Slide outer intermediate mast halfway out of top of outer mast. Connect crane to center of outer intermediate mast. Slide outer intermediate mast out of outer mast until stub shafts are in notches of outer mast. Remove outer intermediate mast from outer mast. 15. Remove and disassemble chain and hose sheaves as necessary for repair and cleaning.

4000 YRM 1405

Four-Stage Mast With Full Free-Lift Repair

Figure 70. Mast Weldments Removal

Four-Stage Mast With Full Free-Lift Repair

4000 YRM 1405 Legend for Figure 70

A. REMOVE INNER MAST B. REMOVE INNER INTERMEDIATE MAST

C. REMOVE OUTER INTERMEDIATE MAST

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11.

MOVE TOWARD TO OF MAST LIFT CHAIN MOVE TOWARD BOTTOM OF MAST INNER MAST INNER INTERMEDIATE MAST STUB SHAFT

CLEAN AND INSPECT

STOP LOAD ROLLER CHAIN ANCHORS OUTER INTERMEDIATE MAST STRIP BEARINGS

Always wear protective clothing and eye protection when working with compressed air.

WARNING Never replace only the worn section of a chain. Replace the complete chain. Never replace only one chain of a chain pair. Replace both chains.

CAUTION DO NOT use steam to clean lift chains, sheaves, or load rollers. The bearings in the sheaves and load rollers are sealed and lubricated.

CAUTION Lift chains, which were not checked before removal, must be checked for correct length again once installed in the mast and the mast installed on the lift truck. 1. Inspect the chain and hose sheaves and load rollers for wear or damage. NOTE: The chains must be inspected in the area of chain that passes over the chain sheave during the first portion of a lift. Those links will show maximum wear. 2. Inspect the lift chains for wear or damage. A lift chain becomes longer when it is worn. If a chain is 3% longer than a new lift chain, the lift chain must be replaced. If a chain scale is available, check the lift chain as shown in Figure 71. If a chain scale is not available, measure 20 links of the lift chain. Compare the measurement with the lengths given in Figure 71.

WARNING Cleaning solvents may be flammable and toxic and can cause severe skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety precautions.

CAUTION Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 3. Clean the lift chains by soaking in solvent for 30 minutes and remove all dirt and grease. Hang lift chains over a drip pan and let drip. Remove residual solvent using compressed air. 4. Lubricate the chains by soaking them in SAE 30 engine oil for 30 minutes. Hang chains over a drip pan for one hour to remove excess oil. 5. Inspect the chain anchors and pins. Replace any parts that are worn or damaged.

WARNING Be careful when cleaning with steam. Steam can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose your skin to steam. 6. Clean the mast weldments with steam or solvent.

WARNING Improper welding procedures can damage the structure of the mast or cause incorrect function of the mast. Consult Resident Service Engineering through the Contact Management System for approval before welding on the mast. 7. Inspect sliding surfaces for wear or damage. Inspect load roller contact surfaces for wear or damage. Inspect all welds for cracks.

4000 YRM 1405

Four-Stage Mast With Full Free-Lift Repair 2. Connect crane to center of outer intermediate mast. See Figure 70. Fit lower stub shafts of outer intermediate mast into notches in top of outer mast. Slide outer intermediate mast into outer mast so stub shafts are seen at top and bottom of both mast uprights. 3. Install strip bearing and shims into the channels at top of outer mast. See Figure 72. Apply multipurpose grease with 2 to 4% molybdenum disulfide to strip bearing surfaces. 4. Install load rollers and shims onto stub shaft at top of outer mast and at bottom of outer intermediate mast. Install chain sheaves, shims, and snap rings on outer intermediate mast. See Figure 69. 5. Install chain sheaves and snap rings on inner intermediate mast.

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE (YALE PART NO. 580037684). 1. CHAIN WEAR SCALE Pitch

12.7 mm (0.50 in.) 15.9 mm (0.63 in.) 19.1 mm (0.75 in.) 25.4 mm (1.00 in.)

Total length of 20 links (pitch) of new chain 254.0 (10.0 317.5 (12.5 381.0 (15.0 508.0 (20.0

mm in.) mm in.) mm in.) mm in.)

Wear Limit The maximum length of 20 links 261.6 (10.3 327.0 (12.9 392.4 (15.5 523.3 (20.6

6. Connect crane to center of inner intermediate mast. Slide inner intermediate mast into outer intermediate mast so stub shafts are seen at top and bottom of both mast uprights. See Figure 70. 7. Install strip bearings and shims on channels of outer intermediate mast. Apply multipurpose grease with 2 to 4% molybdenum disulfide to strip bearing surfaces. Install load rollers and shims on both inner and outer intermediate masts.

mm in.) mm in.) mm in.) mm in.)

Figure 71. Lift Chains Check

ASSEMBLE NOTE: The shims for the load rollers keep the mast uprights parallel and provide correct clearance. During assembly, the shim arrangement will be approximately the same as before disassembly. Check clearance and adjust strip bearings for wear or for changes caused by repairs. The strip bearings may also be adjusted using shims. See Mast Adjustments, in this section for the adjustment procedures. 1. Put outer mast across wooden beams or a pallet, with mast pivots toward floor.

1. SHIM 2. STRIP BEARING 5. LOAD ROLLER

3. STUB SHAFT 4. SHIMS 6. MAST CHANNEL

Figure 72. Strip Bearings and Load Rollers

Four-Stage Mast With Full Free-Lift Repair 8. Install chain sheaves at top of outer intermediate mast. Install outer intermediate mast chain anchors and chains 9. Install chain sheaves and connect lift chains to chain anchors at outer mast. Put lift chains over chain sheaves on outer intermediate mast and connect them to anchors at bottom of inner intermediate mast. 10. Connect crane to center of inner mast. See Figure 70. Slide mast into inner intermediate mast so stub shafts are seen at top and bottom of both uprights. 11. Install strip bearings and shims on channels of inner intermediate mast. See Figure 72. Apply multipurpose grease with 2 to 4% molybdenum disulfide to strip bearing surfaces. Install load rollers and shims on inner intermediate mast and inner mast. 12. Connect lift chains to chain anchors at top of outer intermediate mast. Put lift chains over chain sheaves on inner intermediate mast and connect them to anchors at bottom of inner weldment. 13. Install free-lift supply tube assembly and connect free-lift supply hose. See Figure 69. 14. Install free-lift chain anchors and chains to inner mast crossmember. 15. Install main lift cylinders to mast. See the section Cylinder Repair 2100 YRM 1382 for procedures.

INSTALL 1. Lubricate the bushings with multipurpose grease with 2 to 4% molybdenum disulfide and install bushings and shims onto the stub shafts at the bottom of the outer mast weldment. See Figure 68.

WARNING Mast parts are heavy and can shift. Distances between parts are small. Serious injury can result if part of the body is hit by parts of the mast or the carriage.

WARNING The mast is heavy. The mast can weigh approximately 1100 kg (2385 lb). Make sure all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast. Serious injury can occur if the mast falls.

4000 YRM 1405 2. Lift the mast using an overhead lifting device with chain hooks attached to the upper outer crossmember. Make sure all mast weldments are fastened together. Make sure chains will not damage chain sheaves, tubing, or other parts of the mast assembly. 3. Use lifting device and install mast into transmission housing mounts. Apply Loctite™ #242 adhesive sealant to bolt threads. Install the bolts, shims and retainer caps. See Figure 68. Tighten bolts in a diametric pattern to 24 N•m (18 lbf ft).

WARNING Use a driver, NOT your fingers, to push the anchor pins from the clevises on the tilt cylinders. The tilt cylinder or mast can move and cause serious injury. 4. Apply multipurpose grease with 2 to 4% molybdenum disulfide to rod end pin and connect tilt cylinders to mast using rod end pin, capscrew, special washer, and external tooth lockwasher. Tighten capscrews to 38 N•m (28 lbf ft). See Figure 67. 5. Install free-lift cylinder to mast. See Cylinder Repair 2100 YRM 1382 for procedures. 6. Connect the lift truck hydraulic supply hose to the lowering control valve. See Figure 65. Connect hydraulic hoses as tagged during removal. NOTE: If mast was disassembled, then the header hoses and attaching hardware need to be installed. Go to Step 7 before going to Step 8. If header hoses and attaching hardware were not removed, proceed to Step 8 7. Install header hoses and attaching hardware as noted during removal. See Header Hose Installation and Adjustment for procedures. 8. Install carriage and load backrest. See Carriages Repair for procedures. 9. Check the tilt cylinder adjustment. See the section Cylinder Repair 2100 YRM 1382 for procedures. Operate the mast and check for leaks and to ensure mast is operating correctly. Check lift chains as described in the section Lift Chains Adjustment. NOTE: Before checking for mast side kicking, the mast must be fully assembled to include the carriage, forks, load backrest and any attachments if the lift truck is equipped with one.

4000 YRM 1405 10. Raise the mast, without a load to its full height and check for side kicking. Mast side kicking is where the mast, without a load, moves either to the right or left as it is being raised. If the mast is side kicking, see the Mast Adjustments section for procedures to correct mast side kicking.

Four-Stage Mast With Full Free-Lift Repair 1. Make sure free-lift cylinder hose guards and hose sheaves are installed on free-lift cylinder. See the section Cylinder Repair 2100 YRM 1382 for procedures. The capscrew on hose guard should be finger tight only. See Figure 74.

11. Lubricate the sliding surfaces and load roller surfaces with multipurpose grease with 2 to 4% molybdenum disulfide along the full length of the channels as shown in Figure 73. Apply grease only to surfaces indicated in Figure 73.

1. 2. 3. 4.

CHAIN SHEAVE CAPSCREW HOSE SHEAVE SPACER

5. 6. 7. 8.

STUB SHAFT HOSE GUARD NUT FREE-LIFT CHAIN

Figure 74. Free-Lift Crosshead Assembly 2. Install carriage hose bracket to center tab on lower carriage bar. See Figure 75. A. LOWER LOAD ROLLERS B. UPPER LOAD ROLLERS 1. LUBRICATE STRIP BEARING SURFACES 2. LUBRICATE LOAD ROLLER SURFACES 3. LOAD ROLLER Figure 73. Mast Lubrication

HEADER HOSE INSTALLATION AND ADJUSTMENT The four-stage mast covered in this manual can have either three functions or four functions. The header hose installation and adjustment procedures for a four function mast are covered below. If mast is three-function, there are four hoses: two free-lift #6, one rear inside and one rear outside hoses, and one lower and upper hose guide. NOTE: Before installing new header hoses, verify the lift height of the mast. The lift height is on the Nameplate of the lift truck and on the right side of the outer mast.

3. Install fittings to bracket. See Figure 76. a. Three Function Mast - Install fittings to the left or right side. Finger tighten fittings. b. Four Function Mast - Install fittings to the left and right side. Finger tighten fittings. 4. Install lower bracket to blocks at bottom of inner mast. See Figure 66 or Figure 77. Tighten capscrews to 71 N•m (52 lbf ft). DO NOT install plate. 5. Install lower hose guides to outer intermediate mast. Tighten capscrews to 41 N•m (30 lbf ft). Install hose clamps to lower hose guide. Finger tighten capscrews. 6. Completely lower the carriage. NOTE: A three function mast will only have one set of free-lift #6 hoses. 7. Route free-lift #6 and free-lift #4 hoses down behind carriage bar to carriage bracket fittings. See Figure 77.

Four-Stage Mast With Full Free-Lift Repair

4000 YRM 1405 8. Connect free-lift #6 and #4 hose ends to fittings and tighten fittings with fingers. If mast has four functions, connect free-lift #4 hose ends to the two fitting on right side. See Figure 76. 9. Pull free-lift #6 and #4 hoses over free-lift crosshead hose sheaves (item #8, Figure 77). 10. Route free-lift #6 and #4 hoses down between free-lift cylinder and crossmember (#15, Figure 77). Tighten hose ends at the hose bracket on lower carriage bar. See Figure 75. 11. Connect the rear inside and rear outside hoses to free-lift #6 #4 hoses behind free-lift cylinder (item #6, Figure 77). The rear outside hoses are approximately 102 mm (4 in.) shorter than the rear inside hoses.

1. CARRIAGE 2. FITTING

3. HOSE BRACKET

Figure 75. Installing Hose Bracket to Lower Carriage Bar

12. Pull down on rear inside, rear outside, and free-lift #6 and #4 hoses to remove slack from hoses. Clamp hoses to lower bracket on crossmember of inner mast. Tighten clamp capscrews to 7 to 11 N•m (62 to 97 lbf in). 13. Position rear inside, rear outside, and free-lift #6 and #4 hoses on inner mast bracket (item #16, Figure 77). 14. Install plate to lower bracket. See Figure 66. Tighten capscrews to 41 N•m (30 lbf ft). 15. Pull hoses toward top of mast, following inner mast lift chains, and over inner intermediate mast hose sheave (item #12, Figure 77).

1. THREE FUNCTION (RIGHT) 2. THREE FUNCTION (LEFT) 3. FOUR FUNCTION Figure 76. Fittings Configuration Legend for Figure 77 A. BACK VIEW B. FRONT VIEW

C. THREE FUNCTION ARRANGEMENT D. FOUR FUNCTION ARRANGEMENT

1. 2. 3. 4. 5. 6. 7. 8. 9.

11. PULL HOSES UNDER HOSE CLAMPS AT TOP OF UPPER HOSE GUIDE 12. PULL HOSES UP TOWARD TOP OF MAST 13. INNER INTERMEDIATE SHEAVE 14. LOWER HOSE GUIDE 15. ROUTE FREE-LIFT HOSES BETWEEN FREE-LIFT CYLINDER AND CROSSMEMBER 16. INNER MAST BRACKET 17. FREE-LIFT #6 HOSE 18. FREE-LIFT #4 HOSE

REAR OUTSIDE HOSE REAR INSIDE HOSE LOWER BRACKET CARRIAGE BRACKET FITTING CARRIAGE BRACKET CONNECT HOSES HERE UPPER HOSE GUIDE ROUTE HOSES OVER FREE-LIFT CROSSHEAD ROUTE HOSES DOWN TO LOWER HOSE GUIDE 10. ROUTE HOSES BELOW BOTTOM OF LOWER HOSE CLAMP

4000 YRM 1405

Four-Stage Mast With Full Free-Lift Repair

Figure 77. Header Hose Arrangement, Four-Stage FFL Mast

Four-Stage Mast With Full Free-Lift Repair

4000 YRM 1405 Legend for Figure 78 1. 2. 3. 4. 5. 6. 7.

CROSSHEAD SHAFT CHAIN AND HOSE GUARD HOSE CLAMP HOSE CLAMP UPPER HOSE GUIDE LOWER HOSE GUIDE CONNECTION TO CARRIAGE BRACKET FITTINGS

16. Route rear inside, rear outside, and free-lift #6 and #4 hoses down to lower hose guides (item #9, Figure 77). Place hoses under hose clamp at top of lower hose guides. Pull downward on hoses with enough force to remove slack from hoses. Tighten clamp capscrews 7 to 11 N•m (62 to 97 lbf in). 17. Install upper hose guides to outer mast. Tighten capscrews to 41 N•m (30 lbf ft). See Figure 66. 18. Loop the hoses 125 mm (5 in.) below the bottom of lower hose clamps and rout hoses into upper hose guide (item #10, Figure 77). 19. Install hose clamps to upper hose guide. Finger tighten capscrews. 20. Pull rear inside, rear outside, and free-lift #6 and #4 hoses under hose clamps at top of upper hose guide (item #11, Figure 77). Finger tighten capscrews. 21. Route hoses under hose clamps at the bottom of upper hose guide. See Figure 78. Finger tighten capscrews. 22. Tighten free-lift crosshead hose guard capscrew to 71 N•m (52 lbf ft). See Figure 77. 23. Make sure hoses are aligned properly and are centered on free-lift hose sheaves. Hoses should travel parallel to each other. Tighten fittings to prevent hoses from twisting. 24. Loosen hose clamps at top of lower hose guide. See Figure 78. Pull down on hoses with enough force to remove slack from hoses. Tighten clamp capscrews to 7 to 11 N•m (62 to 97 lbf in). See Figure 78. 25. Tighten upper hose clamp capscrews on upper hose guide to 7 to 11 N•m (62 to 97 lbf in). See Figure 78.

Figure 78. Header Hose Clamps

4000 YRM 1405

Lift Chains Adjustment

26. Raise and lower the mast slowly through several cycles to check for proper hose alignment, clearances and hose tracking in the hose upper and lower guides.

27. After completing installation and adjustment of header hoses, go to section Install and complete Step 8 through Step 11.

Lift Chains Adjustment WARNING When working on or near the mast, see the section Safety Procedures When Working Near Mast. During test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests. Never allow anyone under a raised carriage. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. Never check for leaks by putting hands on hydraulic lines or components under pressure. Hydraulic oil under pressure can be injected into the skin.

NOTE: Prior to performing adjustment procedures, make sure the forklift truck is parked on a level surface and the mast is in the vertical position. 2. Adjust the chain anchors that support the carriage, until the bottom of the fork heel is 6.0 ±3.0 mm (0.24 ±0.12 in.) above the floor level. See Figure 79. 3. Adjust the chain anchors that support the carriage, until the bottom of the lower carriage bar is above the floor level as shown in Table 7 and Figure 80. Table 7. Hook-Type Carriage Chain Adjustment Class II and III

82.5 ±3.0 mm (3.25 ±0.12 in.)

Class IV

133.5 ±3.0 mm (5.26 ±0.12 in.)

When the lift chains are correctly adjusted: • The tension will be the same on each chain of the chain set. Check tension by pushing on both chains at the same time. • The chain length will be correct. • The chains must travel freely through the complete cycle. NOTE: When the lift chain adjustments are complete, make sure the threads on the nuts of the chain anchors are completely engaged. Make sure the chain anchors are not adjusted too tight. The chain anchors must be able to move on their mounting. NOTE: When directed to a step from step 1, perform that step only. 1. When adjusting the lift chains on forklift trucks equipped with either pin or hook-type forks installed, go to Step 2. If the forklift truck is normally equipped with a hook-type carriage and has an attachment without forks, go to Step 3. If the forklift truck is normally equipped with a pin-type carriage and has an attachment without forks, go to Step 4.

1. 2. 3. 4.

MAST CARRIAGE FORK HEEL OF FORK IS 6.0 ±3.0 mm (0.24 ±0.12 in.) ABOVE FLOOR LEVEL Figure 79. Lift Chain Adjustment, Hook- or Pin-Type Forks

Lift Chains Adjustment

4000 YRM 1405

1. MAST 2. CARRIAGE 3. DISTANCE FROM FLOOR TO LOWER CARRIAGE BAR Figure 80. Lift Chain Adjustment, Hook-Type Carriage 4. See Figure 81. Adjust the chain anchors, which support the carriage, until the center line of the fork pin is above the floor level as shown in Table 8. Table 8. Pin-Type Carriage Chain Adjustment

4-5.5T Class III

545.0 ±3.0 mm (21.5 ±0.12 in.)

4-5.5T Class IV

708.0 ±3.0 mm (27.87 ±0.12 in.)

6-7T Class IV

907.0 ±3.0 mm (35.71 ±0.12 in.)

1. LOAD BACK REST 2. FORK PIN 3. DISTANCE FROM FORK PIN TO FLOOR Figure 81. Lift Chain Adjustment, Pin-Type Carriage

4000 YRM 1405

Tilt Cylinders Adjustment

Carriage Adjustments 1. Install the load rollers on the carriage. Install the shims for the load rollers onto the stubshaft in the same sequence as when disassembled. On carriages equipped with six load rollers, there are no shims under the top load rollers. 2. Use a lifting device to raise carriage. Find the point of tightest fit between the carriage load rollers and inner mast channels. 3. Remove carriage from mast. Adjust shim arrangement for each roller for clearance between roller and inner channel. Repeat Step 1 and Step 2 until there is zero clearance at the point of tightest fit.

centered within the inner mast within +1.50 mm (0.06 in.).

CAUTION Too much grease will cause the rollers to slide and wear flat areas on the rollers and introduce contamination into and on mast channels. 5. After adjustment, lubricate channels with a thin layer of grease. Adjust hydraulic hoses and make sure connections are correct, if the carriage is equipped with hydraulic attachments.

4. Keep shim arrangement on each side of carriage approximately equal. The carriage must be

Tilt Cylinders Adjustment To adjust the tilt cylinders, see the service manual Cylinder Repair 2100 YRM 1382 for adjustment procedures.

Mast Adjustments

4000 YRM 1405

Mast Adjustments LOAD ROLLER, ADJUST NOTE: Shims are installed on both sides of the load rollers. Do not add to or remove shims from the stub shafts. To change the position of the roller on the stub shaft, move the shims from one side of the load roller to the other.

2. Perform the following steps to adjust the mast load rollers: a. Use a crowbar to move mast uprights from side to side to measure movement. Measure movement in a minimum of three different positions of each mast upright.

During assembly, the shim arrangement will be approximately the same as before disassembly. Check the clearance and adjust shims after repairs have been completed.

b. Separate mast uprights and change shim arrangements as required. Assemble uprights. Slide upright all the way to the top and bottom to find the tightest fit.

1. The load rollers control the alignment of the mast uprights. See Figure 82. The alignment conditions are given on a list below with the most important condition first.

c. Repeat Step a and Step b until there is zero clearance at the point of the tightest fit.

a. The mast uprights must be parallel to each other. b. Use shims to adjust load rollers so there is zero clearance between load roller and channel at point of tightest fit. c. The number of shims under a load roller must be approximately the same as the stub shaft in the opposite side of the upright. This ensures the uprights will be approximately in the center.

d. Measure distance between channels of mast uprights on top and bottom. Change shims to keep distance equal between top and bottom so mast uprights are parallel. Also make sure the mast uprights are parallel within 1.5 mm (0.060 in.). 3. Adjust strip bearings. See Figure 83. Insert shims under strip bearing. Adjust clearance until there is less than 0.8 mm (0.030 in.) at the tightest fit. See Figure 82.

4000 YRM 1405

Mast Adjustments

NOTE: USE SHIMS TO KEEP CARRIAGE AND MAST UPRIGHTS PARALLEL, TO GIVE APPROXIMATELY EQUAL SPACE BETWEEN BOTH SIDES OF CARRIAGE AND UPRIGHTS, AND TO GIVE ZERO CLEARANCE AT POINT OF TIGHTEST FIT. A. TOP VIEW B. MAST FRONT VIEW

C. CARRIAGE FRONT VIEW

1. 2. 3. 4. 5. 6.

7. 8. 9. 10.

CHANNEL LOAD ROLLER STUB SHAFT SNAP RING SHIMS PARALLEL TO CHANNEL ±1.5 mm (0.060 in.)

ZERO CLEARANCE AT POINT OF TIGHTEST FIT EQUAL SPACE ±1.5 mm (0.060 in.) PARALLEL TO CHANNEL ±1.5 mm (0.060 in.) PUT SPACER ON OUTSIDE OF TOP LOAD ROLLER, UNDER SNAP RING 11. SHIM FOR ZERO CLEARANCE AT POINT OF TIGHTEST FIT Figure 82. Mast Adjustments

Mast Adjustments

4000 YRM 1405

1. STRIP BEARING 2. LOAD ROLLER 3. MAST UPRIGHT

4. SHIMS 5. O-RING Figure 83. Strip Bearings Arrangement

MAST SIDE KICKING, ADJUST Mast side kicking is where the mast, without a load, moves either to the right or left as it is being raised. When this happens, it is an indication that one of the main lift cylinders is raising at a faster rate then the other. Before checking for mast side kicking, the mast must be completely assembled to include the carriage, forks, load backrest, and any attachments if the lift truck is equipped with one. To adjust the mast for side kicking, do the following: 1. Place the lift truck on a level surface and apply the parking brake. 2. Raise the mast and visually inspect it as it reaches its full height.

3. If the mast is moving to the left, shims will need to either be added or removed from the top of the right main lift cylinder. If mast moves to the right, shims will need to either be added or removed from the top of the left main lift cylinder. See Figure 33 and Figure 52 4. If shims will be added, use the smallest shim size that can be used on the mast that is being adjusted. See the Parts Manual for shim sizes and part numbers. 5. Raise the mast again and visually inspect it to ensure that it is no longer side kicking. If it is, repeat Step 3 and Step 4.

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

4000 YRM 1405

5/10 (2/10)(6/09)(1/09)(9/08) Printed in U.S.A.

Maintenance

METRIC AND INCH (SAE) FASTENERS ALL MODELS

PART NO. 524150797

8000 YRM 231

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Metric and Inch (SAE) Fasteners

Table of Contents

1 1 1 2 2 7 9

This section is for the following models: All Models

8000 YRM 231

General

General THREADED FASTENERS Threaded fasteners, like bolts, nuts, capscrews, and studs, are made to specifications that describe the mechanical strength and hardness of the fastener. A fastener used in a design application is selected according to its specifications. Yale Company buys parts from many countries. Parts that are purchased must be to Yale Company standards. There are several standards used by these countries in the manufacture of threaded fasteners. Many of these fasteners are similar, but cannot be used as a direct replacement. To make sure that you have the correct fastener, order fasteners and parts through the Yale Parts Depot. Service persons must use replacement fasteners that have the same specifications. Fasteners made to each specification have identification marks for that specification. This specification is commonly called "Grade" for SAE standards and "property class" for metric standards. This section describes the identification of some common fasteners. The metric system used by Yale Company is described as SI (Le Systeme d’Unites or the International System of units, also called SI in all languages). The SI System of measurement is described in ISO Standard 1000, 1973. A conversion table of common measurements is shown in Table 7.

The diameter of the shank of the fastener is shown first in the series [M12 = 12 mm, M20 = 20 mm (1/2 = 1/2 in., 3/4 = 3/4 in.)]. The number of threads per inch is normally not shown for inch nomenclature and only the UNC (Unified National Coarse) or UNF (Unified National Fine) is shown. This number of threads per inch is not shown because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter. Metric fasteners show the number of threads per millimeter. The length of the shank is often indicated as part of the description of a fastener. This length is shown in inches for inch fasteners and in millimeters for metric fasteners. A capscrew will have the following description: Metric

Inch

M12 × 1.75 × 50

1/2 × 13 UNC × 1-1/2

ABC

ABCD

A = Thread Size

A = Shank Diameter

B = Pitch

B = Number of Threads Per Unit of Length

C = Length

C = Type of Thread D = Shank Length

NOMENCLATURE, THREADS The thread design is specified by a series of numbers and letters for inch and metric fasteners. See Figure 1.

Figure 1. Thread Design

General

8000 YRM 231

STRENGTH IDENTIFICATION CAUTION When fasteners must be replaced, the new fasteners must be of the same strength or greater than the original fasteners. The new fasteners must also be the correct size. NOTE: Identification marks are according to bolt strength. The higher the number or the increase in the number of marks indicates increased bolt strength. The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked with a number on the head of the capscrew or on a nut. Property classes less than 8.8 are often not marked. Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally do not have any marks. The following tables show the marks that identify the grades and property classes for different fasteners.

Figure 2. Minimum Angle Between Cotter Pin Legs Unless otherwise specified, the legs of chain anchor cotter (split) pins are to be bent against the pin. See Figure 3.

COTTER (SPLIT) PINS Cotter (split) pins are used in many applications on your forklift. They are typically used to retain parts such as pins and nuts. Cotter (split) pins are typically not used as load-bearing members. Service personnel must use new cotter (split) pins. Do not reuse a cotter (split) pin. Replacement cotter (split) pin must be of the correct size. See Table 8. The legs of a cotter (split) pin are bent for the following reasons: • To retain the cotter (split) pin in the part • To provide clearance between the cotter pin legs and other parts or members. One or both cotter (split) pin legs must be bent to provide a minimum 90 angle between the legs. See Figure 2.

1. COTTER PIN Figure 3. Cotter (Split) Pins Used On Mast Chain Anchors

8000 YRM 231

General Table 1. Bolts and Screws

General

8000 YRM 231 Table 2. Studs and Nuts

8000 YRM 231

General Table 3. Torque Nuts

General

8000 YRM 231 Table 4. Torque Nuts with Nylon Insert

8000 YRM 231

General

FASTENER TORQUE TABLES Table 5. Torque Values for Metric Fasteners* Property Class 5.8 1

Size and Pitch

Grade 8.8 2

Grade 10.9 3

N•m

lbf ft

N•m

lbf ft

N•m

lbf ft

M3 × 0.5 M3.5 × 0.6 M4 × 0.7 M5 × 0.8 M6 × 1

0.62 0.97 1.44 2.91 4.94

0.5 0.7 1.1 2.1 3.6

0.99 1.55 2.30 4.65 7.90

0.7 1.1 2.1 3.6 6

1.34 2.11 3.13 6.33 10.8

1.0 1.6 2.3 4.7 8

M8 × 1.25 M8 × 1 M10 × 1.5 M10 × 1.25

12.0 12.8 23.8 25.1

9 9 18 19

19.2 20.5 38.0 40.1

14 15 28 30

26.1 27.9 52 55

19 21 38 41

M12 × 1.75 M12 × 1.25 M14 × 2 M14 × 1.5

41.4 45.3 66 72

31 33 49 53

66 72 105 115

49 53 77 85

90 98 145 155

66 72 105 115

M16 × 2 M16 × 1.5 M20 × 2.5 M20 × 1.5

105 110 200 225

77 81 150 165

165 175 320 355

122 130 235 260

225 240 435 485

165 175 320 360

345 375 505 550

255 275 370 405

555 605 810 875

410 445 600 645

755 820 1,100 1,190

560 605 810 880

690 715 765 940 1,030

510 530 565 695 760

1,100 1,140 1,220 1,500 1,640

810 840 900 1,100 1,210

1,500 1,550 1,660 2,040 2,240

1,100 1,140 1,230 1,510 1,660

1,200 1,280 1,560 1,640

885 945 1,150 1,210

1,930 2,040 2,490 2,630

1,430 1,510 1,840 1,940

2,620 2,780 3,390 3,570

1,940 2,050 2,500 2,640

1,930 2,070 2,410 2,580 2,900 3,160

1,430 1,530 1,780 1,910 2,140 2,330

3,080 3,320 3,850 4,120 4,630 5,040

2,280 2,450 2,840 3,040 3,420 3,720

4,200 4,510 5,240 5,610 6,300 6,860

3,100 3,330 3,870 4,140 4,650 5,060

M24 M24 M27 M27

× × × ×

3 2 3 2

M30 × 3.5 M30 × 3 M30 × 2 M33 × 3.5 M33 × 2 M36 M36 M39 M39

× × × ×

4 3 4 3

M42 × 4.5 M42 × 3 M45 × 4.5 M45 × 3 M48 × 5 M48 × 3

* Unless otherwise specified 1 Approximately equal to Grade 2 2 Approximately equal to Grade 5 3 Approximately equal to Grade 8

General

8000 YRM 231 Table 6. Torque Values for Inch Fasteners* Grade 21

Size and Pitch

Grade 52

lbf ft

N•m

lbf ft

N•m

lbf ft

N•m

1/4 1/4

20 UNC 28 UNF

4 5

6 6

6 7

9 10

12 14

5/16 5/16

18 UNC 24 UNF

8 9

11 13

13 14

18 20

25 28

3/8 3/8

16 UNC 24 UNF

15 17

20 23

23 26

31 36

33 37

44 50

7/16 7/16

14 UNC 20 UNF

24 27

33 36

37 41

50 56

52 58

71 79

1/2 1/2

13 UNC 20 UNF

37 41

50 56

57 64

77 86

80 90

110 120

9/16 9/16

12 UNC 18 UNF

53 59

72 80

82 91

110 125

115 130

155 175

5/8 5/8

11 UNC 18 UNF

73 83

99 110

115 130

155 175

160 180

215 245

3/4 3/4

10 UNC 16 UNF

130 145

175 195

200 225

270 300

280 315

380 425

7/8 7/8

9 UNC 14 UNF

125 140

170 185

320 355

435 480

455 500

615 680

1 1

8 UNC 14 UNF

185 210

255 285

485 540

655 735

680 765

925 1,040

1-1/8 1-1/8

7 UNC 12 UNF

265 300

360 405

595 670

805 905

965 1,080

1,310 1,470

1-1/4 1-1/4

7 UNC 12 UNF

375 415

510 565

840 930

1,140 1,260

1,360 1,500

1,850 2,050

1-3/8 1-3/8

6 UNC 12 UNF

490 560

665 760

1,100 1,250

1,490 1,700

1,780 2,040

2,420 2,760

1-1/2 1-1/2

6 UNC 12 UNF

650 735

885 995

1,460 1,650

1,980 2,230

2,370 2,670

3,210 3,620

* Unless otherwise specified 1 Approximately equal to metric Property Class 5.8 2 Approximately equal to metric Property Class 8.8 3 Approximately equal to metric Property Class 10.9

Grade 83

8000 YRM 231

General

CONVERSION TABLE Table 7. Conversion Table for Metric and English Units Multiply

Multiply

To Get

× 0.155

= inches

Area inches feet

(in. )

(ft 2)

× 6.452

= centimeters

× 0.093

= meters

(cm )

centimeters

(m 2)

meters

(cm 2)

(m 2)

× 10.764 = feet

(in. 2)

(ft 2)

Linear inches (in.)

× 25.4

= millimeters (mm)

millimeter (mm)

× 0.039

= inches (in.)

feet (ft)

× 0.305

= meters (m)

meter (m)

× 3.281

= feet (ft)

yards (yd)

× 0.914

= meters (m)

meter (m)

× 1.094

= yards (yd)

miles (mi)

× 1.609

= kilometers (km)

kilometer (km)

× 0.621

= miles (mi)

Mass ounces (oz)

× 28.35

= grams (g)

grams (g)

× 0.035

= ounces (oz)

pounds (lb)

× 0.454

= kilograms (kg)

kilograms (kg)

× 2.205

= pounds (lb)

tons (2,000 lb)

× 907.18

= kilograms (kg)

kilograms (kg)

× 0.001

= tons (2,000 lb)

tons (2,000 lb)

× 0.907

= metric ton (t)

metric ton (t)

× 1.102

= tons (2,000 lb)

× 1.34

= horsepower (hp)

Power horsepower (hp)

× 0.746

= kilowatts (kW)

kilowatts (kW)

Pressure pounds/in.

(psi)

× 6.895

= kilopascal (kPa)

kilopascals (kPa)

× 0.145

= pounds/in.

(psi)

pounds/in.

(psi)

× 0.007

= megapascal (MPa)

megapascals (MPa)

× 145.04 = pounds/in.

(psi)

Temperature ( Fahrenheit 32)

× 0.56

= Celsius (C)

( Celsius × 1.8) +32

= Fahrenheit

Torque pound inches (lbf in.)

× 0.113

= Newton meter (N•m)

Newton meter (N•m)

× 8.851

= pound inches (lb f in.)

pound feet (lbf ft)

× 1.356

= Newton meter (N•m)

Newton meter (N•m)

× 0.738

= pound feet (lb f ft)

× 0.621

= miles/hour (mph)

× 0.061

= inches

(in. 3)

Velocity miles/hour (mph)

× 1.609

= kilometer/hour (km/h)

kilometer/hr (km/h)

Volume inches

(in. )

× 16.387

= centimeters

inches

(in. 3)

× 0.016

= liters (l)

liters (l)

× 61.024 = inches

quarts, U.S. (qt)

× 0.946

= liters (l)

liters (l)

× 1.057

= quarts, U.S. (qt)

quarts, U.S. (qt)

× 0.83

= quarts, Imp. (qt)

quarts, Imp. (qt)

× 1.205

= quarts, U.S. (qt)

gallons, U.S. (gal)

× 3.785

= liters (l)

liters (l)

× 0.264

= gallons, U.S. (gal)

gallons, U.S. (gal)

× 0.83

= gallons, Imp. (gal)

gallons, Imp. (gal)

× 1.205

= gallons, U.S. (gal)

ounces (oz)

× 29.57

= milliliters (ml)

milliliters (ml)

× 0.034

= ounces (oz)

(cm )

centimeters

(cm 3)

General

8000 YRM 231 Table 8. Cotter Pin Dimensional Data

Nominal Size

Shank Diameter A

Head Dia. B

Length of Extended Prong C

Recommended Hole Size

max

min

max

min

max

1.00 mm (0.031 in.)

0.90 mm (0.035 in.)

0.70 mm (0.028 in.)

1.50 mm (0.060 in.)

1.52 mm (0.060 in.)

0.25 mm (0.01 in.)

0.91 mm (0.036 in.)

1.37 mm (0.054 in.)

1.60 mm (0.047 in.)

1.20 mm (0.048 in.)

0.90 mm (0.035 in.)

1.50 mm (0.060 in.)

2.54 mm (0.10 in.)

0.51 mm (0.02 in.)

1.50 mm (0.059 in.)

1.78 mm (0.070 in.)

2.00 mm (0.062 in.)

1.50 mm (0.060 in.)

1.30 mm (0.051 in.)

2.40 mm (0.094 in.)

2.54 mm (0.10 in.)

0.76 mm (0.03 in.)

1.90 mm (0.075 in.)

2.18 mm (0.086 in.)

2.50 mm (0.094 in.)

2.30 mm (0.091 in.)

2.10 mm (0.083 in.)

4.00 mm (0.158 in.)

2.54 mm (0.10 in.)

1.00 mm (0.04 in.)

2.41 mm (0.095 in.)

2.95 mm (0.116 in.)

3.20 mm (0.125 in.)

3.00 mm (0.120 in.)

2.70 mm (0.106 in.)

5.10 mm (0.201 in.)

3.30 mm (0.13 in.)

1.52 mm (0.06 in.)

3.12 mm (0.123 in.)

3.76 mm (0.148 in.)

4.00 mm (0.156 in.)

3.80 mm (0.150 in.)

3.50 mm (0.138 in.)

6.50 mm (0.256 in.)

4.06 mm (0.16 in.)

1.78 mm (0.07 in.)

3.94 mm (0.155 in.)

4.55 mm (0.179 in.)

5.00 mm (0.188 in.)

4.60 mm (0.181 in.)

4.40 mm (0.172 in.)

8.00 mm (0.315 in.)

4.06 mm (0.16 in.)

2.03 mm (0.08 in.)

4.93 mm (0.194 in.)

5.33 mm (0.210 in.)

6.30 mm (0.250 in.)

5.90 mm (0.232 in.)

5.60 mm (0.220 in.)

10.3 mm (0.406 in.)

4.06 mm (0.16 in.)

2.03 mm (0.08 in.)

6.22 mm (0.245 in.)

6.96 mm (0.274 in.)

8.00 mm (0.312 in.)

7.50 mm (0.295 in.)

7.00 mm (0.275 in.)

13.1 mm (0.516 in.)

4.06 mm (0.16 in.)

2.03 mm (0.08 in.)

7.85 mm (0.309 in.)

8.28 mm (0.326 in.)

9.50 mm (0.375 in.)

9.50 mm (0.374 in.)

8.40 mm (0.329 in.)

16.6 mm (0.654 in.)

6.35 mm (0.25 in.)

4.06 mm (0.16 in.)

9.45 mm (0.372 in.)

9.73 mm (0.383 in.)

13.0 mm (0.500 in.)

12.4 mm (0.488 in.)

11.9 mm (0.467 in.)

21.7 mm (0.854 in.)

6.35 mm (0.25 in.)

3.05 mm (0.12 in.)

12.62 mm (0.497 in.)

13.21 mm (0.520 in.)

16.0 mm (0.625 in.)

15.4 mm (0.606 in.)

15.0 mm (0.590 in.)

27.0 mm (1.063 in.)

8.89 mm (0.35 in.)

3.05 mm (0.12 in.)

15.80 mm (0.622 in.)

16.28 mm (0.641 in.)

8000 YRM 231

General Table 9. Cotter Pin Dimensional Data

Nominal Length L

Length Range

Nominal Size - Part Numbers 1.00 mm (0.031 in.)

1.60 mm (0.047 in.)

2.00 mm (0.062 in.)

2.50 mm (0.094 in.)

3.20 mm (0.125 in.)

11.5 mm (0.453 in.)

015414100

505959587

015414700

015415900

015417600

20.5 mm (0.807 in.)

18.3 mm (0.720 in.)

015414300

015414900

015416200

015417900

25.4 mm (1.000 in.)

26.9 mm (1.060 in.)

23.9 mm (0.940 in.)

015414500

015415100

015416500

015418200

31.75 mm (1.250 in.)

33.3 mm (1.310 in.)

29.2 mm (1.150 in.)

015415200

015416600

015418300

38.1 mm (1.500 in.)

40.9 mm (1.610 in.)

36.6 mm (1.440 in.)

015415400

015416700

015418400

44.45 mm (1.750 in.)

46.0 mm (1.810 in.)

42.9 mm (1.690 in.)

015415500

015416800

015418500

50.8 mm (2.000 in.)

52.3 mm (2.060 in.)

49.3 mm (1.940 in.)

015415600

015416900

015418600

57.15 mm (2.250 in.)

58.7 mm (2.310 in.)

55.1 mm (2.170 in.)

015417000

015418700

63.5 mm (2.500 in.)

65.0 mm (2.560 in.)

62.0 mm (2.440 in.)

015417100

015418800

69.85 mm (2.750 in.)

72.1 mm (2.840 in.)

68.3 mm (2.690 in.)

015418900

76.2 mm (3.000 in.)

81.3 mm (3.200 in.)

74.7 mm (2.940 in.)

015419000

88.9 mm (3.500 in.)

91.4 mm (3.600 in.)

87.4 mm (3.440 in.)

101.6 mm (4.000 in.)

113.3 mm (4.460 in.)

98.8 mm (3.890 in.)

max

min

6.35 mm (0.250 in.)

7.10 mm (0.280 in.)

5.50 mm (0.217 in.)

9.525 mm (0.375 in.)

10.5 mm (0.413 in.)

8.80 mm (0.345 in.)

12.7 mm (0.500 in.)

13.5 mm (0.530 in.)

19.05 mm (0.750 in.)

General

8000 YRM 231

Table 9. Cotter Pin Dimensional Data (Continued) Nominal Length L

Length Range max

min

127.0 mm (5.000 in.)

128.5 mm (5.060 in.)

123.7 mm (4.870 in.)

152.4 mm (6.000 in.)

153.9 mm (3.060 in.)

5.460 mm (138.7 in.)

Nominal Size - Part Numbers 1.00 mm (0.031 in.)

1.60 mm (0.047 in.)

2.00 mm (0.062 in.)

2.50 mm (0.094 in.)

3.20 mm (0.125 in.)

Table 10. Cotter Pin Dimensional Data Nominal Length L

Length Range 4.00 mm (0.156 in.)

5.00 mm (0.188 in.)

18.3 mm (0.720 in.)

015419600

015421000

23.9 mm (0.940 in.)

015419800

015421200

max

min

6.35 mm (0.250 in.)

7.10 mm (0.280 in.)

5.50 mm (0.217 in.)

9.525 mm (0.375 in.)

10.5 mm (0.413 in.)

8.80 mm (0.345 in.)

12.7 mm (0.500 in.)

13.5 mm (0.530 in.)

11.5 mm (0.453 in.)

19.05 mm (0.750 in.)

20.5 mm (0.807 in.)

25.4 mm (1.000 in.)

26.9 mm (1.060 in.)

Nominal Size - Part Numbers 6.30 mm (0.250 in.)

8.00 mm (0.312 in.)

015423200

015425100

9.52 mm (0.375 in.)

8000 YRM 231

General

Table 10. Cotter Pin Dimensional Data (Continued) Nominal Length L

Length Range

Nominal Size - Part Numbers 4.00 mm (0.156 in.)

5.00 mm (0.188 in.)

6.30 mm (0.250 in.)

8.00 mm (0.312 in.)

9.52 mm (0.375 in.)

29.2 mm (1.150 in.)

015420000

015421300

015423300

015425200

015426700

40.9 mm (1.610 in.)

36.6 mm (1.440 in.)

015420100

015421400

015423400

015425300

015426800

44.45 mm (1.750 in.)

46.0 mm (1.810 in.)

42.9 mm (1.690 in.)

015420300

015421600

015423500

015425400

015426900

50.8 mm (2.000 in.)

52.3 mm (2.060 in.)

49.3 mm (1.940 in.)

015420400

015421700

015423600

015425500

015427000

57.15 mm (2.250 in.)

58.7 mm (2.310 in.)

55.1 mm (2.170 in.)

015420500

015421800

015423800

015425600

015427100

63.5 mm (2.500 in.)

65.0 mm (2.560 in.)

62.0 mm (2.440 in.)

015420600

015421900

015423900

015425700

015427200

69.85 mm (2.750 in.)

72.1 mm (2.840 in.)

68.3 mm (2.690 in.)

015420700

015422000

015424000

015425800

015427300

76.2 mm (3.000 in.)

81.3 mm (3.200 in.)

74.7 mm (2.940 in.)

015420800

015422100

015424100

015425900

015427400

88.9 mm (3.500 in.)

91.4 mm (3.600 in.)

87.4 mm (3.440 in.)

015422300

015424300

015426100

056602300

101.6 mm (4.000 in.)

113.3 mm (4.460 in.)

98.8 mm (3.890 in.)

015422400

015424400

015426200

015427700

127.0 mm (5.000 in.)

128.5 mm (5.060 in.)

123.7 mm (4.870 in.)

015426400

015427900

152.4 mm (6.000 in.)

153.9 mm (3.060 in.)

5.460 mm (138.7 in.)

max

min

31.75 mm (1.250 in.)

33.3 mm (1.310 in.)

38.1 mm (1.500 in.)

015428100

General

8000 YRM 231 Table 11. Cotter Pin Dimensional Data

Nominal Length L

Length Range

Nominal Size - Part Numbers 13.0 mm (0.500 in.)

max

min

19.05 mm (0.750 in.)

20.5 mm (0.807 in.)

18.3 mm (0.720 in.)

25.4 mm (1.00 in.)

26.9 mm (1.060 in.)

23.9 mm (0.940 in.)

31.75 mm (1.250 in.)

33.3 mm (1.310 in.)

29.2 mm (1.150 in.)

38.1 mm (1.500 in.)

40.9 mm (1.610 in.)

36.6 mm (1.440 in.)

44.45 mm (1.750 in.)

46.0 mm (1.810 in.)

42.9 mm (1.690 in.)

015428400

50.8 mm (2.000 in.)

52.3 mm (2.060 in.)

49.3 mm (1.940 in.)

015428500

57.15 mm (2.250 in.)

58.7 mm (2.310 in.)

55.1 mm (2.170 in.)

015428600

63.5 mm (2.500 in.)

65.0 mm (2.560 in.)

62.0 mm (2.440 in.)

015428700

69.85 mm (2.750 in.)

72.1 mm (2.840 in.)

68.3 mm (2.690 in.)

015428800

76.2 mm (3.000 in.)

81.3 mm (3.200 in.)

74.7 mm (2.940 in.)

015428900

88.9 mm (3.500 in.)

91.4 mm (3.600 in.)

87.4 mm (3.440 in.)

015429100

101.6 mm (4.000 in.)

113.3 mm (4.460 in.)

98.8 mm (3.890 in.)

015429200

127.0 mm (5.000 in.)

128.5 mm (5.060 in.)

123.7 mm (4.870 in.)

015429400

152.4 mm (6.000 in.)

153.9 mm (3.060 in.)

138.7 mm (5.460 in.)

052670500

16.00 mm (0.625 in.)

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

8000 YRM 231

12/04 (3/04)(3/03)(7/02)(8/01) Printed in U.S.A.

Maintenance

OPERATOR’S CAB ERP22-35VL (ERP045-070VL) [A976]; ERP15-20VT [G807]; ERC22-35VG (ERC045-070VG) [A968]; ERP16-20VF [A955]

PART NO. 550025937

100 YRM 1446

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Operator’s Cab

Table of Contents

TABLE OF CONTENTS Window Replacement.......................................................................................................................................... Front Panel ...................................................................................................................................................... Remove....................................................................................................................................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Install .......................................................................................................................................................... Rear Panel ...................................................................................................................................................... Remove....................................................................................................................................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Install .......................................................................................................................................................... Door Window................................................................................................................................................... Disassemble Window.................................................................................................................................. Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble Window ...................................................................................................................................... Window Wipers Replacement ............................................................................................................................. Front Wiper Assembly ..................................................................................................................................... Remove....................................................................................................................................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Install .......................................................................................................................................................... Cab Component Repair....................................................................................................................................... Roof Liner........................................................................................................................................................ Remove....................................................................................................................................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Install .......................................................................................................................................................... Top Panel ........................................................................................................................................................ Remove....................................................................................................................................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Install .......................................................................................................................................................... Cab Door Assembly............................................................................................................................................. Door Assembly ................................................................................................................................................ Remove....................................................................................................................................................... Disassemble Left Door................................................................................................................................ Disassemble Right Door ............................................................................................................................. Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble Right Door .................................................................................................................................. Assemble Left Door .................................................................................................................................... Install .......................................................................................................................................................... Cab Heater .......................................................................................................................................................... Cab Heater...................................................................................................................................................... Remove....................................................................................................................................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Install .......................................................................................................................................................... Troubleshooting........................................................................................................................................... Weather Panel Replacement for Lift Truck Model ERC22-35VG (ERC045-070VG) (A968)................................

1 1 1 1 2 2 2 2 5 5 5 6 6 7 7 7 7 7 7 11 11 11 12 12 12 13 13 13 13 13 15 15 15 15 15 15 18 20 20 20 22 22 22 23 23 23 23 26 26 26 29

Table of Contents

Operator’s Cab

29 29 32 32 32 32

100 YRM 1446

Window Replacement

Window Replacement FRONT PANEL Remove WARNING All windows installed in the cab are made of safety glass. All replacement windows must be made of the correct material and must be made the correct thickness. Failure to have the correct material or thickness may cause the glass to break easily when struck and may cause personal injury.

Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Using compressed air, blow dirt and debris from components as needed. 2. Using a lint free cloth, wipe down front window and other components as needed.

WARNING Disconnect the battery before doing any work on the electrical system. Serious injury to personnel and/or damage to lift truck components can occur if battery is not disconnected. Discharge capacitors as directed in Discharging the Capacitors in General section of this manual. NOTE: In Step 1 and Step 2 note placement of components during removal to aid in installation. 1. Remove nut, bolt, and six washers from upper right hand corner of front window. See Figure 1. 2. Remove nut cover, nut, five washers, and screw from front window in five places. Remove front window from overhead guard. See Figure 2. 3. Remove and discard seal from front window. See Figure 2. NOTE: Perform Step 4 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 4. Remove light brackets from overhead guard, if equipped. See section Electrical System 2200 YRM 1369 Light Assemblies Replacement for proper instruction.

Clean WARNING Compressed air can move particles so that they cause injury to the user or to other personnel.

NOTE: OVERHEAD GUARD NOT SHOWN FOR CLARITY. 1. 2. 3. 4. 5. 6.

FRONT WINDOW INSERT WASHER SCREW NUT COVER WIRE HARNESS

7. 8. 9. 10. 11. 12.

WIPER KIT SWITCH CAPSCREW BOLT NUT BRACKET

Figure 1. Front Panel and Wiper

Window Replacement

100 YRM 1446 3. Install front window on overhead guard. Install two washers, screw, two washers, bracket, washer, nut, and nut cover on front window in five places. See Figure 2. 4. Install two washers, bolt, four washers, and nut on upper right hand corner of front window. See Figure 1.

REAR PANEL Remove 1. Remove flange nut, cover, wiper arm, and wiper blade from wiper motor. See Figure 3. 2. Disconnect wiring harness from wiper motor and remove wiper motor from rear panel. See Figure 3. 3. Remove two screws and latch from overhead guard legs in two places. See Figure 3. NOTE: OVERHEAD GUARD NOT SHOWN FOR CLARITY. 1. 2. 3. 4.

FRONT WINDOW SEAL SCREW WASHER

5. 6. 7. 8.

BRACKET NUT NUT COVER LIGHT BRACKET

Figure 2. Front Panel Assembly

Inspect 1. Inspect front window for damage and cracks, replace if damaged. 2. Inspect components and hardware for cracks and defects. Replace as needed.

Install 1. Install seal on front window. See Figure 2. NOTE: Perform Step 2 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 2. Install light brackets on overhead guard, if equipped. See section Electrical System 2200 YRM 1369 Light Assemblies Replacement for proper instructions.

4. Remove five capscrews and bracket from cab body. See Figure 3. 5. Disconnect gas spring from lower ball stud in two places. See Figure 4. 6. Remove cap, capscrew and washer from overhead guard and rear panel in two places. Remove rear panel from overhead guard. See Figure 3. 7. If damaged, remove ball stud from overhead guard leg in two places. See Figure 4. 8. Remove nut cover, nut, four washers, and hinge from rear panel in two places. See Figure 4. 9. Remove nut cover, nut, plate, washer, screw, and cap from hinge. Repeat for second hinge. See Figure 4. 10. Disconnect gas spring from upper ball stud on knob in two places. See Figure 4. 11. Remove ball stud from knob in two places. See Figure 4.

100 YRM 1446

Window Replacement

NOTE: OVERHEAD GUARD NOT SHOWN FOR CLARITY. 1. 2. 3. 4. 5. 6. 7.

REAR PANEL CAP CAPSCREW WASHER SCREW WIRE HARNESS SWITCH

8. 9. 10. 11. 12. 13. 14.

WIPER MOTOR WIPER BLADE WIPER ARM BRACKET LATCH COVER FLANGE NUT

Figure 3. Rear Panel and Wiper Attachment

Window Replacement

100 YRM 1446

NOTE: OVERHEAD GUARD NOT SHOWN FOR CLARITY. 1. 2. 3. 4. 5. 6. 7. 8. 9.

REAR PANEL SEAL NUT COVER PLATE WASHER HINGE SCREW NUT BALL STUD

10. 11. 12. 13. 14. 15. 16. 17. 18.

GAS SPRING KNOB ORING PLUG GRIP LATCH CONNECTOR BRACKET CAP

Figure 4. Rear Panel Assembly

100 YRM 1446 12. Remove screw, three washers, o-ring, and knob from rear panel in two places. See Figure 4. 13. Remove nut cover, nut, and two washers from connector on outside of rear panel. Repeat for opposite side. See Figure 4. 14. Remove plug, grip, nut, two washers, plug, connector, and two washers from inside of rear panel. Repeat for opposite side. See Figure 4. 15. Remove and discard seal from rear screen. See Figure 4.

Clean WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Using compressed air, blow dirt and debris from components as needed. 2. Using a lint free cloth, wipe down rear screen and other components as needed.

Inspect 1. Inspect components for cracks and defects. Replace as needed. 2. Inspect gas springs for proper travel and extension. Replace as necessary. a. Extended length; 735 mm (28.9 in.). b. Stroke length, 315 mm (12.4 in.). c. Resistance, 150 N (33.7 lbf). 3. Inspect wiper blade for cracks and tearing. Replace as needed.

Window Replacement 2. Install two washers, connector, plug, two washers, nut, grip, and plug on inside of rear panel. Repeat for opposite side. See Figure 4. 3. Install two washers, nut, and nut cover on connector on outside of rear panel. Repeat for opposite side. See Figure 4. 4. Install knob, o-ring, three washers, and screw on rear screen in two places. See Figure 4. 5. Install ball stud on knob in two places. See Figure 4. 6. Connect gas spring to upper ball stud on knob in two places. See Figure 4. 7. Install plate, washer, screw, nut, nut cover, and cap on hinge. Repeat for second hinge. See Figure 4. 8. Install washer, hinge, screw, three washers, nut, and nut cover on rear panel in two places. See Figure 4. 9. If removed, install ball stud on overhead guard leg in two places. See Figure 4. 10. Install rear panel on overhead guard. Install washer, capscrew, and cap on rear panel and overhead guard in two places. See Figure 3. 11. Connect gas spring to two lower ball stud in two places. See Figure 4. 12. Install bracket and five capscrews on cab body. See Figure 3. 13. Install latch and two screws on overhead guard legs in two places.. See Figure 3. 14. Install rear wiper motor on rear panel and connect wiring harness to rear wiper motor. See Figure 3. 15. If removed, install wiper blade on wiper arm. See Figure 3. 16. Using a flange nut, install wiper arm and wiper blade on wiper motor. See Figure 3.

Install 1. Install seal on rear screen. See Figure 4.

Window Replacement

100 YRM 1446

DOOR WINDOW

3. Remove two sliding windows from window frame. See Figure 5.

Disassemble Window NOTE: The following procedure applies to right and left doors. 1. Remove window frame and window assembly from door assembly. See Figure 5. 2. Remove two latches from two sliding windows. See Figure 5.

4. Remove and discard four guides from two sliding windows. See Figure 5. 5. Remove and discard seal from rear of sliding window. See Figure 5. 6. Remove and discard five seals from window frame. See Figure 5.

NOTE: RIGHT-HAND SIDE SHOWN. 1. 2. 3. 4.

SLIDING WINDOW SEAL LATCH STRIP SEAL

5. 6. 7. 8.

CLIP WINDOW FRAME EDGE PROTECTOR GUIDE

Figure 5. Window Components

100 YRM 1446

Window Wipers Replacement

7. Remove and discard strip seal from window frame. See Figure 5.

2. Inspect latch assembly and hardware. proper operation.

8. Remove and discard six clips from window frame. See Figure 5.

3. Inspect windows for chips and cracks. Replace as necessary.

9. Remove and discard edge protector from window frame. See Figure 5.

Assemble Window

Ensure

NOTE: The following procedure applies to right and left doors.

1. Install edge protector and six clips on window frame. See Figure 5. 2. Install strip seal and five seals on window frame. See Figure 5. 3. Install seal on rear of sliding window. See Figure 5.

1. Using compressed air, blow dirt and debris from components as needed.

4. Install four guides on two sliding windows. See Figure 5.

2. Using a lint free cloth, wipe down windows on both doors and other components as needed.

5. Install two sliding windows on window frame. See Figure 5.

Inspect

6. Install two latches to sliding windows. See Figure 5.

1. Inspect all components and hardware for cracks and defects. Replace as needed.

7. Install window frame and window assembly to door assembly. See Figure 5.

Window Wipers Replacement FRONT WIPER ASSEMBLY Remove 1. Disconnect wire harness from wiper motor connector. See Figure 6 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 7 for lift truck models • ERP15-20VT (G807) 2. Disconnect wire harness from washer pump connector.

See Figure 7 for lift truck models • ERP15-20VT (G807) NOTE: Perform Step 3 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 3. Disconnect hose (6) from connector (7). See Figure 6. NOTE: Perform Step 4 for lift truck models ERP15-20VT (G807). 4. Disconnect hose (15) from connector (11). See Figure 7.

See Figure 6 for lift truck models • ERP22-35VL (ERP045-070VL) (A976)

Window Wipers Replacement

1. 2. 3. 4. 5. 6. 7. 8.

WIPER MOTOR WIPER ARM WIPER BLADE NOZZLE (CLIP) CLAMP HOSE CONNECTOR (SPRAY NOZZLE) HOSE

100 YRM 1446

9. 10. 11. 12. 13. 14. 15.

CHECK VALVE BRACKET RESERVOIR WASHER CAPSCREW WASHER PUMP CONNECTOR WIPER MOTOR CONNECTOR

Figure 6. Front Wiper Assembly for Lift Truck Model ERP22-35VL (ERP045-070VL) (A976) NOTE: Perform Step 5 for lift truck model ERP22-35VL (ERP045-070VL) (A976).

See Figure 6 for lift truck models • ERP22-35VL (ERP045-070VL) (A976)

5. Remove two clamps (5), hose (6), and nozzle (4) from wiper arm. Set aside for installation. See Figure 6.

See Figure 7 for lift truck models • ERP15-20VT (G807)

6. Remove two flange nuts, wiper arms, and wiper blade from wiper motor. See Figure 8. 7. Remove wiper blade from wiper arm.

8. Remove two nut covers, two nuts, two washers, and wiper motor from lift truck. See Figure 8.

100 YRM 1446

1. 2. 3. 4. 5. 6. 7. 8.

Window Wipers Replacement

WIPER MOTOR WIPER ARM WIPER BLADE RESERVOIR CAP CAPSCREW WASHER BRACKET

9. 10. 11. 12. 13. 14. 15. 16.

NUT CHECK VALVE CONNECTOR CHECK VALVE CONNECTOR HOSE HOSE HOSE WIRING CONNECTOR

Figure 7. Front Wiper Assembly for LIft Truck Model ERP15-20VT (G807)

Window Wipers Replacement

1. 2. 3. 4.

100 YRM 1446

WIPER MOTOR WASHER NUT NUT COVER

5. WIPER ARM 6. FLANGE NUTS 7. WIPER BLADE

Figure 8. Wiper Attachment 9. Disconnect hose from reservoir. See Figure 6 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 7 for lift truck models • ERP15-20VT (G807) NOTE: Perform Step 10 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 10. Remove two capscrews, two washers, and reservoir from cowl. NOTE: Perform Step 11 for lift truck model ERP1520VT (G807). 11. Remove three caps, three nuts, six washers, three capscrews, reservoir, and bracket from overhead guard leg. See Figure 7.

NOTE: Perform Step 12 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 12. Remove four capscrews, washers, and reservoir from bracket. See Figure 6. 13. Disconnect and remove check valve. Set aside for installation. See Figure 6 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 7 for lift truck models • ERP15-20VT (G807) NOTE: Perform Step 14 for lift truck modelERP22-35VL (ERP045-070VL) (A976). 14. Disconnect and remove connector from hose (8). Set hose aside for installation. See Figure 6.

100 YRM 1446

Window Wipers Replacement

NOTE: Perform Step 15 for lift truck model ERP1520VT (G807).

5. Install reservoir, washers, and four capscrews on bracket. See Figure 6.

15. Disconnect and remove connector (11) from hose (13). Set aside for installation. See Figure 7.

NOTE: Perform Step 6 for lift truck model ERP15-20VT (G807).

Clean

6. Install bracket, pump, six washers, three capscrews, three nuts, and three caps on overhead guard leg. See Figure 7.

NOTE: Perform Step 7 for lift truck model ERP22-35VL (ERP045-070VL) (A976).

1. Using compressed air, clean outside of wiper motor, reservoir and wiper arms.

8. Connect hose to reservoir.

7. Using two washers and two capscrews, install reservoir on cowl.

Inspect

See Figure 6 for lift truck models • ERP22-35VL (ERP045-070VL) (A976)

1. Inspect hoses for cracks and wear. Replace if damaged.

See Figure 7 for lift truck models • ERP15-20VT (G807).

2. Check washer reservoir for leaks by filling with water and checking seams. Replace if leaking.

9. Using two washers, two nuts, and two caps, install wiper motor to lift truck. See Figure 8.

3. Inspect wiper blades for cracks and tearing. Replace as needed.

10. Install wiper blade on wiper arm.

Install NOTE: Perform Step 1 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 1. Connect hose (8) to connector. See Figure 6. NOTE: Perform Step 2 for lift truck model ERP15-20VT (G807). 2. Connect hose (13) to connector (11). See Figure 7. NOTE: Perform Step 3 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 3. Connect check valve into hose (8). Connect hose (8) to other end of check valve. See Figure 6. NOTE: Perform Step 4 for lift truck model ERP15-20VT (G807). 4. Connect check valve to hose (13). Connect hose (14) to other end of check valve. See Figure 7. NOTE: Perform Step 5 for lift truck model ERP22-35VL (ERP045-070VL) (A976).

See Figure 6 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 7 for lift truck models • ERP15-20VT (G807). 11. Using two flange nuts, install wiper arm and wiper blade on wiper motor. See Figure 6 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 7 for lift truck models • ERP15-20VT (G807) NOTE: Perform Step 12 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 12. Install nozzle (4), hose (6),and two clamps (5) on wiper arm. See Figure 6. NOTE: Perform Step 13 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 13. Connect hose (6) to connector (7). See Figure 6. NOTE: Perform Step 14 for lift truck model ERP1520VT (G807). 14. Connect hose (15) to connector (11). See Figure 7.

Cab Component Repair

100 YRM 1446

15. Connect wire harness to wiper motor connector.

16. Connect wire harness to washer pump connector.

See Figure 6 for lift truck models • ERP22-35VL (A976)

See Figure 6 for lift truck models • ERP22-35VL (ERP045-070VL) (A976)

See Figure 7 for lift truck models • ERP15-20VT (G807)

Cab Component Repair ROOF LINER Remove NOTE: Perform Step 1 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 1. Remove seven caps, seven capscrews, and seven washers from roof liner. See Figure 9. NOTE: Perform Step 2 for lift truck model ERP15-20VT (G807). 2. Remove seven capscrews and seven washers from roof liner. See Figure 10.

1. ROOF PANEL 2. CAPSCREW 3. WASHER

4. ROOF LINER 5. DOME LIGHT 6. SCREW

Figure 10. Roof Liner for Lift Truck Model ERP15-20VT (G807) NOTE: Note position of wire harness and washer hose through notched cutout in rear of roof liner. 3. Disconnect dome light harness and rear wiper switch harness (if equipped). 4. Remove two screws and dome light from roof liner. See Figure 9 for truck models • ERP22-35VL (ERP045-070VL) (A976) 1. 2. 3. 4.

ROOF PANEL CAP CAPSCREW WASHER

5. ROOF LINER 6. DOME LIGHT 7. SCREW

Figure 9. Roof Liner for Lift Truck Model ERP22-35VL (ERP045-070VL) (A976)

See Figure 10 for truck models • ERP15-20VT (G807) 5. Remove rear wiper switch from roof liner (if equipped). 6. Remove roof liner from overhead guard.

100 YRM 1446

Clean WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Using compressed air, blow dirt and debris off of roof liner. 2. Using a lint free cloth, wipe down overhead guard.

Inspect 1. Inspect roof liner for cracks and defects. Replace as needed. 2. Inspect hardware for defects, replace as needed.

Install 1. Install roof liner on overhead guard. 2. Route wire harness and washer hose through notched cut out in rear of roof liner as noted during removal. 3. Install rear wiper switch to preformed cutout of roof liner (if equipped). 4. Using two screws, install dome light on roof liner.

Cab Component Repair 7. Install seven washers and seven capscrews on roof liner. See Figure 10.

TOP PANEL Remove NOTE: Perform Step 1 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 1. Disconnect front light wiring. See section Electrical System 2200 YRM 1369 Light Assemblies Replacement for proper procedures.

CAUTION All windows installed in the cab are made of safety glass. All replacement windows must be made of the correct material and must be made the correct thickness. Failure to have the correct material or thickness may cause the glass to break easily when struck and may cause personal injury. NOTE: Due to use of glue and RTV sealer, replacement of front screen and rear screen is to be done only if damaged. 2. Remove and discard grommets from top panel assembly. See Figure 11. 3. Remove four nuts, four washers, four capscrews, and roof panel from top panel assembly. See Figure 11.

See Figure 9 for truck models • ERP22-35VL (ERP045-070VL) (A976)

4. Remove and discard seal from screen. See Figure 11.

See Figure 10 for truck models • ERP15-20VT (G807)

5. Remove two nuts, four washers, two hinges, and pin from screen. See Figure 11.

5. Connect dome light harness and rear wiper switch harness, if equipped.

6. Remove two nut covers, two nuts, two washers, and plate from screen. See Figure 11.

NOTE: Perform Step 6 for lift truck model ERP22-35VL (ERP045-070VL) (A976).

7. Remove screw, spring, and grip from screen. See Figure 11.

6. Install seven washers, seven capscrews, and seven caps on roof liner. See Figure 9.

8. Remove two nut covers, two nuts, two washers, and grip mounting plate from screen. See Figure 11.

NOTE: Perform Step 7 for lift truck model ERP15-20VT (G807).

Cab Component Repair

100 YRM 1446

Figure 11. Top Panel

100 YRM 1446

Cab Door Assembly

Legend for Figure 11 1. 2. 3. 4. 5. 6. 7. 8.

ROOF PANEL TOP PANEL ASSEMBLY GROMMET SCREEN PIN HINGE WASHER NUT

9. 10. 11. 12. 13. 14. 15.

Clean

PLATE GRIP MOUNTING PLATE NUT COVER GRIP SPRING SCREW SEAL

2. Install grip, spring, and screw on screen. See Figure 11.

3. Install plate, two washers, two nuts, and two nut covers on screen. See Figure 11. 4. Install pin, two hinges, four washers, and two nuts on screen. See Figure 11. 5. Install seal on screen. See Figure 11.

1. Using compressed air, blow dirt and debris from all components as needed. 2. Using warm soapy water, clean plastic, rubber, and vinyl components. Wipe dry with a lint free cloth.

6. Install roof panel, four washers, four capscrews, and four nuts on top panel assembly. See Figure 11.

Inspect

7. Install two grommets to top panel assembly. See Figure 11.

1. Inspect hinges, rod, spring and grip for damage or cracks. Replace as needed.

NOTE: Perform Step 8 for lift truck model ERP22-35VL (ERP045-070VL) (A976).

Install

8. Install front light wiring. See Electrical System 2200 YRM 1369 Light Assemblies Replacement section for proper procedures.

1. Install grip mounting plate, two washers, two nuts, and two nut covers on screen. See Figure 11.

Cab Door Assembly DOOR ASSEMBLY Remove WARNING The door assemblies are heavy, verify the lifting device being used during repairs can lift the weight of the parts and assembly. 1. Disconnect gas spring from top of door assembly. See Figure 12 for lift truck models • ERP22-35VL (ERP045-070VL) (A976)

NOTE: Perform Step 2 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 2. Remove three capscrews from upper hinge. Remove three capscrews from lower hinge. See Figure 12. NOTE: Perform Step 3 for lift truck model ERP15-20VT (G807). 3. Remove two screws from mounting plate and hinge in two places. Remove three bolts from mounting plate and overhead guard leg in two places. See Figure 13.

See Figure 13 for lift truck models • ERP15-20VT G807)

Cab Door Assembly

1. 2. 3. 4. 5. 6. 7. 8.

DOOR ASSEMBLY (RH) DOOR ASSEMBLY (LH) HINGE (UPPER) HINGE (LOWER) BOLT GUARD BLOCK STRIKER

100 YRM 1446

9. 10. 11. 12. 13. 14. 15.

BRACKET GAS SPRING NUT BALL STUD CAPSCREW WASHER CAP

Figure 12. Door Assembly for Lift Truck Model ERP22-35VL (ERP045-070VL) (A976)

100 YRM 1446

Cab Door Assembly

Figure 13. Door Assembly for Lift Truck Model ERP15-20VT (G807)

Cab Door Assembly

100 YRM 1446

Legend for Figure 13 1. 2. 3. 4. 5. 6. 7.

DOOR ASSEMBLY DOOR ASSEMBLY MOUNTING PLATE HINGE GAS SPRING BRACKET BLOCK

8. 9. 10. 11. 12. 13. 14.

GUARD BOLT SCREW CAPSCREW WASHER CAP CAP

4. Using a lifting device, remove door assembly from lift truck and set aside.

1. Remove and discard two seals from door assembly. See Figure 14.

NOTE: Perform Step 5 for lift truck model ERP22-35VL (ERP045-070VL) (A976).

NOTE: Perform Step 2 for lift truck model ERP15-20VT (G807).

5. Remove three caps, three bolts, four washers, bolt, guard, striker, and block from front overhead guard leg. See Figure 12.

NOTE: Lift truck models ERP15-20VT (G807) have a one piece seal around door assembly.

NOTE: Perform Step 6 for lift truck model ERP15-20VT (G807). 6. Remove two caps, two capscrews, two washers, bolt, guard, bracket and block from front overhead guard leg. See Figure 13. 7. Remove gas spring from overhead guard. 8. Remove two caps, two capscrews, two washers, and bracket from overhead guard. See Figure 12 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 13 for lift truck models • ERP15-20VT (G807) 9. Repeat Step 1 through Step 8 for opposite side.

Disassemble Left Door NOTE: Perform Step 1 for lift truck model ERP22-35VL (ERP045-070VL) (A976).

2. Remove and discard seal from door assembly. See Figure 14. 3. Remove screw, washer, lock plate cover, and plate from door assembly. See Figure 14. 4. Disconnect rod from latch. See Figure 14. 5. Remove screw, washer, door handle, tube, rod, and lock from door assembly. See Figure 14. 6. Remove seven fasteners and door cover from door assembly. See Figure 14. 7. Remove two screws and latch from door assembly. See Figure 14. 8. Remove screw and plate from grip. See Figure 14. 9. Remove two screws, two washers, seal, and grip from door assembly. See Figure 14.

100 YRM 1446

1. 2. 3. 4. 5. 6. 7. 8.

SEAL SCREW WASHER LOCK PLATE COVER PLATE ROD TUBE DOOR HANDLE

Cab Door Assembly

9. 10. 11. 12. 13. 14. 15. 16.

FASTENER COVER (DOOR) LOCK LATCH DOOR ASSEMBLY GRIP WINDOW DOOR WINDOW

Figure 14. Left Door Components

Cab Door Assembly

Disassemble Right Door NOTE: Perform Step 1 and Step 2 if lift truck is equipped with cab heater. 1. Remove eight screws and four washers from cab heater and heater control (if equipped). 2. Disconnect wiring harness from cab heater and heater control. Remove cab heater and heater control from door assembly. 3. Remove and discard two seals from door assembly. See Figure 15. 4. Remove four screws, four washers, and plate from door assembly. See Figure 15. 5. Remove four screws and cover from door assembly. See Figure 15. 6. Remove four screws, and handle from inside door assembly. See Figure 15.

100 YRM 1446 NOTE: Perform Step 15 for lift truck model ERP1520VT (G807). 15. Remove three screws, three washers, seal, and grip from door assembly. See Figure 15.

Inspect

7. Remove two screws and clamp from inside door assembly. See Figure 15.

1. Inspect all components and hardware for cracks and defects. Replace as needed.

8. Remove two screws, two washers, and plate from door assembly. See Figure 15.

2. Inspect latch assembly and hardware. proper operation.

9. Remove seven fasteners and cover from door assembly. See Figure 15.

3. Inspect hinges and lubricate as necessary.

10. Disconnect rod from latch. See Figure 15. 11. Remove two screws and latch from door assembly. See Figure 15. 12. Remove two screws, two washers, two nuts, rod, and lever from door assembly. See Figure 15. 13. Remove screw and plate from grip. See Figure 15. NOTE: Perform Step 14 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 14. Remove four screws, four washers, seal, and grip from door assembly. See Figure 15.

Ensure

4. Inspect gas springs for proper travel and extension. a. Left door extended length 406 mm (16 in.). Right door extended length 880 mm (34.6 in.). b. Left door stroke 160 mm (6.3 in.). Right door stroke 393 mm (15.5 in.) c. Left door resistance 200 N (50 lbf). Right side resistance 200 N (50 lbf).

100 YRM 1446

1. 2. 3. 4. 5. 6. 7. 8.

WINDOW SEAL GRIP DOOR SCREW HANDLE PLATE COVER

Cab Door Assembly

9. 10. 11. 12. 13. 14. 15.

NUT LEVER WASHER ROD FASTENER LATCH CLAMP

Figure 15. Right Door Components

Cab Door Assembly

Assemble Right Door NOTE: Perform Step 1 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 1. Install seal, grip, four washers, and four screws on door assembly. See Figure 15. NOTE: Perform Step 2 for lift truck ERP15-20VT (G807).

100 YRM 1446 3. Install latch and two screws on door assembly. See Figure 14. 4. Install door cover and seven fasteners on door assembly. See Figure 14. 5. Install lock, rod, door handle, tube, washer, and screw onto door assembly. See Figure 14. 6. Connect rod onto door latch. See Figure 14.

2. Install seal, grip, three washers, and three screws on door assembly. See Figure 15.

7. Install plate, cover, washer, and screw on door assembly. See Figure 14.

3. Install plate and screw on grip. See Figure 15.

NOTE: Perform Step 8 for lift truck model ERP22-35VL (ERP045-070VL) (A976).

4. Install lever, rod, two nuts, two washers, and two screws on door assembly. See Figure 15.

8. Install two seals to door assembly. See Figure 14.

5. Install latch and two screws on door assembly. See Figure 15.

NOTE: Perform Step 9 for lift truck model ERP15-20VT (G807).

6. Attach rod to latch. See Figure 15.

9. Install seal to door assembly. See Figure 14.

7. Install cover and seven fasteners on door assembly. See Figure 15.

Install

8. Install plate, two washers, and two screws on door assembly. See Figure 15. 9. Install clamp and two screws on door assembly. See Figure 15. 10. Install handle and four screws on door assembly. See Figure 15. 11. Install plate, four washers, and four screws on door assembly. See Figure 15. 12. Install cover and four screws on door assembly. See Figure 15.

NOTE: Use Loctite Yale P/N 501702902 or equivalent during installation of capscrews and bolts. 1. Install ball stud and screw onto door assembly. See Figure 12. 2. Install bracket, two washers, two capscrews, and two caps on overhead guard. See Figure 12 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 13 for lift truck models • ERP15-20VT (G807) 3. Install gas spring on overhead guard.

13. Install two seals on door assembly. See Figure 15. NOTE: Perform Step 14 and Step 15 if lift truck is equipped with cab heater. 14. Connect wiring to heater control and cab heater.

See Figure 12 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 13 for lift truck models • ERP15-20VT (G807)

15. Install heater control, cab heater, four washers and eight screws on door assembly.

NOTE: Perform Step 4 for lift truck model ERP22-35VL (ERP045-070VL) (A976).

Assemble Left Door

4. Install striker, block, guard, bolt, four washers, three bolts, and three caps on front overhead guard legs. See Figure 12.

1. Install seal, grip, two washers, and two screws on door assembly. See Figure 14. 2. Install plate and screw on grip. See Figure 14.

100 YRM 1446

Cab Heater

NOTE: Perform Step 5 for lift truck model ERP15-20VT (G807). 5. Install striker, block, guard, bolt, two washers, two bolts, and two caps to front overhead guard legs. See Figure 13. NOTE: Perform Step 6 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 6. Using a lifting device, lift door assembly in place and install six capscrews on overhead guard at rear of door. See Figure 12. NOTE: Perform Step 7 for lift truck model ERP15-20VT (G807).

7. Using a lifting device, lift door assembly in place and install six bolts and four screws to hinge mounting plate on overhead guard legs at rear of door. See Figure 13. NOTE: Perform Step 8 for truck model ERP22-35VL (ERP045-070VL) (A976). 8. Repeat Step 1 through Step 6 for opposite side door installation. NOTE: Perform Step 9 for lift truck model ERP15-20VT (ERP030-040VT) (G807). 9. Repeat Step 1 through Step 7 for opposite side door installation.

Cab Heater CAB HEATER Remove 1. Remove two screws and connector cover from cab heater. See Figure 16. 2. Disconnect wiring harness from cab heater. See Figure 16. 3. Remove four screws, four washers, and cab heater from door assembly. See Figure 16. 4. Remove two air filters from cab heater. See Figure 16. 5. Remove four screws and heater control from door assembly. See Figure 16. 6. Disconnect wiring harness from heater control. See Figure 16. 7. Remove two nuts, two washers, and two capscrews from heater harness and plate located on hydraulic tank. See Figure 17. 8. Remove two nuts, two washers, and two capscrews from contactor and plate located on hydraulic tank. See Figure 17.

9. Disconnect contactor from wire harness and remove from lift truck. See Figure 17. 10. Remove heater wiring harness from lift truck. See Figure 17. NOTE: Perform Step 11 only if heater fan motor inoperative prior to removing from lift truck. 11. Remove 25 Amp fuse from in line fuse holder and inspect for broken element. Replace as necessary. See Figure 17.

Clean WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Using compressed air, blow dirt and debris from cab heater, heater control, air filters and all other components as necessary. 2. Using a lint free cloth, wipe down components as needed.

Cab Heater

1. 2. 3. 4. 5.

CAB HEATER WIRE HARNESS SCREW CAPSCREW WASHER

100 YRM 1446

6. 7. 8. 9.

CONTROL (HEATER) CONNECTOR COVER AIR FILTER SECONDARY AIR FILTER

Figure 16. Cab Heater 24

100 YRM 1446

1. 2. 3. 4.

CAB HEATER WIRE HARNESS CONTACTOR BOOT

Cab Heater

5. 6. 7. 8.

SCREW WASHER NUT CAPSCREW

9. PLATE WELDMENT 10. HEATER CONTROL 11. FUSE HOLDER AND FUSE

Figure 17. Cab Heater Electrical

Cab Heater

100 YRM 1446

Inspect 1. Inspect components for damage and cracks. Replace as needed. 2. Inspect air filters after cleaning, replace as necessary.

6. Connect wiring harness on heater control. See Figure 16. 7. Using four screws, install heater control on door assembly. See Figure 16. 8. Install two air filters on cab heater. See Figure 16.

3. Inspect wiring harness for damage and exposed wires. Replace as necessary.

9. Using four screws and four washers, install cab heater on door assembly. See Figure 16.

Install

10. Connect wiring harness on cab heater. See Figure 16.

NOTE: Perform Step 1 only if Remove Step 11 was performed.

11. Using two screws, install connector cover on cab heater. See Figure 16.

1. Install new 25 Amp fuse into in line fuse holder. See Figure 17.

Troubleshooting

2. Install heater wiring harness on lift truck. See Figure 17.

NOTE: If a malfunction disappears, the heater will return to normal operation.

3. Connect wiring harness to contactor. ure 17.

NOTE: For Error Code 3 to 9; After five repeated errors of the same kind, the heater will turn off automatically and return to Standby Mode.

See Fig-

4. Install two capscrews, two washers and two nuts to contactor and plate located on hydraulic tank. See Figure 17. 5. Install two capscrews, two washers and two nuts to heater harness and plate located on hydraulic tank. See Figure 17.

NOTE: For repair procedures, as directed by Error Code E0 through E9, refer to Figure 18 and Table 1 through Table 7.

100 YRM 1446

Cab Heater

Error

Error Code

Measure

External keyswitch off

1. Check that the keyswitch is switched on. 2. Check that there is voltage to the keyswitch.

Thermostat Sensor Error

1. Check the Printed Circuit Board (PCB) connector. 2. Inspect the sensor and sensor wiring for damage. 3. Replace the sensor.

Overheat Protection Sensor Error

See Error Code E1.

Overheat Protection Activated

1. Inspect heater outlets for debris or obstruction of air flow. 2. Clean the inlet Air Filter. 3. Inspect heater Inlet for debris or obstruction of air flow.

Max Temperature in the Cabin Achieved

Normal operating cabin temperature is 35°C (95°F). The heater will automatically turn off and back on again at a lower temperature. Inspect all air outlet louver’s for proper directionality. Ensure all louver’s are directing warm air away from heater inlet.

E5,E6

Fan Error; Current Consumption too high

The fan does not rotate smoothly or has stopped; replace the fan.

Fan Error; Current Consumption too low

Does the fan rotate? If no: 1. Check the fan in-line fuse. 2. Check the fan connections. 3. Check that there is voltage between the PCB and fan. 4. Check that the feed through Capacitors are conducting. 5. Replace the fan. If yes: 1. Clean the inlet filter. 2. Check that there are no obstacles in the air inlet and air outlet.

Voltage Too Low

1. Disconnect the power to the Heater for a minimum of 7 seconds; connect again and test. 2. Battery voltage too low; charge lift truck battery.

Voltage too High

Disconnect the power to the heater for a minimum of 7 seconds; connect again and test.

Cab Heater

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

100 YRM 1446

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

HEATER ELEMENT FAN EMC FILTER CONTROL BOARD THERMOSTAT SENSOR OVERHEAT SENSOR CONTROL PANEL WIRE EMC FILTER EMC FILTER

IN LINE FUSE FUSE HOLDER CONTROL PANEL CONTACT C1 CONNECTOR C2 CONNECTOR C3 CONNECTOR C4 CONNECTOR C5 CONNECTOR C6 CONNECTOR C7 CONNECTOR

Figure 18. Cab Heater Wiring Schematic Table 1. Connector C1 Pin #

Connector Function

Table 2. Connector C2 Pin #

Connector Function

Driver Low Power

+ 12 V

Driver Full Power

+ From Start Key

Incoming Ground (-)

Control Output for Defroster

Incoming Ground (-)

Ground (-)

Incoming Power (+)

100 YRM 1446

Weather Panel Replacement

Table 3. Connector C3 Pin #

Connector Function

Overheat Sensor (+5V)

Overheat Sensor (Sense)

Table 5. Connector C5 (Continued) Pin # 3

RS485A

Ground(-)

Table 4. Connector C4 Pin #

Connector Function

Thermostat Sensor (+5V)

Thermostat Sensor (Sense)

Ground (-) Not Connected

Connector Function

Table 6. Connector C6 Pin #

Connector Function

Fan -

Fan +

Table 7. Connector C7 Table 5. Connector C5 Pin # Pin #

Connector Function

+12V

RS485B

1-6

Connector Function Programming Connector

Weather Panel Replacement for Lift Truck Model ERC22-35VG (ERC045-070VG) (A968) REMOVE WARNING All windows installed in the cab are made of safety glass. All replacement windows must be made of the correct material and must be made the correct thickness. Failure to have the correct material or thickness may cause the glass to break easily when struck and may cause personal injury. NOTE: Before replacing roof or front screen panel, remove all broken glass bits. Verify replacement glass is dry, clean, and free of grease.

2. Remove nuts, capscrews, washers, and roof mounting brackets from overhead guard canopy and roof panel. See Figure 19. 3. Remove nuts, capscrews, washers, and "U" brackets from panel plates and overhead guard. See Figure 19. NOTE: The rear roof panel contains an access panel for the opening in the overhead guard, the access panel may be removed if necessary. Perform Step 4 through Step 6 to remove access panel. 4. Remove nuts, capscrews, and washers from hinges and plates. See Figure 20.

Roof Panels 1. Remove nuts, washers, and "S" brackets from din bolts. See Figure 19

5. Remove access panel from rear roof panel. See Figure 20. 6. Remove nuts, washers, capscrews, and hinges from rear roof panel. See Figure 20.

Weather Panel Replacement

Figure 19. Roof Panels for Lift Truck ERC22-35VG (ERC045-070VG) (A968)

100 YRM 1446

Weather Panel Replacement

Legend for Figure 19 A. BOTTOM VIEW

B. FRONT VIEW

1. 2. 3. 4. 5. 6.

ROOF PANEL OVERHEAD GUARD CANOPY NUT WASHER ROOF MOUNTING BRACKET CAPSCREW

7. 8. 9. 10. 11.

1. 2. 3. 4.

REAR ROOF PANEL ACCESS PANEL PLATE HINGE

5. CAPSCREW 6. WASHER 7. NUT

"S" BRACKET "U" BRACKET OVERHEAD GUARD PANEL PLATES DIN BOLTS

Figure 20. Rear Roof Panels for Lift Truck ERC22-35VG (ERC045-070VG) (A968)

Weather Panel Replacement

Front Screen Panel 1. Remove nuts capscrews, washers, and front screen upper bracket from overhead guard canopy and front screen panel. See Figure 21.

100 YRM 1446 4. Install front screen upper brackets, washers, capscrews, and nuts onto front screen panel and overhead guard canopy. See Figure 21.

Roof Panels

2. Remove front screen panel from front screen lower brackets. See Figure 21.

NOTE: Perform Step 1 and Step 2 if access panel removed.

3. Remove front screen upper seals from overhead guard. See Figure 21.

1. Install hinges, washers, capscrews, and nuts onto rear roof panel. See Figure 20.

INSTALL

2. Install access panel, washers, capscrews, and nuts onto hinges and plates. See Figure 20.

Front Screen Panel 1. Install front screen upper seals on overhead guard. See Figure 21. 2. Install front screen upper brackets. See Figure 21. 3. Install front screen panel into front screen lower brackets. See Figure 21.

3. Install "U" brackets, washers, capscrews, and nuts on overhead guard and panel plates. See Figure 19. 4. Install roof mounting brackets, washers, capscrews, and nuts on roof panel and overhead guard canopy. See Figure 19. 5. Install "S" brackets, washers, and nuts onto din bolts. See Figure 19.

1. 2. 3. 4. 5.

FRONT SCREEN UPPER BRACKET OVERHEAD GUARD CANOPY NUT CAPSCREW WASHER

6. 7. 8. 9.

FRONT SCREEN PANEL FRONT SCREEN LOWER BRACKET FRONT SCREEN UPPER SEAL OVERHEAD GUARD

Figure 21. Front Screen Panel for Lift Truck ERC22-35VG (ERC045-070VG) (A968)

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

100 YRM 1446

5/11 (12/10) Printed in U.S.A.

Maintenance

PERIODIC MAINTENANCE ERP030-040VT [G807]

PART NO. 524320287

8000 YRM 1339

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Periodic Maintenance

Table of Contents

TABLE OF CONTENTS Introduction.......................................................................................................................................................... General ........................................................................................................................................................... Serial Number ................................................................................................................................................. Discharging the Capacitors ............................................................................................................................. How to Tow a Disabled Lift Truck .................................................................................................................... How to Put Lift Truck on Blocks....................................................................................................................... How to Raise Drive Tires ............................................................................................................................ How to Raise Steer Tires ............................................................................................................................ How to Clean a Lift Truck ................................................................................................................................ Safety Procedures When Working Near Mast ..................................................................................................... WHEN WORKING NEAR THE MAST ALWAYS: ............................................................................................ Maintenance Schedule ........................................................................................................................................ Maintenance Procedures Every 8 Hours or Daily................................................................................................ How to Make Checks With the Key or Keyless Switch OFF............................................................................ Wheels and Tires ........................................................................................................................................ Safety Labels .............................................................................................................................................. Frame and Covers ...................................................................................................................................... Forks, General ............................................................................................................................................ Forks, Remove............................................................................................................................................ Forks, Inspect ............................................................................................................................................. Fork Install .................................................................................................................................................. Forks, Adjust ............................................................................................................................................... Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments .............................................. Hydraulic Oil Level and Leaks..................................................................................................................... Operator Restraint System ......................................................................................................................... Emergency Locking Retractor (ELR) .......................................................................................................... Battery Restraint System ............................................................................................................................ Steering Column Adjustments .................................................................................................................... Tilt Adjust Feature .................................................................................................................................. Tilt Memory Feature ............................................................................................................................... Telescopic Feature ................................................................................................................................. Battery Check ............................................................................................................................................. How to Make Checks With the Key or Keyless Switch ON.............................................................................. Control Levers and Pedals.......................................................................................................................... Direction and Speed Controls ..................................................................................................................... Electrical Components................................................................................................................................ Steering System ......................................................................................................................................... Hydraulic System ........................................................................................................................................ Service Brakes............................................................................................................................................ Automatic Parking Brake............................................................................................................................. Operator Presence System......................................................................................................................... Oil Leaks ..................................................................................................................................................... Maintenance Procedures After First 100 Hours or 2 Months of Service ............................................................. Tire and Wheel Assemblies ............................................................................................................................ Mast Sliding Surfaces...................................................................................................................................... Mast Pivot Pins and Mounting Hardware ........................................................................................................ Fork Guides and Pins...................................................................................................................................... Integral Sideshift Carriage............................................................................................................................... Check Upper and Lower Bearings .............................................................................................................. Header Hoses, Hose Fittings, and Clamps ..................................................................................................... Maintenance Procedures Every 500 Hours or Three Months .............................................................................

1 1 1 2 2 3 3 4 5 5 5 8 15 15 15 15 16 16 16 17 17 18 18 19 19 20 21 25 25 25 25 26 26 26 26 26 28 28 28 28 29 29 29 29 29 30 30 31 31 31 32

Table of Contents

Periodic Maintenance

TABLE OF CONTENTS (Continued) Tire and Wheel Assemblies ............................................................................................................................ Mast and Carriage........................................................................................................................................... Mast Sliding Surfaces ................................................................................................................................. Mast Pivot Pins, Bushings, and Mounting Hardware .................................................................................. Header Hoses ............................................................................................................................................. Fourth Function Mini Rollers Lubrication .................................................................................................... Lift Chain Lubrication .................................................................................................................................. Lift Chain Wear Check ................................................................................................................................ Integral Sideshift Carriage............................................................................................................................... Check Upper and Lower Bearings .............................................................................................................. Fork Guides and Pins ................................................................................................................................. Tilt Cylinder Rod End Pins .............................................................................................................................. Control Levers, Pedals, and Hinges ................................................................................................................ Direction and Speed Control Pedals ............................................................................................................... Hydraulic Hoses, Fittings, and Clamps ........................................................................................................... Hydraulic Breather Cap................................................................................................................................... Service Brakes ................................................................................................................................................ Master Cylinder Oil Check .......................................................................................................................... Parking Brake.................................................................................................................................................. Manual Override Handle ............................................................................................................................. Electrical Inspection ........................................................................................................................................ Contactors .................................................................................................................................................. Maintenance Procedures Every 2000 Hours or Yearly........................................................................................ Hydraulic System ............................................................................................................................................ Hydraulic Oil Filter, Change ........................................................................................................................ Hydraulic Breather, Check .......................................................................................................................... Steering Axle................................................................................................................................................... Steering Actuator and Steering Plate Torque Check .................................................................................. Transaxle Oil Level Check ............................................................................................................................... Transaxle Breather Check ............................................................................................................................... Brake Oil Change ............................................................................................................................................ Integral Sideshift Carriage............................................................................................................................... Lift Chains ....................................................................................................................................................... Maintenance Procedures Every 4000 Hours or Two Years ................................................................................. Hydraulic Oil Change ...................................................................................................................................... Steering Direction Sensor Inspection.............................................................................................................. Fixed Steering Column ............................................................................................................................... Telescopic Steering Column ....................................................................................................................... Telescopic Steering Column Lubrication ......................................................................................................... Welding Repairs .................................................................................................................................................. Lift and Tilt System Leak Check .......................................................................................................................... Lift Cylinders Leak Check ............................................................................................................................... Tilt Cylinder Leak Check ................................................................................................................................. Battery Maintenance ........................................................................................................................................... How to Charge Battery.................................................................................................................................... How to Change Battery ................................................................................................................................... Remove the Battery .................................................................................................................................... Install the Battery ........................................................................................................................................ Optional Side Removal of Battery............................................................................................................... Battery Size Specifications.............................................................................................................................. Wheel and Tires ..................................................................................................................................................

32 32 32 33 33 34 35 35 36 36 36 36 36 37 37 37 38 38 38 38 39 39 40 40 40 42 42 42 43 43 44 44 44 45 45 46 46 48 49 50 50 50 51 51 51 52 52 54 55 56 56

Periodic Maintenance

Table of Contents

TABLE OF CONTENTS (Continued) General ........................................................................................................................................................... Pneumatic Tires Repair................................................................................................................................... Remove Wheels From Lift Truck ................................................................................................................. Remove Tire From Wheel ........................................................................................................................... Remove Tire From Two-Piece Wheel ..................................................................................................... Remove Tire From Three- and Four-Piece Wheels................................................................................ Install Wheel in Tire .................................................................................................................................... Install Two-Piece Wheel in Tire .............................................................................................................. Install Three- or Four-Piece Wheel in Tire.............................................................................................. Add Air to Tires ........................................................................................................................................... Wheels, Install............................................................................................................................................. Solid Rubber Tires on Pneumatic Wheels, Change ........................................................................................ Remove Tire From Wheel ........................................................................................................................... Install Tire on Wheel ................................................................................................................................... Install the Wheels ....................................................................................................................................... Solid Rubber (Cushioned) Tire Repair ............................................................................................................ Remove Wheels From Lift Truck ................................................................................................................. Remove and Install Tire on Wheel.............................................................................................................. Lift Chain Adjustments.........................................................................................................................................

56 56 56 57 57 58 59 60 61 62 62 62 63 64 65 66 66 66 67

This section is for the following models: ERP030-040VT [G807]

iii

8000 YRM 1339

Introduction

Introduction GENERAL WARNING DO NOT make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can create dangerous operating conditions.

WARNING DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag to the steering wheel. Remove the key from the key switch. Disconnect the battery connector.

WARNING DO NOT work under a raised carriage. Lower the carriage or use a chain to prevent the carriage and the inner or intermediate weldments from lowering when doing maintenance. Make sure that the moving parts are attached to parts that cannot move.

The Maintenance Schedule has four time periods. Perform maintenance at the DAILY, 3-MONTHS, 1-YEAR, and 2-YEAR periods. Your dealer for Yale lift trucks will advise you on the maintenance time intervals based on their survey of the application. Your dealer for Yale lift trucks has the equipment and trained service personnel to do a complete program of inspection, lubrication, and maintenance. A regular program of inspection, lubrication, and maintenance will help your lift truck provide more efficient performance and operate for a longer period of time. Some users have service personnel and facilities to do the items listed in the Maintenance Schedule. Service manuals are available from your dealer for Yale lift trucks to help users who do their own maintenance. Throughout this section, forward will refer to travel in the direction of the forks and left and right will be determined by sitting in the seat facing forward. See Figure 1.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations This section contains a Maintenance Schedule and the instructions for maintenance and inspection. The Maintenance Schedule has time intervals for inspection, lubrication, and maintenance for your lift truck. The service intervals are given in both operating hours recorded on the lift truck hourmeter, and in calendar time. Use the interval that occurs first. The recommendation for time intervals are for eight hours of operation per day. Time intervals must be decreased from the recommendations in the Maintenance Schedule for the following conditions: • If the lift truck is used more than eight hours per day. • If the lift truck must work in dirty operating conditions. • Poor ground conditions. • Intensive usage at high performance levels or other abnormal conditions will require more frequent servicing.

A. LEFT SIDE B. RIGHT SIDE

C. FORWARD TRAVEL

Figure 1. Truck Orientation

SERIAL NUMBER The serial number code for the lift truck is on the Nameplate. The serial number code is also stamped on the left side of the front frame bulkhead, top edge surface.

Introduction

DISCHARGING THE CAPACITORS WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the battery. Disconnect the battery and allow the capacitors to discharge before opening any compartment covers or inspecting or repairing the electrical system. DO NOT place tools on top of the battery. If a tool causes a short circuit, the high current flow from the battery can cause personal injury or property damage. Some checks and adjustments are performed with the battery connected. DO NOT connect the battery until the procedure instructs you to do so. Never wear any metallic items on your fingers, arms, or neck. Metal items can accidentally make an electrical connection and cause injury. Before performing any tests or adjustments, block the lift truck to prevent unexpected movement. The capacitor in the transistor controller(s) can hold an electrical charge for about 10 seconds after the battery is disconnected. To prevent an electrical shock and personal injury, discharge the capacitor(s) before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Make certain the Emergency Disconnect Switch has not been activated. This will isolate the controller and prevent the capacitors from discharging properly. The proper way to disconnect the battery is by separating the battery connectors. 1. Ensure the capacitors are discharged by performing Step 2 through Step 5 below. 2. Turn the key switch to the OFF position. 3. Disconnect the battery by separating the connectors. Block drive wheels to prevent lift truck from moving.

8000 YRM 1339 4. Make sure the Emergency Disconnect Switch HAS NOT been activated. If the Emergency Disconnect Switch is activated, rotate the switch to the right until it pops up 5. Wait 10 seconds. The capacitors will have discharged themselves.

HOW TO TOW A DISABLED LIFT TRUCK WARNING Use extra care when towing a lift truck if there is a problem with any of the following: • Brakes do not operate correctly. • Steering does not operate correctly. • Tires are damaged. • Traction conditions are bad. • Moving the lift truck on a steep grade. If the hydraulic pump motor, which includes the steering control functions, does not operate, steering control of the lift truck can be slow. This can make the control of the lift truck difficult. If there is no electrical power, steering can be difficult. DO NOT tow the lift truck if there is no power. Poor traction can cause the disabled lift truck or towing vehicle to slide. Steep grades will require additional brake force to stop the lift truck. Never carry a disabled lift truck unless the lift truck MUST be moved and cannot be towed. The lift truck used to carry the disabled lift truck MUST have a rated capacity equal to or greater than the weight of the disabled lift truck. The capacity must be for a load center equal to half the width of the disabled lift truck. See the nameplate of the disabled lift truck for the approximate total weight. The forks must extend the full width of the disabled lift truck. Center the weight of the disabled lift truck on the forks and be careful not to damage the under side of the lift truck. NOTE: The towed lift truck must have an operator. Tow the lift truck slowly. 1. Raise the carriage and forks approximately 30 cm (12 in.) from the surface. Install a chain to prevent the carriage and mast channels from moving. 2. If another lift truck is used to tow the disabled lift truck, it must have a weight equal to or greater than that of the disabled lift truck. Install an approximate half-capacity load on the forks of the lift truck that is being used to tow the disabled lift truck. This

8000 YRM 1339

Introduction

half-capacity load will increase the traction of the towing lift truck. Keep the load as low as possible. 3. Use a towing link made of steel that attaches to the tow pins in the counterweights of both lift trucks. 4. Remove floor mats and floor plates. 5. Pull up on the manual override handle to release the parking brake. See Figure 2. 6. Tow the lift truck slowly.

HOW TO PUT LIFT TRUCK ON BLOCKS How to Raise Drive Tires

battery, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: • Before removing the mast and drive axle assembly, put blocks under the counterweight so that the lift truck cannot tip backward. • Before removing the battery and counterweight, put blocks under the mast assembly so that the lift truck cannot tip forward. Put the lift truck on blocks only if the surface is solid, even and level. Make sure that any blocks used to support the lift truck are solid, one piece units. 1. Put blocks on each side (front and back) of the steer tires to prevent movement of the lift truck. See Figure 3.

WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast and drive axle assembly,

2. Put the mast in a vertical position. Put a block under each outer mast channel.

1. FRONT BULKHEAD 2. MANUAL OVERRIDE HANDLE

3. PIVOT PIN 4. TRACTION MOTORS

Figure 2. Manual Override Handle

Introduction

8000 YRM 1339

1. DRIVE TIRES

2. STEER TIRES

Figure 3. Putting Lift Truck on Blocks 3. Tilt the mast fully forward until the drive tires are raised from the surface. 4. Put additional blocks under the frame behind the drive tires. 5. If the hydraulic system will not operate, use a hydraulic jack under the side of the frame near the front. Make sure that the jack has a capacity equal to at least half the weight of the lift truck. See the Nameplate.

How to Raise Steer Tires WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast and drive axle assembly, battery, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: • Before removing the mast and drive axle assembly, put blocks under the counterweight so that the lift truck cannot tip backward.

• Before removing the battery and counterweight, put blocks under the mast assembly so that the lift truck cannot tip forward. Put the lift truck on blocks only if the surface is solid, even and level. Make sure that any blocks used to support the lift truck are solid, one piece units. NOTE: Under the counterweight cover is a hole to insert a lifting eye. This lift point can be used to raise the steer tire so blocks can be positioned under the frame. 1. Put blocks in front and back of the drive tires to prevent movement of the lift truck. See Figure 3. 2. Use a hydraulic jack to raise the steering tires. Make sure that the jack has a capacity of at least 2 /3 of the total weight of the lift truck as shown on the Nameplate. 3. Put the jack under the frame to raise the lift truck. Put blocks under the frame to support the lift truck.

8000 YRM 1339

Safety Procedures When Working Near Mast

HOW TO CLEAN A LIFT TRUCK WARNING

CAUTION Units may be washed with a non-heated pressure washer. Steam cleaning is not recommended in most instances, as condensation may form in electrical components causing damage or erratic behavior.

NOTE: Lift trucks used in paper applications may need cleaning beyond what is described here. Please refer to Paper Application section in the applicable Operating Manual and to available Service Gram/Bulletin for more detail.

If it becomes necessary to clean the fork lift, follow the guidelines listed below. 1. Assure truck components are cool before starting the cleaning procedure. 2. Disconnect the battery. If an electric truck, remove the traction battery. 3. Remove accumulated debris using a compressed air line and nozzle. 4. Lightly spray a non-corrosive cleaning agent onto the areas to be cleaned. This will help loosen

10.

grime, so close contact direct spraying will not be necessary. Be sure to avoid directing the spray into electrical panel compartment. Ensure over-spray does not come in contact with electrical components; do not spray water directly at electrical components, wiring connectors or electrical enclosures. Even sealed connectors may allow water egress under pressure or if connector is damaged. Avoid spraying in areas containing electrical components such as: • Floor Plates • Battery Compartment • Dash/cowl assembly • Armrests with electrical components Clean the battery compartment by using a clean cloth to wash the battery with water. Dry with compressed air. Care should be taken to keep moisture at a minimum as some units have a traction or hydraulic motor directly below the battery compartment. DO NOT pressure wash the battery. Do not use hot water. For cleaning traction batteries, refer to the Battery section of the Service Manual. DO NOT pressure wash lift chains, sheaves or load rollers in the mast assembly. Refer to the Chains, Sheaves and Load Rollers maintenance section in the Service Manual for proper cleaning procedures. After cleaning, immediately run the lift truck to dry out components.

Safety Procedures When Working Near Mast WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage. • Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed. Also make sure that the power is OFF and the key is removed. Put a DO NOT OPERATE tag in the operator’s compartment. • Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury. • DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast. • DO NOT use blocks to support the mast weldments nor to restrain their movement.

• Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the applicable Service Manual section for the mast. The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WHEN WORKING NEAR THE MAST ALWAYS: 1. Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered.

Safety Procedures When Working Near Mast

8000 YRM 1339 of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast.

OR 2. If parts of the mast must be in raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures:

d. Lower the mast until there is tension in the safety chain and the free-lift cylinder (free-lift and three-stage masts only) is completely retracted. Install a DO NOT REMOVE tag on the safety chain(s).

a. Put the mast in a vertical position. b. Raise the mast to align the bottom crossmember of the weldment that moves in the outer weldment with a crossmember on the outer weldment. On the two-stage and free-lift mast, the moving part is the inner weldment. On the three-stage mast, it is the intermediate weldment. On the four-stage mast, it is the first intermediate weldment. See Figure 4. c. Use a 9.4 mm (0.370 in.) (3/8 inch) minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Put the hook on the back side

e. Install another safety chain, 9.4 mm (0.370 in.) minimum, between the top or bottom crossmember of the carriage and a crossmember on the outer weldment. 3. Apply the parking brake, shut off the power and remove the key. Put a DO NOT OPERATE tag in the operator’s compartment. Disconnect battery connector.

Legend for Figure 4 NOTE: ILLUSTRATION FOR REFERENCE ONLY. A. TWO-STAGE MAST B. FREE-LIFT MAST

C. THREE-STAGE MAST D. FOUR-STAGE MAST

1. 2. 3. 4.

5. 6. 7. 8.

OUTER WELDMENT INNER WELDMENT INTERMEDIATE WELDMENT FIRST INTERMEDIATE WELDMENT

HOOK FREE-LIFT CYLINDER CROSSMEMBER CROSSMEMBER

8000 YRM 1339

Safety Procedures When Working Near Mast

Figure 4. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts

Maintenance Schedule

8000 YRM 1339

Maintenance Schedule The Maintenance Schedule has time intervals for inspection, lubrication, and maintenance for your lift truck. The service intervals are given in both operating hours recorded on the lift truck hourmeter, and in calendar time. The recommendation is to use the interval that comes first. The approximate locations of the items indicated in the Maintenance Schedule are shown in Figure 5.

The Maintenance Schedule has the maximum service intervals for usage under normal conditions. Inspect and lubricate more frequently if the lift truck operates in dirty, dusty, wet, or difficult conditions.

Figure 5. Maintenance Points

8000 YRM 1339

Maintenance Schedule

Table 1. Maintenance Schedule Item No.

Item

8 hr/ Daily

500 hr or 3 Months

2000 hr or 1 Year

4000 hr or 2 Years

Procedure or Quantity

Specification

Drive Tire and Wheel Assemblies Tire and Wheel

Pedals, Seat Assembly, Hood, Hinges, and Hood latch

Frames, Covers, and Floor Plates

Remove foreign Check condition. objects embedded See NOTE 1. in tire. Check operation/ repair as required. L

Lube as required.

Use multipurpose grease. See NOTE 2 and NOTE 3.

Visually inspect for damage/ repair as required.

X = Check, C = Change, L = Lubricate, CIL = Check Indicator Light during operation. NOTE: Never use steam to clean electrical parts.

Maintenance Schedule

8000 YRM 1339

Table 1. Maintenance Schedule (Continued) Item No.

Item

Hydraulic System

Hydraulic Hoses, Hose Fittings and Clamps

8 hr/ Daily

500 hr or 3 Months

2000 hr or 1 Year

4000 hr or 2 Years

Check operation/ repair as required.

Check for leaks/ repair as required.

Inspect for visible damage and defects. Adjust, repair, or replace if necessary. X

Hydraulic Oil

Check for leaks/ repair as required

Hydraulic Oil Filter

Breather Cap

Change oil. 19.0 liter (5.0 gal) ISO-VG46 Total system capacity. Change oil filter. See Parts Manual. See NOTE 3. Clean or replace. See Parts Manual. See NOTE 3.

Steering Tire and Wheel Assemblies Tire and Wheel

Check condition. Remove foreign See NOTE 1. objects embedded in tire.

X = Check, C = Change, L = Lubricate, CIL = Check Indicator Light during operation. NOTE: Never use steam to clean electrical parts.

Specification

Inspect for kinked, flattened, stiff or charred hoses/ replace if necessary

Procedure or Quantity

8000 YRM 1339

Maintenance Schedule

Table 1. Maintenance Schedule (Continued) Item No.

Item

8 hr/ Daily

Battery

Battery Restraint 7

Steering System

4000 hr or 2 Years

Procedure or Quantity

Specification

Check level. See NOTE 5. Check connection between truck and battery.

Check operation.

Check operation. Repair as required.

Check for leaks.

Use distilled water. Maintain in accordance with manufacturer’s service instructions.

Check sensor assembly and column gear teeth.

Replace sensor or column gear as required

Telescopic Steering Column

Lubricate.

Use manual steering gear grease. See NOTE 7

Steering Actuator Bolts

Check torque. 3 bolts.

270 N•m (200 lbf ft)

Plate

Check torque. 4 bolts.

305 N•m (225 lbf ft)

Automatic Parking Brake

CIL X

Manual Override Handle 9

2000 hr or 1 Year

Steering Position Sensor

Steering Bolts 8

500 hr or 3 Months

Service Brake

Lubricate pivot pin. See NOTE 3.

Use multipurpose grease. See NOTE 2.

Check operation. Use Dexron III.

Check for leaks.

Linkage and Shafts Master Cylinder Reservoir

Check operation/ Must hold full capacity applies and load on a 15% grade. releases properly.

CIL

Lubricate.

Check oil level. C

Change oil. 0.25 liter (0.26 qt).

Silicone spray lubricant, Yale P/N 504236201.

Use Dexron III.

X = Check, C = Change, L = Lubricate, CIL = Check Indicator Light during operation. NOTE: Never use steam to clean electrical parts.

Maintenance Schedule

8000 YRM 1339

Table 1. Maintenance Schedule (Continued) Item No.

Item

Mast

8 hr/ Daily

X L

Mast Mounting Capscrews Lift Chains

2000 hr or 1 Year

Pivot Pins

Sliding Surfaces

500 hr or 3 Months

2 fittings. Check lubrication. See NOTE 1.

Use multipurpose grease. See NOTE 2.

Lubricate as required. See NOTE 1 and NOTE 4.

Use multipurpose grease. See NOTE 2.

Tighten if required. See NOTE 1.

24 N•m (212 lbf in).

Check stretch SAE 30W engine oil. and lubricate. See NOTE 3 and NOTE 6 Check adjustment and length. See NOTE 3. Remove chains to clean and lubricate.

SAE 30W engine oil.

Inspect for visible Adjust, repair, or damage and replace if necessary. defects. See NOTE 1.

Inspect for kinked, flattened, stiff or charred hoses/ replace if necessary.

Lubricate as required.

X = Check, C = Change, L = Lubricate, CIL = Check Indicator Light during operation. NOTE: Never use steam to clean electrical parts.

Specification

Mast Fourth Function Mini Rollers

Procedure or Quantity

Inspect for visible damage/ check operation.

Header Hoses, Hose Fittings and Clamps

4000 hr or 2 Years

Use multipurpose grease. See NOTE 2.

8000 YRM 1339

Maintenance Schedule

Table 1. Maintenance Schedule (Continued) Item No.

Item

Carriage Assembly

8 hr/ Daily

2000 hr or 1 Year

4000 hr or 2 Years

Procedure or Quantity

Inspect for visible damage/ check operation.

Forks

Check condition/ replace if necessary.

Fork Guides and Pins

Integral Sideshift Carriage Integral Sideshift Carriage (Upper and Lower Bearings)

500 hr or 3 Months

Specification

Lubricate as required. See NOTE 1.

Use multipurpose grease. See NOTE 2.

Lubricate 2 fittings. See NOTE 1.

Use multipurpose grease. See NOTE 2.

Check wear, 2.50 mm (0.09 in.) 4 bearings. See Minimum thickness. NOTE 1. C

Replace bearings.

Oil Level

Check oil level.

Breather

Clean and check operation/ replace as necessary.

See Parts Manual.

Transaxle Use Dexron III.

Electrical Circuits Battery Disconnect Switch

Check operation.

Horn, Lights, Alarms, and Seat Switch

Check operation/ repair as required.

Display Panel

Check operation.

Contactors

Direction and Speed Control Pedal

Check condition/ repair as required.

Check operation/ Use silicone spray lubricate as lubricant, needed. Yale P/N 504236201.

X = Check, C = Change, L = Lubricate, CIL = Check Indicator Light during operation. NOTE: Never use steam to clean electrical parts.

Maintenance Schedule

8000 YRM 1339

Table 1. Maintenance Schedule (Continued) Item No.

Item

8 hr/ Daily

500 hr or 3 Months

2000 hr or 1 Year

4000 hr or 2 Years

Procedure or Quantity

Safety Labels and Operating Manual

Replace if necessary.

Steering Column Tilt Memory Lever

Check operation.

X CIL

Check condition.

Check operation/ repair if needed.

Seat Belt and Seat Rails Operator Presence System Check

Specification

See Parts Manual.

NOTE 1: Perform maintenance after the first 100 hours or 2 months of service. NOTE 2: Multipurpose grease with 2 to 4% Molybdenum Disulfide for normal operations. NOTE 3: Recommended service intervals are based on a normal application in a clean environment. Applications involving contaminated environments such as high levels of air borne debris (dust and waste paper); chemical or abrasive compounds; poor ground conditions; intensive usage at high performance levels; or other abnormal conditions will require more frequent servicing. At your request your Yale dealer will advise you of the appropriate service intervals based on an application survey. NOTE 4: Maximize life of surfaces by lubricating every 250 hours for first 1000 hours. NOTE 5: Equalization charge is required approximately each month. See manufacturer’s service instructions. NOTE 6: Lubricate if dry or at first sign of visible surface rust. NOTE 7: Multipurpose lithium base grease. X = Check, C = Change, L = Lubricate, CIL = Check Indicator Light during operation. NOTE: Never use steam to clean electrical parts.

8000 YRM 1339

Maintenance Procedures Every 8 Hours or Daily

Maintenance Procedures Every 8 Hours or Daily WARNING DO NOT operate a lift truck that needs repairs. Report the need for repairs immediately. If repair is necessary, put a DO NOT OPERATE tag in the operator’s area. Remove the key from the key switch. Inspect the lift truck every eight hours or daily before use. Put the lift truck on a level surface. Lower the carriage and forks and turn the key or keyless switch to the OFF position. Remove the floor mat and floor plate. Inspect for leaks and conditions that are not normal. Clean any oil spills. Make sure that lint, dust, paper and other materials are removed from the compartments. Make the additional checks as described in the following paragraphs of How to Make Checks With the Key or Keyless Switch OFF and How to Make Checks With the Key or Keyless Switch ON. Park the lift truck on a level surface. Lower the forks, turn the key or keyless switch to the OFF position, and disconnect the battery connector. Check for leaks and conditions that are not normal. Clean up any oil spills.

HOW TO MAKE CHECKS WITH THE KEY OR KEYLESS SWITCH OFF Wheels and Tires Inspect the drive tires and wheel assemblies and the steer tire and wheel assemblies for damage. Look for deep grooves or cuts in the tires. Remove objects embedded in the tire, such as wire, rocks, glass, and pieces of metal that can cause damage. See Figure 6. Remove any wire, strapping, or other material that is wrapped around the axle to prevent damage to the axle seals. Inspect wheel rims for rust or cracks and check for loose or missing lug nuts and broken studs. DO NOT operate a lift truck with damage to any wheel rim, lug nuts, or studs.

1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS, AND OTHER OBJECTS FROM TREAD) 2. MAKE SMOOTH EDGES

Figure 6. Tire Check

Safety Labels WARNING Safety labels are installed on the lift truck to provide information about possible hazards. It is important that all safety labels are installed on the lift truck and can be read. Check that all safety labels are installed in the correct locations on the lift truck. See the Parts Manual or the section Frame 100 YRM 1329 of the Service Manual for the correct locations of the safety labels. Check that the Operating Manual is not worn or damaged and replace it if necessary.

Maintenance Procedures Every 8 Hours or Daily

Frame and Covers The frame is a single weldment with mounts for the counterweight, overhead guard, mast, steering system, hydraulic system, and transaxles. Check the condition of the frame, especially around welds, for rust, cracks, or other damage. The overhead guard must be free

1. OVERHEAD GUARD 2. FLOOR PLATE 3. FRAME

8000 YRM 1339 from defects to ensure protection to the operator. A variety of covers and floor plates provide protection and allow easy access to systems located inside and around the frame. See Figure 7. Make certain that all covers and floor plates are present and secured in their proper locations.

4. HOOD SIDE COVER 5. COUNTERWEIGHT COVER 6. STEERING COLUMN COVER

Figure 7. Frame and Covers Check

Forks, General NOTE: Forks must be removed and installed by trained personnel. The identification of a fork describes how the fork is connected to the carriage. These lift trucks have hook forks.

Forks, Remove WARNING DO NOT try to move a fork without a lifting device. The forks can weigh 45 to 115 kg (99 to 254 lb).

NOTE: Forks are to be replaced only in sets and not individually. A fork can be removed from the carriage for replacement of the fork or other maintenance. Slide a hook fork to the fork removal notch on the carriage. See Figure 8. Lower the fork onto blocks so that the lower fork hook moves through the fork removal notch. See Figure 9 and Figure 10. Lower the carriage further so that the top fork hook is disengaged from the top carriage bar. Move the carriage away from the fork, or use a lifting device to move the fork away from the carriage.

8000 YRM 1339

Maintenance Procedures Every 8 Hours or Daily

1. CARRIAGE BARS 2. HOOK FORK 3. BLOCKS

Figure 9. Hook Fork Removal

Forks, Inspect WARNING Fork Tip Alignment Length of Forks

3% Dimension

915 mm (36 in.) 1067 mm (42 in.) 1220 mm (48 in.) 1372 mm (54 in.) 1524 mm (60 in.) 1830 mm (72 in.)

27 32 37 41 46 55

mm mm mm mm mm mm

(1.10 (1.26 (1.46 (1.61 (1.81 (2.17

in.) in.) in.) in.) in.) in.)

1. TIP ALIGNMENT (MUST BE WITHIN 3% OF FORK LENGTH) 2. CRACKS 3. LOCK PIN 4. HEEL OF FORK (MUST BE 90% OF DIMENSION X, THICKNESS OF FORK SHANK) 5. CARRIAGE 6. LOAD BACKREST EXTENSION 7. MAXIMUM ANGLE 93° 8. FORK REMOVAL NOTCH

Figure 8. Forks Check

DO NOT try to correct fork tip alignment by bending the forks or adding shims. Replace bent forks. Never repair damaged forks by heating or welding. Forks are made of special steel using special procedures. Replace damaged forks. Forks are to be replaced only in sets and not individually. Inspect the forks for cracks and wear. Check that the fork tips are aligned as shown in Figure 8. Check that the bottom of the fork is not worn (item 4 in Figure 8). Replace any damaged or broken parts that are used to keep the forks locked in position. See Figure 10.

Fork Install WARNING DO NOT try to move a fork without a lifting device. The forks can weigh 45 to 115 kg (99 to 254 lbf). Move the fork and carriage so that the top fork hook can engage the top carriage bar. Raise the carriage to move the lower fork hook through the fork removal notch. Slide the fork on the carriage so that both upper and lower fork hooks engage the carriage. Engage the lock pin with a notch in the top carriage bar. See Figure 10.

Maintenance Procedures Every 8 Hours or Daily

8000 YRM 1339 2. Inspect the channels for wear in the areas where the rollers travel. Inspect the rollers for wear or damage. 3. Check mast lubrication. If necessary, lubricate the sliding surfaces and the load roller surfaces along the full length of the channels as shown in Figure 11. Only apply lubricant to surfaces that are clean and dry. Only apply lubricant to the darker areas as indicated by (1) and (2) in Figure 11.

1. 2. 3. 4. 5.

FORK LOCK PIN SPRING WASHER WEDGE

6. KNOB 7. LOCK PIN ASSEMBLY 8. TOP FORK HOOK 9. LOWER FORK HOOK

Figure 10. Fork Lock Pin Assembly

4. Inspect the load backrest extension for cracks and damage. 5. If the lift truck is equipped with a sideshift carriage or attachment, inspect the parts for cracks and wear. Make sure the parts that fasten the sideshift carriage or attachment to the carriage are in good condition.

Forks, Adjust NOTE: During the adjustment of the forks, the heel of the forks should not be touching the ground. The forks are connected to the carriage by hooks and lock pins. See Figure 10. These lock pins are installed through the top fork hooks and fit into slots in the top carriage bar. Adjust the forks as far apart as possible for maximum support of the load. Hook forks will slide along the carriage bars to adjust for the load to be lifted. Raise the lock pin in each fork to slide the fork on the carriage bar. Make sure the lock pin is engaged in the carriage bar to lock the fork in position after the width adjustment is made.

Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments WARNING Lower the lift mechanism completely. Never allow any person under a raised carriage. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the lift truck traction motor is OFF. 1. Inspect the welds on the mast, cylinders, and carriage for cracks. Make sure that the capscrews and nuts are tight.

NOTE: MAST IS DIFFERENT, BUT LUBRICATION AREAS ARE THE SAME. A. UPPER LOAD ROLLERS B. LOWER LOAD ROLLERS 1. LUBRICATE STRIP BEARINGS SURFACES 2. LUBRICATE LOAD ROLLER SURFACES 3. LOAD ROLLER

Figure 11. Mast Lubrication

8000 YRM 1339

Maintenance Procedures Every 8 Hours or Daily NOTE: Chain anchor pins MUST be replaced anytime chains are replaced.

WARNING Never check for leaks by putting hands on hydraulic lines or components under pressure. Hydraulic oil under pressure can be injected into the skin. 6. Visually inspect hoses/fittings for hydraulic leaks; hose covers for cuts, cracks, or exposed reinforcement; defective/broken clamping devices or sheaves; and proper tracking during operation. Adjust/repair/replace hose/components as necessary. 7. Check that lift chains are correctly lubricated. Use SAE - 30W engine oil to lubricate lift chains. 8. Inspect the lift chains for cracks or broken links and worn or turned pins. Lift chains must be replaced as a set. See Figure 12.

9. Inspect the chain anchors and pins for cracks and damage. 10. Make sure the lift chains are adjusted so that they have equal tension. Adjustments or replacement of the lift chains must be done by authorized personnel.

Hydraulic Oil Level and Leaks WARNING At operating temperature the hydraulic oil is HOT. Do not permit the oil to contact the skin and cause a burn.

CAUTION Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Never operate the pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump. Inspect the hydraulic system for leaks and damaged or loose components. Heavy-duty or high-temperature operations can require more frequent checks.

Operator Restraint System There is an indicator icon on the display panel for the seat belt. The icon is ON as described in the Operating Manual. The indicator icon can help the operator remember to fasten the seat belt. 1. WORN PIN 2. CRACKS 3. EDGE WEAR (MAXIMUM 5% OF NEW)

4. 5. 6. 7.

HOLE WEAR LOOSE LEAVES DAMAGED PIN CORROSION

The seat belt, hip restraint brackets, and the seat and mounting are the parts of the operator restraint system. See Figure 13 and Figure 14. Each item must be checked to make sure it is attached securely, functions correctly and is in good condition.

Figure 12. Lift Chains Check

Maintenance Procedures Every 8 Hours or Daily The seat belt must latch securely. Make sure the seat belt extends and retracts smoothly and is not damaged or torn. If the seat belt cannot be pulled from the belt housing, the seat belt assembly must be replaced. Keep the belt straight so that it pulls out and retracts smoothly.

8000 YRM 1339 Make sure the seat rails are not loose. The seat rails must lock securely in position, but move freely when unlocked. The seat rails must be securely attached to the mounting surface.

1. HOOD LATCH HANDLE 2. SEAT BELT 3. HIP RESTRAINT BRACKETS

Figure 13. Operator Restraint System

Emergency Locking Retractor (ELR) When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips over, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operators lower torso in the seat. See Figure 13 and Figure 14. A seat belt that is damaged, worn, or does not operate properly will not provide protection when it is needed. The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if it is damaged or worn. The following seat belt operation checks must be performed at least three times before replacing the seat belt assembly:

• With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly. Make sure the seat belt pulls out and retracts smoothly. If the seat belt does not pull out of the retractor assembly the internal latch may be locked. Pull firmly on the seat belt and hold for a moment to remove slack from the belt in the retractor. Release the seat belt. Seat belt will retract and the internal latch will unlock. If the seat belt cannot be pulled from the retractor assembly or the belt will not retract, replace the seat belt assembly. • With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor when it is pulled with a sudden jerk, replace the seat belt assembly.

8000 YRM 1339

Maintenance Procedures Every 8 Hours or Daily

• With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, with

the hood in the open position, replace the seat belt assembly.

NOTE: STANDARD SEAT SHOWN. AN OPTIONAL SWIVEL SEAT IS AVAILABLE. SWIVEL SEAT ARRANGEMENT IS THE SAME. HIP RESTRAINTS FOR LIFT TRUCKS WITH MANUAL HYDRAULIC SYSTEM SHOWN. A. LEFT VIEW

B. RIGHT VIEW

1. 2. 3. 4. 5.

6. 7. 8. 9.

SEAT BELT HIP RESTRAINT BRACKET MOUNTING HARDWARE SEAT RAILS BACKREST ANGLE ADJUSTMENT LEVER

FORWARD/BACKWARD ADJUSTMENT LEVER RIDE POSITION INDICATOR WEIGHT ADJUSTMENT KNOB SEAT HARNESS

Figure 14. Seat Components

Battery Restraint System The Battery Restraint System is designed to hold the battery within the battery compartment if a tip over occurs. The battery restraint system contains a front spacer plate, a battery plate, front and rear bulkheads, and the left and right frame plates. The lift truck can be equipped with optional side rollers on the battery plate to help in removing the battery from the truck. See Figure 15 and Figure 16. The hood and hood latch mechanism also help keep the battery within the battery compartment if a tip over occurs. The hood can be raised for access to the battery. A gas spring helps raise and hold the hood in the up position. See Figure 18.

The battery restraint system must function so that the operator restraint system can operate correctly. Operation of the battery restraint system requires that the maximum movement allowed for the battery is 13 mm (0.5 in.) in any horizontal direction. This will reduce the risk of operator injury in a truck tip over. An adjustable front battery spacer plate prevents the front-toback movement of the battery. Batteries for this series of lift trucks must all have the same length dimension to just fit the battery compartment width. For correct battery sizes, see the Battery Maintenance section in the back of this manual.

Maintenance Procedures Every 8 Hours or Daily

1. BATTERY PLATE 2. REAR BULKHEAD 3. FRONT BULKHEAD

8000 YRM 1339

4. FRONT SPACER PLATE 5. RIGHT FRAME PLATE

Figure 15. Standard Battery Compartment

8000 YRM 1339

Maintenance Procedures Every 8 Hours or Daily

1. REAR BULKHEAD 2. BATTERY PLATE 3. SIDE ROLLER

4. FRONT BULKHEAD 5. FRONT SPACER PLATE 6. REMOVABLE SIDE PLATE

Figure 16. Optional Battery Compartment To raise the hood, perform the following: 1. Use the tilt memory lever and tilt the steering column all the way up.

hood. Place hand on the hood handle on the left side of the hood, and raise hood to the up position. See Figure 18.

2. Slide the seat all the way back, and if necessary, move the armrest all the way back if lift truck is equipped with E-Hydraulic control levers.

To close hood, lower the hood to the down position and pull the hood release lever towards right side of the truck and release to lock. Try to lift the hood to make sure the hood is fastened correctly.

3. If lift truck is equipped with manual hydraulic levers, release the latch for the control lever assembly (see Figure 17) and move the assembly to the forward position before raising the hood.

The hood must be locked in the down position during lift truck operation. The battery must have the front spacer plate correctly adjusted to prevent any horizontal movement of more than 13 mm (0.5 in.).

From the left side of the lift truck, push the hood release lever out towards the right side of the truck to unlatch the

Maintenance Procedures Every 8 Hours or Daily

8000 YRM 1339

Legend for Figure 17 1. RELEASE LEVER 2. EMERGENCY DISCONNECT SWITCH

Figure 17. Release Lever, Manual Hydraulic Control Levers

Figure 18. Hood and Hood Latch Components

8000 YRM 1339

Maintenance Procedures Every 8 Hours or Daily

Legend for Figure 18 A. CLOSED POSITION B. PULL THIS DIRECTION TO OPEN

C. FRONT VIEW D. BOTTOM VIEW

1. LATCH ASSEMBLY 2. HOOD 3. HOOD RELEASE LEVER

4. HOOD MOUNTING BRACKET 5. HOOD HINGE 6. GAS SPRING

Steering Column Adjustments Make sure the steering column adjustment features are functioning properly. If lift truck is equipped with the optional telescoping steering column, make sure the tilt memory and telescoping features are operating correctly. The tilt memory lever must NOT allow the column to move unless the tilt memory lever is released. See Figure 19.

Tilt Adjust Feature The column tilt angle should be locked in position whenever the steering column tilt position lever is released. Use multipurpose grease as shown in the Maintenance Schedule and lubricate the lever and pivots as needed. NOTE: DO NOT use multipurpose grease to lubricate the sliding surfaces of the telescopic column.

Tilt Memory Feature After the tilt memory lever is released, tilt the column down until the column locks into position. The column should remain locked in place and NOT move. Use multipurpose grease as shown in the Maintenance Schedule and lubricate the lever and pivots as needed.

Telescopic Feature When the telescopic column locking handle is tightened to 6 N•m (53 lbf in), the steering wheel should remain locked in place. Use multipurpose grease as shown in the Maintenance Schedule and lubricate the lever and pivots as needed.

NOTE: OPTIONAL TELESCOPIC STEERING COLUMN SHOWN. 1. TILT POSITION LEVER 2. TILT MEMORY LEVER 3. TELESCOPIC COLUMN LOCKING HANDLE

Figure 19. Steering Column Tilt Memory Lever

Maintenance Procedures Every 8 Hours or Daily

Battery Check WARNING Never put tools or other metal on the battery. Metal on the battery can cause a short circuit and possible damage or injury. The acid in the electrolyte can cause injury. If the electrolyte is spilled, use water to flush the area. Make the acid neutral with a solution of sodium bicarbonate (soda). Acid in the eyes must be flushed with water immediately. Batteries generate explosive fumes. Keep the vents in the caps clean. Keep sparks or open flames away from the battery area. Do not make a spark from the battery connections. Disconnect the battery when doing maintenance. NOTE: There can be one of two types of batteries. One type has removable cell caps (flooded cell). The other type has sealed cells (maintenance free). The sealed batteries require a different charger, the electrolyte level or specific gravity cannot be checked and water cannot be added to the electrolyte. Make sure that the voltage and the weight of the battery are correct as shown on the Nameplate. See the Operating Manual to check for correct battery dimensions. See the section Battery Maintenance for procedures to change the battery and for a schedule on when to charge the battery. Keep the battery case and the area for the battery clean and painted. Leakage from the battery and corrosion can cause a malfunction in the electric controls of the lift truck. Use a water and sodium bicarbonate (soda) solution to clean the battery and the battery area. Keep the top of the battery clean, dry and free of corrosion. Make sure the battery is charged and has the correct voltage and ampere hour rating for the lift truck. See the Nameplate. Inspect the battery case, connector and cables for damage, cracks or breaks. See the battery dealer in the area to repair any damage. On batteries with cell caps, check the level of the electrolyte daily on a minimum of one cell. Add only distilled water, as necessary, to all cells that do not have

8000 YRM 1339 the correct electrolyte level. The correct level is halfway between the top of the plates and the bottom of the fill hole.

HOW TO MAKE CHECKS WITH THE KEY OR KEYLESS SWITCH ON WARNING FASTEN YOUR SEAT BELT! The seat belt is installed to help the operator stay on the truck if the lift truck tips over. IT CAN ONLY HELP IF IT IS FASTENED. After completing the Checks With the Key or Keyless Switch OFF, perform the Checks With the Key or Keyless Switch ON before placing the lift truck into service. Make sure the area around the lift truck is clear before moving the lift truck. Be careful when making the checks.

Control Levers and Pedals Check that the levers for the mast and attachment operate as described in the Operating Manual. Check that the pedals operate correctly as described in the Operating Manual.

Direction and Speed Controls Check that the direction and speed control pedals operate as described in the Operating Manual. Lubricate the Foot Directional Control pedal or accelerator pedal joints as needed. See the Maintenance Schedule for the type of lube to use.

Electrical Components • Check the operation of the horn by pressing the horn button on the steering wheel. The horn will operate when the key or keyless switch is in any position. If lift truck is equipped with E-Hydraulic controls, there is a horn button located on the armrest. See Figure 20. There is also a handle with a horn button on the right overhead guard leg. See Figure 21.

8000 YRM 1339

Maintenance Procedures Every 8 Hours or Daily

1. HORN BUTTON 2. EMERGENCY DISCONNECT SWITCH 3. FORWARD/REVERSE SWITCH

Figure 20. Horn Button Location - E-Hydraulic Controls

1. HORN BUTTON 2. HANDLE

3. RIGHT OVERHEAD GUARD LEG

• If lift truck is equipped with lights, check the operation of the lights using the appropriate rocker switch, located on the right side of the steering column. The lights will operate when the key or keyless switch is in any position. • Check the strobe light by turning the key or keyless switch to the ON position and check the operation of the light. • Check the backup alarm on lift trucks equipped with a direction control switch by sitting in the seat and turning the key or keyless switch to the ON position. Pushing down on the direction control switch to put it in reverse will sound the alarm. • Check the backup alarm on lift trucks equipped with a Foot Directional Control pedal by sitting on the seat, turning the key or keyless switch to the ON position and pressing the reverse arrow on the Foot Directional Control pedal. • Check the seat switch. Turn the key or keyless switch to the OFF position and leave the seat. The display panel will register a seat unoccupied error. Do not apply the parking brake. If the seat switch is working correctly, an alarm will sound when the operator leaves the seat after turning the lift truck OFF, but does not apply the parking brake. If lift truck is equipped with the Seat Activated parking brake option, the parking brake will be automatically applied when the operator leaves the seat after turning the lift truck OFF. The parking brake will release when the operator returns to the seat and the accelerator or Foot Directional Control pedal is applied. • The display panel, located in the upper right corner of the operator’s compartment (see the Operating Manual) is also energized when the key or keyless switch is turned to the ON position. The display is essential to safe and productive operation of the lift truck. Systems such as the battery condition and fault codes are monitored by the controller and are expressed by the display. A malfunctioning display unit may not alert an operator to a condition in time to prevent damage to system components on the lift truck. • In the event of an emergency, the emergency disconnect switch may be used to cut off power and automatically apply the park brake. To test that this switch is working properly turn the key or keyless switch to the ON position. The operator can disconnect almost all electrical power to the lift truck by pushing the emergency disconnect switch in until it clicks. To reset (reconnect) the emergency disconnect switch and energize the electrical circuits, the operator must turn the switch clockwise until it pops up. See Figure 17 and Figure 20.

Figure 21. Horn Button - Overhead Guard

Maintenance Procedures Every 8 Hours or Daily

Steering System The steering system should operate when a properly charged battery is connected, an operator is present in the seat, and the key or keyless switch is in the ON position. Move the steering tire and wheel assembly completely to the left by turning the steering wheel. The assembly should turn smoothly to its stop. The steering tire should stop approximately parallel to the battery. Turn the steering tire and wheel assembly completely to its right hand stop using the steering wheel. The steering system should move smoothly and make a full range of motion from its full left to full right position (approximately 180 degrees).

Hydraulic System WARNING At operating temperature the hydraulic oil is HOT. DO NOT permit the oil to contact the skin and cause a burn.

CAUTION DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Never operate the pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump. NOTE: Some parts of the mast move at different speeds during raising and lowering. Slowly raise and lower the mast several times without a load. The mast components must raise and lower smoothly in the correct sequence. The carriage raises first, then the inner weldment and intermediate weldment (three-stage masts only). The inner and intermediate weldments and the carriage must lower completely. Raise the forks 1 m (3 ft) with a capacity load. The inner weldment and carriage must raise smoothly. Lower the forks. All moving components must lower smoothly.

8000 YRM 1339 With the load lowered, tilt the mast backward and forward. The mast must tilt smoothly and both tilt cylinders must stop evenly. Check that the controls for the attachment operate the functions of the attachment. See the symbols by each of the controls. See the Operating Manual for a description of what each symbol does. Make sure all of the hydraulic lines are connected correctly and do not leak.

Service Brakes WARNING Loss of fluid from the brake fluid reservoir indicates a leak. Repair the brake system before using the lift truck. Replace the brake fluid (Dexron III) in the system if there is dirt, water or oil in the system. There is an indicator icon on the display panel for the brake fluid level. The icon is illuminated as described in the Operating Manual. If the icon is illuminated during operation, the fluid in the reservoir for the brake master cylinder is too low. Add brake fluid (Dexron III) and check for leaks. The reservoir is under the brake pedal and floor plate. See Figure 5. Clean the area around the fill cap so that no dirt enters the reservoir. Check the operation of the service brakes. Push on the brake pedal. The brakes must be applied before the pedal reaches the floor plate. The brake pedal must stop firmly and must not move slowly down after the brakes are applied. The brakes must apply equally to both drive wheels with no noticeable pull to either side.

Automatic Parking Brake There is an indicator icon on the display panel for the Automatic Parking Brake (APB). The icon is illuminated as described in the Operating Manual. The parking brake is automatically applied when the lift tuck is not in motion, or direction with acceleration has not been selected. Make sure the service brakes operate correctly before checking the operation of the Automatic Parking Brake. Check the operation of the Automatic Parking Brake. The Automatic Parking Brake, when in good condition and correctly adjusted, will hold a lift truck with a capacity load on a 15% grade [a slope that increases 1.5 m in 10 m (1.5 ft. increase in 10 ft)]. If Automatic Parking Brake requires adjustment, notify service personnel.

8000 YRM 1339

Maintenance Procedures After First 100 Hours or 2 Months of Service

Operator Presence System Check the operation of the Operator Presence System (OPS). Turn the lift truck power ON while sitting in the seat. Once lift truck power is ON, get up off the seat. If the OPS is working correctly, a switch in the operator’s seat will automatically disable all hydraulic and electrical functions so that the lift truck cannot travel forward or backward when the operator is not on the seat. If the lift truck can travel forward or backward, or the hydraulic functions operate, when the operator is not on

the seat, the OPS system is not working properly. See the section Electrical System 2200 YRM 1337 to repair or replace the seat switch that makes up the OPS system. See the Operating Manual for more information on how the OPS works.

Oil Leaks Visually check the hydraulic system, steering system, brake system, and transaxles for leaks.

Maintenance Procedures After First 100 Hours or 2 Months of Service TIRE AND WHEEL ASSEMBLIES Inspect the wheel rims for rust and cracks. DO NOT weld a cracked wheel rim or straighten a bent rim. Welding, heating, or bending a wheel rim can weaken its capacity. Always replace damaged tires or wheel rims immediately. DO NOT operate a truck with a broken stud or missing lug nuts.

NOTE: The load rollers and sheaves have sealed bearings that do not need additional lubrication. Lubricate the sliding surfaces and the load roller surfaces along the full length of the channels of the mast and carriage as shown in Figure 22 and Figure 23. Apply lubricant only to the indicated surfaces.

MAST SLIDING SURFACES WARNING Use special safety precautions when working on or near the mast or carriage. See Safety Procedures When Working Near Mast. DO NOT work under a raised carriage. Lower the carriage or install a safety chain to prevent the carriage from lowering when performing maintenance on the mast and lift chains. Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

CAUTION DO NOT use steam or high-pressure water to clean the load rollers or the lift chains. Steam and highpressure water can remove the lubrication from the bearings in the load rollers. Water in the bearings of the sheaves and the link pins of chains can also shorten the service life of these parts.

A. UPPER LOAD ROLLERS B. LOWER LOAD ROLLERS 1. LUBRICATE STRIP BEARINGS SURFACES 2. LUBRICATE SURFACES WHERE LOAD ROLLERS TRAVEL 3. LOAD ROLLER

Figure 22. Mast Lubrication

Maintenance Procedures After First 100 Hours or 2 Months of Service

1. LUBE FITTING 2. PIVOT PIN

8000 YRM 1339

3. OUTER MAST

Figure 24. Mast Mounting Lubrication

FORK GUIDES AND PINS 1. 2. 3. 4. 5. 6.

OUTER WELDMENT INNER WELDMENT FREE-LIFT CHAIN FREE-LIFT CYLINDER MAIN LIFT CYLINDER LOWERING CONTROL VALVE (EXTERNAL)

Figure 23. Two-Stage Mast With Full Free Lift

Lubricate the fork pins and guides with multipurpose grease as shown in the Maintenance Schedule. If lift truck is used in dirty, dusty, or difficult conditions, lubrication of the fork pins and guides may be required more frequently. Inspect the forks for wear. See Maintenance Procedures Every 8 Hours or Daily for the procedures to inspect the forks. See Figure 25.

MAST PIVOT PINS AND MOUNTING HARDWARE Lubricate the mast pivot pins at the grease fittings on the pivot pins. Use multipurpose grease shown in the Maintenance Schedule. See Figure 24. Check the mast mounting capscrews on the retainer caps. Tighten capscrews to the torque value shown in the Maintenance Schedule.

1. 2. 3. 4.

FORK LOCK PIN SPRING WASHER

5. WEDGE 6. KNOB 7. LOCK PIN ASSEMBLY

Figure 25. Fork Lock Pin Assembly

8000 YRM 1339

Maintenance Procedures After First 100 Hours or 2 Months of Service

INTEGRAL SIDESHIFT CARRIAGE

tracking during operation. Adjust/repair/replace hoses/ components as necessary.

Check Upper and Lower Bearings 1. Lower the carriage completely and remove the forks. 2. Remove the backrest and the lower mounting hooks from the sideshift carriage. 3. Use a crane with a capacity of at least 450 kg (1000 lb) to lift the outer frame away from the inner carriage. 4. Clean the bearing areas. Inspect the sideshift bearings for wear as follows: a. If either of the upper bearings is worn to less than 2.50 mm (0.09 in.) thickness, replace both of the upper bearings by driving the upper bearings out of the carriage bar. See Figure 26. b. If either of the lower bearings is worn to less than 2.50 mm (0.09 in.) thickness, replace both of the lower bearings by prying the lower bearings from the lower carriage bar. 5. Lubricate the bearings at the lube fittings with multipurpose grease as shown in the Maintenance Schedule. See Figure 26.

HEADER HOSES, HOSE FITTINGS, AND CLAMPS Visually inspect hoses/fittings for hydraulic leaks; hose covers for cuts, cracks, or exposed reinforcement; defective/broken clamping devices or sheaves; and proper

NOTE: TWO- AND THREE-STAGE FULL FREE-LIFT CARRIAGE SHOWN. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

UPPER BEARING LOWER HOOK LOAD ROLLER SNAP RING SIDESHIFT CYLINDER LOWER BEARING SHIMS INNER CARRIAGE LUBE FITTING OUTER FRAME

Figure 26. Integral Sideshift Carriage

Maintenance Procedures Every 500 Hours or Three Months

8000 YRM 1339

Maintenance Procedures Every 500 Hours or Three Months NOTE: Perform the checks in the Maintenance Procedures Every 8 Hours or Daily section prior to performing the procedures in this section.

bearings in the load rollers. Water in the bearings of the sheaves and the link pins of chains can also shorten the service life of these parts.

TIRE AND WHEEL ASSEMBLIES

NOTE: The load rollers and sheaves have sealed bearings that do not need additional lubrication.

Inspect the wheel rims for rust and cracks. DO NOT weld a cracked wheel rim or straighten a bent rim. Welding, heating, or bending a wheel rim can weaken its capacity. Always replace damaged tires or wheel rims immediately. DO NOT operate a truck with a broken stud or missing lug nuts.

Lubricate the sliding surfaces and the load roller surfaces along the full length of the channels of the mast and carriage as shown in Figure 27 and Figure 28. Apply lubricant only to the indicated surfaces.

MAST AND CARRIAGE Mast Sliding Surfaces WARNING Use special safety precautions when working on or near the mast or carriage. See Safety Procedures When Working Near Mast. DO NOT work under a raised carriage. Lower the carriage or install a safety chain to prevent the carriage from lowering when performing maintenance on the mast and lift chains. Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

CAUTION DO NOT use steam or high-pressure water to clean the load rollers or the lift chains. Steam and highpressure water can remove the lubrication from the

A. UPPER LOAD ROLLERS B. LOWER LOAD ROLLERS 1. LUBRICATE STRIP BEARINGS SURFACES 2. LUBRICATE SURFACES WHERE LOAD ROLLERS TRAVEL 3. LOAD ROLLER

Figure 27. Mast Lubrication

8000 YRM 1339

Maintenance Procedures Every 500 Hours or Three Months

Mast Pivot Pins, Bushings, and Mounting Hardware Lubricate the mast pivot pins with multipurpose grease at the grease fittings on the pivot pins. Use multipurpose grease shown in the Maintenance Schedule. See Figure 29. Check the mast mounting capscrews on the retainer caps. If needed, tighten capscrews to the torque value shown in the Maintenance Schedule.

1. GREASE FITTING 2. PIVOT PIN

3. OUTER MAST

Figure 29. Mast Mounting Lubrication

Header Hoses Visually inspect hoses/fittings for hydraulic leaks; hose covers for cuts, cracks, or exposed reinforcement; defective/broken clamping devices or sheaves; and proper tracking during operation. Adjust/repair/replace hoses/ components as necessary.

NOTE: TYPICAL MAST SHOWN. 1. 2. 3. 4. 5. 6.

OUTER WELDMENT INNER WELDMENT FREE-LIFT CHAIN FREE-LIFT CYLINDER MAIN LIFT CYLINDER LOWERING CONTROL VALVE (EXTERNAL)

Figure 28. Two-Stage Mast With Full Free Lift

Maintenance Procedures Every 500 Hours or Three Months

Fourth Function Mini Rollers Lubrication WARNING When working on or near the mast, see Safety Procedures When Working Near Mast in this YRM If the lift truck is equipped with a four function mast, the mini rollers for the fourth function hoses need to be lubricated at the 500 hours/3 months service interval. The fourth function mini rollers are located on top of the free-lift cylinder. See Figure 30. 1. To lubricate the mini rollers, raise the carriage to remove tension and loosen the fourth function hoses. Place blocks under carriage to keep fourth function hoses loose.

8000 YRM 1339

2. Remove four nuts, spacers, and capscrews from hose bracket. See Figure 30. 3. Remove hose bracket and mini rollers from free-lift cylinder. 4. Clean hose brackets and lubricate mini rollers with multipurpose grease shown in the Maintenance Schedule. 5. Install hose brackets and mini rollers to free-lift cylinder using four nuts, spacers, and capscrews. 6. Remove blocks from carriage and lower carriage to increase tension of hoses on hose sheaves.

NOTE: SEVERAL MAST COMPONENTS OMITTED FOR CLARITY. 1. 2. 3. 4.

CAPSCREW LEFT HOSE BRACKET MINI ROLLERS SPACER

5. 6. 7. 8.

NUT FREE-LIFT CYLINDER FREE-LIFT CHAIN RIGHT HOSE BRACKET

Figure 30. Fourth Function Mini Rollers Lubrication

8000 YRM 1339

Maintenance Procedures Every 500 Hours or Three Months

Lift Chain Lubrication WARNING When working on or near the mast, see Safety Procedures When Working Near Mast in this YRM DO NOT repair worn or damaged lift chains. If a lift chain is worn or damaged, both lift chains must be replaced. NOTE: Perform this maintenance only if not performing the 2000 hours maintenance procedures. Otherwise, go to the Maintenance Procedures Every 2000 Hours or Yearly for lift chain lubrication procedures. Lubricate lift chains with SAE 30W engine oil. The best procedure is to remove the chains from the lift truck and soak them in engine oil. Be sure to clean any dirt or grease from chains before lubricating. DO NO USE STEAM TO CLEAN THE LIFT CHAINS.

Lift Chain Wear Check

Pitch

WARNING When working on or near the mast or carriage, refer to Safety Procedures When Working Near Mast in this section. DO NOT work under a raised carriage. Lower the carriage or use a safety chain to prevent the carriage from lowering when doing maintenance on the mast and lift chains. 1. If a section of chain is 3% longer than a similar section of new chain, the chain is worn and must be replaced. If a chain scale is available (Yale Part No. 580037684), check the lift chains as shown in Figure 31. If a chain scale is not available, measure 20 links of chain. Measure from the center of a pin to the center of another pin 20 pitches away. Compare the length with the chart in Figure 31. Replace the chain if the length of 20 links of the worn section is more than the maximum wear limit.

12.7 mm (0.5 in.) 15.90 mm (0.63 in.) 19.10 mm (0.75 in.) 25.4 mm (1.0 in.) 31.80 mm (1.25 in.) 44.50 mm (1.75 in.) 50.8 mm (2.0 in.)

Total length of 20 links (pitch) of new chain

Wear Limit The maximum length of 20 links.

254.0 mm (10.0 in.) 317.5 mm (12.5 in.) 381.0 mm (15.0 in.) 508.0 mm (20.0 in.) 635.0 mm (25.0 in.) 889.0 mm (35.0 in.) 1016.0 mm (40.0 in.)

261.6 mm (10.3 in.) 327.0 mm (12.9 in.) 392.4 mm (15.4 in.) 523.3 mm (20.6 in.) 654.10 mm (25.75 in.) 915.70 mm (36.05 in.) 1046.5 mm (41.2 in.)

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE. 1. CHAIN WEAR SCALE

Figure 31. Lift Chains Check

Maintenance Procedures Every 500 Hours or Three Months

INTEGRAL SIDESHIFT CARRIAGE

b. If either of the lower bearings is worn to less than 2.50 mm (0.09 in.) thickness, replace both of the lower bearings by prying the lower bearings from the lower carriage bar.

8000 YRM 1339

5. Lubricate the bearings at the lube fittings with multipurpose grease as shown in the Maintenance Schedule. See Figure 32.

Fork Guides and Pins Lubricate the fork pins and guides with multipurpose grease as shown in the Maintenance Schedule. If lift truck is used in dirty, dusty or difficult conditions, lubrication of the fork pins and guides may be required more frequently. Inspect the forks for wear. See Maintenance Procedures Every 8 Hours or Daily for the procedures to inspect the forks. See Figure 33.

1. 2. 3. 4.

FORK LOCK PIN SPRING WASHER

5. WEDGE 6. KNOB 7. LOCK PIN ASSEMBLY

Figure 33. Fork Lock Pin Assembly

TILT CYLINDER ROD END PINS NOTE: TWO- AND THREE-STAGE FULL FREE-LIFT CARRIAGE SHOWN. 1. 2. 3. 4. 5.

UPPER BEARING LOWER HOOK LOAD ROLLER SNAP RING SIDESHIFT CYLINDER

6. 7. 8. 9. 10.

LOWER BEARING SHIMS INNER CARRIAGE LUBE FITTING OUTER FRAME

Figure 32. Integral Sideshift Carriage

Lubricate the tilt cylinder rod end pins with multipurpose grease shown in the Maintenance Schedule. See Figure 34.

CONTROL LEVERS, PEDALS, AND HINGES Lubricate linkages, pedal shafts, control cables (throttle and parking brake) hood hinges, and seat rails. Use a silicone spray lubricant, Yale Part Number 504236201.

8000 YRM 1339

Maintenance Procedures Every 500 Hours or Three Months

A. FRAME ATTACHMENT

B. MAST ATTACHMENT

1. PIN

2. ROD END PIN

3. LUBRICATION FITTING

Figure 34. Tilt Cylinder Rod End Pins, Lube

DIRECTION AND SPEED CONTROL PEDALS Lubricate the Foot Directional Control pedal or the accelerator pedal joints as needed. See the Maintenance Schedule for lubricant type to use.

HYDRAULIC HOSES, FITTINGS, AND CLAMPS WARNING Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil. Thoroughly wash oil from exposed areas of skin as soon as possible.

WARNING Never check for leaks by putting hands on hydraulic lines or components under pressure. Hydraulic oil under pressure can be injected into the skin

Completely lower forks to relieve hydraulic pressure before disassembling any part of the lift pump or disconnecting any hydraulic hoses. Inspect all hydraulic hoses for kinks, Verify that there are no crushed, flattened, or twisted hoses. Check for hard, stiff, or charred hoses. Adjust or replace any hoses as necessary. Check all fittings and clamps and replace if necessary.

HYDRAULIC BREATHER CAP The hydraulic breather cap allows air to enter the hydraulic tank when the hydraulic oil is pumped out to the cylinders. When the hydraulic oil returns to the tank, air is expelled through the hydraulic breather cap. A filter in the cap protects the hydraulic system from particles of dirt and other contaminants. If the filter becomes excessively dirty, air flow can be restricted, causing pressures and vacuums to build inside the tank. If air flow becomes restricted through the hydraulic breather cap, replace the assembly. Keep the hydraulic tank area clean and DO NOT overfill the hydraulic tank. See Figure 35.

Maintenance Procedures Every 500 Hours or Three Months

8000 YRM 1339

the minimum safe level between checks, as in the case of a leak. The reservoir, mounted on top of the master cylinder (see Figure 36), stores a small amount of hydraulic to compensate for normal loss. Remove the floor plates. Locate the master cylinder assembly near the brake pedal. Remove the reservoir cap and fill the reservoir to the full mark with hydraulic oil according to the Maintenance Schedule. Reinstall the reservoir cap and check for leaks. If there is a leak or if the fluid level has dropped below the minimum safe level, the system may need to be bled before returning to service. See Brake System 1800 YRM 1332 for procedures on bleeding the brake system.

1. HYDRAULIC TANK 2. HYDRAULIC FILTER 3. HYDRAULIC BREATHER CAP/DIPSTICK

Figure 35. Hydraulic Breather Cap Check

SERVICE BRAKES Master Cylinder Oil Check WARNING Loss of fluid from the master cylinder indicates a leak. This condition can cause brake failure, resulting in material damage or personal injury. Repair the brake system before returning to service if a leak is suspected. Drain and flush the service brake system when contaminated by dirt, water, or other unapproved fluids. NOTE: When adding fluid to the reservoir, use only Dexron® III. The service brake system is a self-contained system filled with hydraulic oil and does not require frequent service. However, normal operation does use a small amount of hydraulic oil so the master cylinder reservoir must be checked and refilled at the 500-hr/3-month interval. A float switch inside the reservoir activates an indicator light on the display panel if the hydraulic oil drops below

1. MASTER CYLINDER CAP 2. BRAKE PEDAL

3. MASTER CYLINDER RESERVOIR

Figure 36. Master Cylinder Oil Check

PARKING BRAKE Manual Override Handle Lubricate the pivot pin on the manual override handle with multipurpose grease as shown in the Maintenance Schedule. See Figure 37.

8000 YRM 1339

Maintenance Procedures Every 500 Hours or Three Months

1. FRONT BULKHEAD 2. MANUAL OVERRIDE HANDLE

3. PIVOT PIN 4. TRACTION MOTORS

Figure 37. Manual Override Handle

ELECTRICAL INSPECTION Contactors WARNING Disconnect the battery connector to prevent injury from electric shock before you make any inspections or repairs to the contactors Discharge the capacitors when you make any electrical inspections or repairs inside of the electrical compartment. 1. Disconnect the battery and discharge the capacitors. See Discharging the Capacitors in the Introduction section in the front of this service manual. Place a DO NOT CONNECT BATTERY tag on battery connector and remove key. If truck is equipped with a keyless start switch, place a cover over keyless switch. 2. Remove the floor mat and floor plate for access to the contactors. See Figure 38.

1. CONTACTOR ASSEMBLY 2. TRACTION MOTOR CONTROLLER

Figure 38. Contactor Inspection

Maintenance Procedures Every 2000 Hours or Yearly

8000 YRM 1339

3. Disconnect the power cable connector from contactor assembly.

5. Connect the power cable connector to contactor assembly.

4. Inspect the contactors. The contacts are made of a special silver alloy. The contacts will look black and rough from normal operation. This condition does not cause problems with the operation of the lift truck. Cleaning is not necessary. DO NOT USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE CONTACTS. If the contactors need to be replaced, see service manual Electrical System 2200 YRM 1337 for procedures.

6. Install the floor plate and floor mat. 7. Remove the DO NOT CONNECT BATTERY tag from truck battery connector and reconnect the battery. If lift truck is equipped with a keyless start switch, remove cover from switch.

Maintenance Procedures Every 2000 Hours or Yearly Perform the Maintenance Procedures Every 8 Hours or Daily and Maintenance Procedures Every 500 Hours or Three Months prior to performing the procedures in this section.

HYDRAULIC SYSTEM Hydraulic Oil Filter, Change WARNING At operating temperature, the hydraulic oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn.

CAUTION DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Dirt can cause damage to the components of the hydraulic system. Never operate the hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 1. Put lift truck on a level surface and lower the mast. Remove the tow pin and remove cover from counterweight for access to the hydraulic filter. Unscrew and remove filter lid, O-ring, and spring from filter head. See Figure 39. NOTE: Have a container large enough to hold the filter assembly and allow for final hydraulic oil draining. See the Maintenance Schedule for oil quantity.

2. Remove the hydraulic filter element from the filter housing and place into the container. Cover the filter head to prevent any foreign materials from getting into the hydraulic tank.

CAUTION Filter element must be installed with the debris cup on the bottom and the check valve on the top. Installing the filter element upside down could result in severe damage to the hydraulic system, including blown hoses. 3. Install the new hydraulic filter element into filter housing. 4. Lubricate new O-ring with clean hydraulic oil and install it on filter head. Inspect spring and filter lid. If worn or damaged, replace with new parts. See Parts Manual. 5. Install spring and filter lid onto filter head. Tighten filter lid to 13.6 N•m (120 lbf in). See Figure 39.

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer. 6. Turn lift truck power ON and activate the hydraulic controls for 30 seconds. Check for leaks. Stop truck and check hydraulic oil level. Add oil, if necessary. Use hydraulic oil shown in the Maintenance Schedule. 7. Install the cover on the counterweight and install the tow pin.

8000 YRM 1339

Maintenance Procedures Every 2000 Hours or Yearly

NOTE: COUNTERWEIGHT COVER NOT SHOWN FOR CLARITY. 1. 2. 3. 4. 5.

HYDRAULIC TANK HYDRAULIC FILTER FILTER HOUSING FILTER HEAD FILTER ELEMENT

6. 7. 8. 9. 10.

O-RING SPRING LID BREATHER CAP/DIPSTICK PAN HEAD SCREW

Figure 39. Hydraulic Filter Assembly

Maintenance Procedures Every 2000 Hours or Yearly

Hydraulic Breather, Check WARNING At operating temperature, the hydraulic oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 1. Put lift truck on a level surface and lower the mast. Remove the tow pin and counterweight cover from counterweight for access to the hydraulic breather. See Figure 40. 2. Remove three capscrews and breather from hydraulic tank.

8000 YRM 1339

WARNING Cleaning solvents can be flammable and toxic and may cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 3. Wash breather in solvent and use compressed air to dry. 4. Inspect breather for damage. Replace if damaged. See the Parts Manual if replacement is required. 5. Install the breather and three capscrews into the hydraulic tank. 6. Install cover to counterweight and install the tow pin.

STEERING AXLE Steering Actuator and Steering Plate Torque Check The steering actuator and steering plate are mounted to the rear of the frame below the counterweight. The steering tire and wheel assemblies, steering actuator and steering plate support much of the weight of the battery, frame, and counterweight. The action of steering pushes and pulls on the actuator in various directions. The mounting bolts and nuts that attach the actuator to the frame should be checked to ensure proper torques every 2000 hours or yearly. The bolts and nuts that attach the steering plate to the frame should also be checked. For access to the mounting bolts and nuts for the actuator and steering plate, perform the following: 1. Put lift truck on blocks for access to the steering actuator and steering plate bolts and nuts. See the Introduction section at the beginning of this YRM for the procedures on putting the lift truck on blocks. Turn the key or keyless switch to the OFF position.

1. HYDRAULIC BREATHER 2. CAPSCREW

Figure 40. Hydraulic Breather

2. Remove the steering wheel and tire from steering axle. See the Wheel and Tires section for procedures on removing the steering wheels and tires.

8000 YRM 1339 3. Check the three bolts and nuts that attach the steering actuator to the steering plate. If they are loose, tighten nuts and bolts to 270 N•m (200 lbf ft). See Figure 41.

Maintenance Procedures Every 2000 Hours or Yearly Each transaxle has its own separate oil supply and each transaxle must be checked separately. Remove the oil fill plug to check the level of the oil. See Figure 42. The oil should be level with the bottom of the hole. If it is necessary to add oil, add oil through the fill plug hole until the oil is level with the bottom of the hole. Install the oil fill plug and torque it to 22 N•m (195 lbf in).

NOTE: BOTTOM VIEW SHOWN. 1. 2. 3. 4.

STEERING PLATE BOLTS AND NUTS STEERING ACTUATOR BOLTS AND NUTS STEERING ACTUATOR STEERING PLATE

Figure 41. Steering Actuator and Steering Plate Torque Check 4. Check the four bolts and nuts that secure the steering plate to the counterweight. See Figure 41. If there is play between the steering plate and the bolts, remove the bolts, nuts, and washers from the steering actuator one at a time. 5. Apply Loctite® 271 to the threads of each bolt and reinstall the mounting bolts, washers and nuts. The torque value for each mounting bolt is 305 N•m (225 lbf ft).

NOTE: RIGHT SIDE SHOWN LEFT SIDE IS SIMILAR. 1. OIL FILL PLUG 2. OIL CHECK PLUG

3. OIL DRAIN PLUG

6. After all bolts and nuts on both the steering actuator and steering plate, have been checked, install the steering wheels and tires to the steering axle. See the Wheel and Tires section for procedures on installing the steering wheels and tires.

Install the drive wheel assembly, and tighten the wheel nuts to 170 N•m (125 lbf ft) in a diametric pattern. Remove the lift truck from the blocks.

TRANSAXLE OIL LEVEL CHECK

TRANSAXLE BREATHER CHECK

Place the lift truck on blocks as described in How to Put Lift Truck on Blocks located in the front of this manual and remove the drive wheel assembly.

1. Inspect transaxle breather for visible damage. If damaged, replace breather. See service manual Transaxle 1300 YRM 1330 for procedure.

Figure 42. Transaxle Oil Level Check

Maintenance Procedures Every 2000 Hours or Yearly

BRAKE OIL CHANGE WARNING Loss of fluid from the master cylinder indicates a leak. This condition can cause brake failure, resulting in material damage or personal injury. Repair the brake system before returning to service if a leak is suspected. Drain and flush the service brake system when contaminated by dirt, water, or other unapproved fluids.

CAUTION The brake system uses Dexron® III. Use of automotive or other unapproved fluids can damage the brake system. NOTE: Bleeding air from the brake system requires two technicians. One technician must sit in the seat and operate the brake pedal while the other opens and closes the brake bleed valve located on the transaxle housing. To change oil in the brake system: 1. Place the lift truck on blocks as described in How to Put Lift Truck on Blocks located in the front of this manual. Remove the drive wheel assembly. 2. Remove the floor plates and ensure that the master cylinder reservoir is filled with transmission fluid (Dexron® III). 3. Put one end of a rubber hose on the bleed valve on transaxle housing. Put the other end of the hose into an empty container. 4. Loosen bleed valve one turn counterclockwise to drain brake oil from brake system. Slowly push the brake pedal, and hold it at the end stroke. Close the bleed valve and release the brake pedal. Check level of fluid in master cylinder reservoir, fill as necessary. NOTE: The new brake oil will be easily recognizable, as it is much more clear than the darker used transmission fluid.

8000 YRM 1339 5. Repeat Step 1 through Step 3 until there is new brake oil exiting the bleed valve. 6. Repeat the procedure for the other side of the transaxle. 7. Install the drive wheel assembly and tighten to 170 N•m (125 lbf ft) in a diametric pattern. Remove the lift truck from the blocks.

INTEGRAL SIDESHIFT CARRIAGE Replace all four bearings regardless of wear. The procedures for replacing the bearings are in the Maintenance Procedures Every 500 Hours or Three Months section under Integral Sideshift Carriage.

LIFT CHAINS WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. NOTE: Cleaning and lubrication of lift chains will be needed more frequently in very dirty, dusty, or contaminated applications. Remove the lift chains. Clean the lift chains by soaking them in a solvent that has a petroleum base for at least 30 minutes. Use compressed air to completely dry the chains when they are clean. Lubricate the lift chains by soaking them in SAE 30W engine oil for at least 30 minutes. Remove the chains from the oil. Hang the chains for one hour so excess oil will drain from the chains.

8000 YRM 1339

Maintenance Procedures Every 4000 Hours or Two Years

Maintenance Procedures Every 4000 Hours or Two Years Perform the Maintenance Procedures Every 8 Hours or Daily, Maintenance Procedures Every 500 Hours or Three Months, and Maintenance Procedures Every 2000 Hours or Yearly prior to performing the procedures in this section.

HYDRAULIC OIL CHANGE WARNING At operating temperature, the hydraulic oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 1. Put lift truck on blocks for access to the hydraulic oil drain hose underneath the lift truck. See the Introduction section at the beginning of this YRM for the procedures on putting the lift truck on blocks. Turn the key or keyless switch to the OFF position.

3. Remove the breather cap/dipstick to allow for faster draining. 4. Locate the hydraulic tank drain hose. See Figure 43. Cut the two strap clamps retaining the drain hose and route drain hose under the side of the frame to the outside of the lift truck. Position the drain hose to drain into a container suitable for storing used hydraulic oil. See the Maintenance Schedule for hydraulic oil quantity and container size needed. 5. Remove the screw clamp and remove the button head rivet and allow oil to drain into container. 6. When the oil has drained, reinstall the button head rivet into the drain hose and secure with screw clamp. 7. Coil hose and secure hose into position with two new strap clamps. 8. Fill the hydraulic tank to the proper level with new hydraulic oil as shown in the Maintenance Schedule. DO NOT overfill the hydraulic tank. 9. Install the breather cap/dipstick. See Figure 43. 10. Operate the lift pump for one to two minutes to purge air from the hydraulic system. Remove breather cap/dipstick and check the oil level on the dipstick. If more oil is needed, add oil shown in the Maintenance Schedule. 11. Remove lift truck from blocks.

2. Remove tow pin and counterweight cover from counterweight to allow access to breather cap/dipstick

Maintenance Procedures Every 4000 Hours or Two Years

1. 2. 3. 4.

BUTTON HEAD RIVET SCREW CLAMP HYDRAULIC TANK HYDRAULIC OIL FILTER

5. 6. 7. 8.

8000 YRM 1339

HYDRAULIC BREATHER CAP/DIPSTICK HYDRAULIC MOTOR DRAIN HOSE STRAP CLAMPS

Figure 43. Hydraulic Oil Change

STEERING DIRECTION SENSOR INSPECTION

2. Remove horn button, nut, and rod from steering wheel. See Figure 44.

Fixed Steering Column

3. Remove hex nut and steering wheel from steering column. If necessary, use puller tool to remove steering wheel. See Figure 44.

NOTE: Tag all electrical connectors during removal to aid in installation. 1. Disconnect battery connector. Discharge the capacitors. See Discharging the Capacitors in the Introduction section in the front of this service manual.

4. Remove steering column upper cover by pressing from both sides near the bottom and pulling up. Clips should remain attached to cover. See Figure 45.

8000 YRM 1339

Maintenance Procedures Every 4000 Hours or Two Years 5. Disconnect spring from sensor assembly. See Figure 45. 6. Swing open sensor assembly. It will only swing 30° with the lower cover installed. See Figure 46. 7. Inspect magnet gear teeth. See Figure 46. Replace sensor assembly if magnet teeth are cracked or missing. See Electrical System 2200 YRM 1337 for sensor replacement procedures. 8. Connect battery connector, turn lift truck ON, and rotate steering column to fully inspect column gear teeth. See Figure 46. Replace column gear if teeth are cracked or missing. See Steering System 1600 YRM 1331 for column gear replacement procedure. Disconnect battery connector.

NOTE: TELESCOPIC STEERING COLUMN SHOWN.

9. Swing sensor assembly back to original position.

1. STEERING COLUMN 2. HORN BUTTON 3. NUT

10. Connect spring to sensor assembly.

4. ROD 5. HEX NUT 6. STEERING WHEEL

Figure 44. Steering Wheel

11. Install steering column upper cover by pressing from both sides and pushing against lower cover until snapped in place. See Figure 45. 12. Install steering wheel and hex nut onto steering column. See Figure 44. Tighten hex nut to 40 to 54 N•m (30 to 40 lbf ft). 13. Install rod, nut, and horn button onto steering wheel. See Figure 44.

1. 2. 3. 4.

STEERING COLUMN UPPER COVER FIXED STEERING COLUMN SPRING SENSOR ASSEMBLY

Figure 45. Fixed Steering Column Covers

1. SENSOR ASSEMBLY 2. MAGNET GEAR TEETH 3. COLUMN GEAR TEETH

Figure 46. Steering Gears

Maintenance Procedures Every 4000 Hours or Two Years 14. Connect battery connector.

Telescopic Steering Column NOTE: Tag all electrical connectors during removal to aid in installation. 1. Disconnect battery connector. Discharge the capacitors. See Discharging the Capacitors in the Introduction section in the front of this service manual. 2. Remove horn button, nut, and rod from steering wheel. See Figure 44. 3. Remove hex nut and steering wheel from steering column. If necessary, use puller tool to remove steering wheel. See Figure 44.

8000 YRM 1339

15. Install steering column telescoping cover onto telescopic steering column. See Figure 47. 16. Install steering column top cover, by pressing down onto telescopic steering column. See Figure 47. 17. Lower telescopic steering column to fully DOWN position. 18. Install steering wheel and hex nut onto steering column. See Figure 44. Tighten hex nut to 40 to 54 N•m (30 to 40 lbf ft). 19. Install rod, nut, and horn button onto steering wheel. See Figure 44. 20. Connect battery connector.

4. Telescope steering column to fully UP position. 5. Remove steering column top cover, by pressing both sides near the bottom and pulling up. Clips should remain attached to cover. See Figure 47. 6. Remove steering column telescoping cover from telescopic steering column. See Figure 47. 7. Remove capscrew, washer, and steering column upper cover from telescopic steering column. See Figure 47. 8. Disconnect spring from sensor assembly. See Figure 47. 9. Swing open sensor assembly. It will only swing 30° with the lower cover installed. See Figure 46. 10. Inspect magnet gear teeth. See Figure 46. Replace sensor assembly if magnet teeth are cracked or missing. See Electrical System 2200 YRM 1337 for sensor replacement procedures. 11. Reconnect battery connector, turn lift truck ON, and rotate steering column to fully inspect column gear teeth. See Figure 46. Replace column gear if teeth are cracked or missing. See Steering System 1600 YRM 1331 for column gear replacement procedure. Disconnect battery connector. 12. Swing sensor assembly back to original position. 13. Connect spring to sensor assembly. 14. Install steering column upper cover, washer, and capscrew onto telescopic steering column. See Figure 47.

1. 2. 3. 4. 5. 6. 7. 8.

TELESCOPIC STEERING COLUMN STEERING COLUMN TOP COVER STEERING COLUMN TELESCOPING COVER STEERING COLUMN UPPER COVER CAPSCREW WASHER SPRING SENSOR ASSEMBLY

Figure 47. Telescopic Steering Column Covers

8000 YRM 1339

Maintenance Procedures Every 4000 Hours or Two Years

TELESCOPIC STEERING COLUMN LUBRICATION

11. Install steering column top cover, by pressing down onto telescoping cover. See Figure 47.

NOTE: Tag all electrical connectors during removal to aid in installation.

12. Lower telescopic steering column to fully DOWN position.

1. Disconnect battery connector. Discharge the capacitors. See Discharging the Capacitors in the Introduction section in the front of this service manual.

13. Install steering wheel and hex nut onto telescopic steering column. See Figure 44. Tighten hex nut to 40 to 54 N•m (30 to 40 lbf ft).

2. Remove horn button, nut, and rod from steering wheel. See Figure 44.

14. Install rod, nut, and horn button onto steering wheel. See Figure 44. 15. Connect battery connector.

3. Remove hex nut and steering wheel from telescopic steering column. If necessary, use puller tool to remove steering wheel. See Figure 44. 4. Telescope column to fully UP position. 5. Remove steering column top cover from telescopic steering column by pressing both sides near the bottom and pulling up. Clips should remain attached to cover. See Figure 47. 6. Remove steering column telescoping cover from telescopic steering column. See Figure 47. 7. Remove capscrew, washer, and steering column upper cover from telescopic steering column. See Figure 47. 8. Lubricate telescopic steering column with manual steering gear grease. See Figure 48. See Maintenance Schedule. 9. Install steering column upper cover, washer, and capscrew onto telescopic steering column. See Figure 47. 10. Install steering column telescoping cover onto telescopic steering column. See Figure 47.

NOTE: BOLD ARROW INDICATES GREASE APPLICATION LOCATION.

Figure 48. Telescopic Steering Column Lubrication

Lift and Tilt System Leak Check

8000 YRM 1339

Welding Repairs WARNING Welding can cause a fire or an explosion. Always follow the instructions in the Frame section of the service manual if a hydraulic tank must be welded. Make sure there is no fuel, oil, or grease near the weld area. Make sure there is good ventilation in the area where the welding must be done. DO NOT heat, weld, or bend forks. Forks are made of special steel using special methods. Get information from your dealer for Yale lift trucks before welding on a mast.

WARNING Forklift frames and components may be painted with a catalyzed paint, such as polyurethane or a two-part primer. Welding, burning, or other heat sufficient to cause thermal decomposition of the paint may release isocyanates. These chemicals are allergic sensitizers to the skin and respiratory tract and overexposure may occur without odor warning. Should work be performed, utilize good industrial hygiene practices including removal

of all paint (prime and finish coats) to the metal around the area to be welded, local ventilation, and/or supplied-air respiratory protection.

CAUTION When an arc welder is used, always disconnect the battery connector on the lift truck. This action will prevent damage to the motor controllers. Connect the ground clamp for the arc welder as close as possible to the weld area. This action will prevent damage to a bearing from the large current from the welder. NOTE: Remove all electronic controllers prior to arc welding on these lift trucks. The removal procedures for the electronic controllers are outlined in Electrical System 2200 YRM 1337. All welding repairs require special welding instructions. Talk to your dealer for Yale lift trucks before welding on the lift truck. If an acetylene or arc welder is used, perform the procedures in the previous WARNING and CAUTION.

Lift and Tilt System Leak Check LIFT CYLINDERS LEAK CHECK WARNING Never allow any person under a raised carriage. Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered, the key is in the OFF position, and the key is removed. Before making any repairs, use chains on the mast weldments and carriage so that they cannot move. Make sure the moving parts are attached to the parts that cannot move. DO NOT try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by pressure. During test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests.

1. Operate the hydraulic system. Put a capacity load on the forks and raise and lower the load several times. Lower the load and tilt the mast forward and backward several times. Check for leaks. 2. Raise the carriage and load so that the rods of the main lift cylinders extend at least 60 cm (2 ft). If the carriage lowers slowly with the control valve in the NEUTRAL position, there are leaks inside the hydraulic system. The maximum speed that the carriage is allowed to lower is 50 mm (2 in.) per 10 minutes when the hydraulic oil is 30°C (86°F). If the oil temperature is 70°C (160°F), the maximum speed that the carriage can lower is 150 mm (6 in.) per 10 minutes. 3. If the leak rate is greater than the above specifications, check the lift cylinders for internal leaks. Remove the load from the forks. Install a gate valve in the supply line between the main control valve and the mast. Put a capacity load on the forks again. Raise the carriage and load so that the rods of the main lift cylinders extend at least 0.60 m (2 ft).

8000 YRM 1339

Battery Maintenance

Close the gate valve. If the carriage or mast weldments lower slowly, the seals in the lift cylinders are worn. 4. If the carriage and mast weldments do not move, open the gate valve and check for movement again. If the carriage lowers when the gate valve is open, check for leaks in the hydraulic lines or fittings. If no

leaks are found, the main control valve may have a defect. Remove the load from the forks.

TILT CYLINDER LEAK CHECK To check the tilt system for hydraulic leaks, see the service manual section Cylinder Repair 2100 YRM 1382 for the procedures.

Battery Maintenance HOW TO CHARGE BATTERY WARNING The acid in the electrolyte can cause injury. If electrolyte is spilled, use water to flush the area. Make the acid neutral with a solution of sodium bicarbonate (soda) and water. Acid in the eyes must be immediately flushed with water. Batteries generate explosive fumes when they are being charged. Keep fire, sparks, and burning material away from the battery charger area. Prevent sparks from the battery connectors. Charge batteries only in the special area for charging batteries. When charging the batteries, keep the vent caps clean. The battery charger area must have ventilation so that explosive fumes are removed. Open the hood over the battery or remove the cover if the battery has a cover. Disconnect the battery when doing cleaning and maintenance.

CAUTION Never connect the battery charger plug to the plug of the lift truck; you can damage the electronic controller. Make sure the battery charger voltage is the correct voltage for the battery. Use only battery chargers approved by the battery manufacturer or dealer.

NOTE: This series of trucks can have one of two types of batteries. One type has removable cell caps. A green key for battery voltage shows in the window of the battery connector for batteries with cell caps. The other type has sealed cells and the electrolyte cannot be checked. A gray key for battery voltage shows in the window of the battery connector for sealed batteries. These sealed batteries also require a different charger. NOTE: Many installations have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufacturer. Use the recommendations of the battery manufacturer for charging the battery. Correct use of the hydrometer and proper operation of the battery charger is important. See Figure 49. Follow the instructions of the charger manufacturer. Never let the battery discharge below the minimum value given by the battery manufacturer. A fully charged battery will have a specific gravity of 1.265 to 1.310 at 25°C (77°F). Never charge a battery at a rate that will raise the electrolyte temperature above 49°C (120°F). Never let a battery stay discharged for long periods. NORMAL CHARGE: This is the charge that is normally given to a battery that is discharged from normal service. Many users give this charge at a regular interval based on usage. This practice will keep the battery fully charged if the battery is not discharged below the limit. Always use a hydrometer to check the battery if the interval charge cycle is used. Frequent charging of a battery that has a 2/3 or more charge can decrease battery life.

CAUTION Always make sure the color in the window of the charger connector is the same as the color in the window of the battery connector.

Battery Maintenance

8000 YRM 1339 NOTE: Many users have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufacturer. Use the recommendations of the battery manufacturer for charging the battery.

HOW TO CHANGE BATTERY Remove the Battery WARNING Batteries are heavy and can cause an injury. Use care to avoid injury. DO NOT put hands, arms, feet, or legs between the battery and a solid object.

Specific Gravity Reading

Electrolyte Temp.

Correction Points

Correct Value

1.210

31°C (88°F)

+0.003

1.213

1.210

27°C (81°F)

+0.001

1.211

1.210

25°C (77°F)

0.000

1.210

18°C (64°F)

0.004

1.206

+0.001 or 0.001 for each 2°C (35.6°F) from the 25°C (77°F) base value.

Figure 49. Battery Check NOTE: Some batteries are maintenance free and do not require checking the electrolyte. DO NOT attempt to check electrolyte in batteries with sealed cells. EQUALIZING CHARGE: This charge is at a low rate and balances the charge in all of the cells. The equalizing charge is normally given approximately once a month. It is a charge at a slow rate for 3 to 6 hours in addition to the regular charging cycle. DO NOT give an equalizing charge more than once a week. The most accurate specific gravity measurements for a charged battery will be after an equalizing charge. If the specific gravity difference is more than 0.020 between cells of the battery after an equalizing charge, there may be a defective cell. Consult your battery dealer. See the section Industrial Battery 2240 YRM 1 for additional information on the charging and maintenance of a battery.

Make sure the capacity of the crane and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case. The maximum battery weight is shown on the lift truck Nameplate. The spreader bar must NOT be made of metal or it must have insulated straps. The replacement battery must fit the battery area correctly. Adjust the front spacer plate to prevent battery movement in the battery compartment. Make sure that the battery voltage and weight of the replacement battery is correct as shown on the Nameplate. Before connecting the battery, make sure the key or keyless switch is in the OFF position and the parking brake is set.

CAUTION Batteries must be discarded according to local environmental regulations. 1. Using the tilt memory lever, tilt the steering column fully upright. See Figure 50. 2. If lift truck is equipped with manual hydraulic control levers, pull the release latch for the control lever assembly and move the assembly to the forward position. On lift trucks equipped with E-Hydraulic control mini-levers, move the armrest all the way back if necessary to raise the hood. See Figure 51. 3. Slide the seat all the way back. Push the latch handle to the right to raise the hood and seat to the fully raised position.

8000 YRM 1339

Battery Maintenance

NOTE: OPTIONAL TELESCOPIC STEERING COLUMN SHOWN. 1. TILT POSITION LEVER 2. TILT MEMORY LEVER 3. TELESCOPIC COLUMN LOCKING HANDLE

Figure 50. Steering Column Tilt Memory Lever 4. Disconnect the battery connector and move it to a position so that it will not be damaged during battery removal. Lift the side panels to remove them. 5. Use a spreader bar and crane to lift the battery from the lift truck. See Figure 52.

A. MANUAL CONTROL LEVERS B. E-HYDRAULIC ARMREST MINI-LEVERS 1. MANUAL CONTROL LEVERS RELEASE LATCH 2. E-HYDRAULIC ARMREST ADJUSTMENT HANDLES

Figure 51. Hydraulic Control Lever Release

Battery Maintenance

8000 YRM 1339 13 mm (0.50 in.). Make sure the battery spacer plate is correctly adjusted. Serious injury to personnel can occur if battery spacer plate is not adjusted correctly. 1. When a replacement battery is installed, make sure the battery fits the battery compartment width with a maximum of 13 mm (0.50 in.) clearance. Use a spreader bar and crane and install battery into lift truck. See Figure 52.

Figure 52. Changing Battery

2. The lift trucks are equipped with adjustable spacers in the battery compartment. Add or remove shims from under the front spacer bar to control the movement of the battery. the battery is not to move more than a total of 13 mm (0.50 in.) forward or backward. See Figure 53. 3. Connect the battery connector. Install the side panels.

Install the Battery WARNING Correct operation of the battery restraint system requires that the battery does not move more than

4. Close the hood and pull latch handle to lock hood. Slide seat to desired position.

A. 13 mm (0.50 in.) 1. SPACER PLATE 2. ADJUSTMENT CAPSCREW

3. FRONT BULKHEAD 4. BATTERY

Figure 53. Battery Spacer Adjustment

8000 YRM 1339

Battery Maintenance

5. If lift truck is equipped with E-Hydraulic mini-levers, adjust the armrest if it was moved prior to raising the hood. If lift truck is equipped with manual hydraulic control levers, pull release lever out and move the control lever assembly into position over the hood. Release the release lever to lock the control lever assembly into place.

Optional Side Removal of Battery WARNING Batteries are heavy and can cause an injury. Always use a battery roller stand or tray when trucks are equipped with optional battery rollers or slide. The lift trucks can be equipped for the optional side battery removal. See Figure 54. This option consists of a

1. BATTERY REMOVAL DOOR

battery removal door on the right side of the lift truck and a roller or slider tray beneath the battery. To remove the battery, operate the retention mechanism, and remove the door from the lift truck. Position a suitable battery stand or roller tray next to the battery compartment. Be sure that the height of the battery stand is the same as the height of the bottom of the battery in the lift truck. Remove the battery from the lift truck onto the battery stand. To install the battery, position the battery and battery stand next to the lift truck. Slide the battery from the battery stand into the battery compartment using the roller tray. Make sure the battery fits the battery compartment width with a maximum of 13 mm (0.50 in.) clearance. Secure the battery retention mechanism and install the door.

2. RETENTION MECHANISM

3. ROLLER TRAY

Figure 54. Optional Side Battery Removal

Wheel and Tires

8000 YRM 1339

BATTERY SIZE SPECIFICATIONS Batteries function as part of the lift truck’s counterweight system. Installing a battery that is too small can leave the lift truck lacking sufficient weight to counter the rated load. Refer to the Nameplate when replacing a battery

to verify the truck rating to ensure that the battery (and spacer if so equipped) is of the proper size. See the Operating Manual for exact battery specifications for your lift truck.

Wheel and Tires GENERAL WARNING The type of tire and the tire pressure (pneumatic tires) are shown on the Nameplate. Make sure the Nameplate is correct for the type of tires on the lift truck. Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses. The lift trucks covered in this Operating Manual can be equipped with either solid rubber tires that look like pneumatic tires or solid rubber tires (often called cushion tires). See Figure 55 and Figure 57. These variations in the tires can cause a variation in the types of wheels and in the disassembly and assembly procedures.

PNEUMATIC TIRES REPAIR Remove Wheels From Lift Truck WARNING A solid rubber tire that is the same shape as a pneumatic tire can be installed on a three-piece or four-piece wheel for a pneumatic tire. DO NOT make changes in parts of rim if this type of solid

rubber tire is installed instead of a pneumatic tire. Changes to parts of rim can cause a failure of wheel and can cause an accident. Type of tire and tire pressure (pneumatic tires) are shown on the Nameplate. Make sure Nameplate is correct for type of tires on lift truck.

WARNING Wheels must be changed and tires repaired by trained personnel only. Deflate tire completely before removing wheel from lift truck. Air pressure in tires can cause tire and rim parts to explode, causing serious injury or death. Always wear safety glasses. Never loosen nuts that hold inner and outer wheel halves together when there is air pressure in tire. 1. Put lift truck on blocks as described in How to Put Lift Truck on Blocks at beginning of this section. 2. Remove air from tire. Remove valve core to make sure that all air is out of inner tube. Push a wire through valve stem to make sure that valve stem does not have a restriction. 3. Remove wheel nuts and remove wheel and tire from lift truck. Lift truck tires and wheels are heavy.

8000 YRM 1339

Wheel and Tires

Remove Tire From Wheel NOTE: When disassembling wheels, see Figure 55. There are several types of wheels used on this series of lift trucks.

A. TWO-PIECE WHEEL B. OPTIONAL RIM ASSEMBLY

C. THREE-PIECE WHEEL D. FOUR-PIECE WHEEL

1. WHEEL RIM 2. SIDE FLANGE

3. LOCK RING 4. FLANGE SEAT

Figure 55. Types of Pneumatic Wheels

Remove Tire From Two-Piece Wheel

WARNING Make sure all air pressure is removed from tire before wheel is disassembled. Air pressure in tires can cause tire and rim parts to explode, causing serious injury or death. Keep tire tools in firm contact with wheel parts. If tool slips, it can move with enough force to cause an injury. STEP 1. Remove nuts that fasten wheel rims together.

Wheel and Tires

8000 YRM 1339

STEP 2. Loosen tire bead from wheel rim.

STEP 3. Remove wheel rims from tire. Remove inner tube and flap.

Remove Tire From Three- and Four-Piece Wheels

8000 YRM 1339

Wheel and Tires

STEP 2. Put tire tool into slot between lock ring and wheel rim. Remove lock ring and side flange. If there is a flange seat, remove it.

STEP 3. Loosen bead from outer side of wheel rim. Remove valve stem from wheel. If there is a washer, keep it for installation during assembly.

STEP 4. Remove wheel from tire.

Install Wheel in Tire WARNING Damage to the tire and wheel assembly and injury or death can occur if you do not do the following procedures: • Clean and inspect all parts of wheel before installing tire. • DO NOT use any damaged or repaired wheel parts. • Make sure that all parts of wheel are correct parts for that wheel assembly. • DO NOT mix parts between different types or manufacturers of wheels. • DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any one lift truck.

Do not use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts together. Make sure that side ring is in correct position. Ends of side ring must not touch. Clearance at ends of lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If clearance is wrong, the wrong part has been used. NOTE: There are two types of wheels used on this series of lift trucks. See Figure 55. Make sure you use the correct procedure. 1. Clean and inspect all parts of wheel. Paint any parts that have rust or corrosion. 2. Install a new inner tube in tire. Used tubes and flaps can cause tire failure.

Wheel and Tires

WARNING

8000 YRM 1339

WARNING

Do not lubricate tire bead with antifreeze or petroleum-based liquid. Vapors from these liquids can cause an explosion during inflation or use.

3. Apply rubber lubricant or soap solution to tire bead and tube.

5. Make sure rim is correct size for tire. Lubricate part of wheel that contacts bead and flap.

4. Install new tire flap.

6. Install two-piece wheel in tire as shown in Install Two-Piece Wheel in Tire. Install three-piece or fourpiece wheel in tire as shown in Install Three- or Four-Piece Wheel in Tire.

Install Two-Piece Wheel in Tire

WARNING Damage to tire and wheel assembly and injury or death can occur if you do not do the following procedures: • Clean and inspect all parts of wheel before installing tire. • DO NOT use any damaged or repaired wheel parts. • Make sure that all parts of wheel are correct parts for that wheel assembly. • DO NOT mix parts between different types or manufacturers of wheels. • DO NOT mix types of tires, type of tire tread, or types of wheel assemblies of different manufacturers on any one lift truck. Do not use a steel hammer on wheel. Use a rubber, lead, plastic, or brass hammer to put parts together. Make sure that side ring is in correct position. Ends of side ring must not touch. Clearance at ends of lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If clearance is wrong, the wrong part has been used.

CAUTION Do not use pneumatic-shaped solid tires on two-piece bolt together drive wheels. Spinning may occur. STEP 1. Install inner tube and rubber flap in tire. Install both halves of wheel rim in tire. Make sure stem of inner tube is aligned with slot in rim.

STEP 2. Tighten nuts that hold rim halves together to 175 N•m (129 lbf ft). Add air pressure to tire. (See Nameplate.)

8000 YRM 1339

Wheel and Tires

Install Three- or Four-Piece Wheel in Tire

STEP 2. Install wheel rim in tire. Install the washer on the stem (if removed during disassembly). Make sure stem of inner tube is aligned with slot in rim.

STEP 3. Turn over rim and tire. Put blocks under rim so rim is 8 to 10 cm (3 to 4 in.) above floor. Install flange seat (if used) and lock ring.

Wheel and Tires

8000 YRM 1339

STEP 4. Put lock ring in correct position on rim.

Add Air to Tires WARNING Add air pressure to the tires only in a safety cage. Inspect the safety cage for damage before use. When air pressure is added, use a chuck that fastens onto the valve stem of the inner tube. Make sure there is enough hose to permit the operator to stand away from the safety cage when air pressure is added to the tire.

(166 to 207 lbf ft). Tighten the drive wheel nuts in a cross pattern to a torque value of 339 to 380 N•m (250 to 280 lbf ft). If wheels are two-piece rims, make sure nuts that fasten rim halves together are toward brake drum when they are installed.

Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). 1. Put the tire in a safety cage. See Figure 56. 2. Add 20 kPa (3 psi) of air pressure to the tire. 3. Check that all wheel parts are correctly installed. Tap the lock ring with a soft hammer to make sure that the lock ring is in the seat. 4. If installation is correct, add air pressure to the tire to the specified pressure. 5. Check that all wheel parts are correctly installed. If installation is not correct, remove all of the air pressure from the tire. Remove the valve core to make sure all of the air pressure has been removed and then make adjustments. The clearance at the ends of the lock ring will be 13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air pressure.

Figure 56. Add Air to Tires

SOLID RUBBER TIRES ON PNEUMATIC WHEELS, CHANGE WARNING Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses.

Wheels, Install

1. Put lift truck on blocks as described in How to Put Lift Truck on Blocks at beginning of this section.

Install wheel on hub. Tighten the steering wheel nuts in a cross pattern to a torque value of 225 to 280 N•m

2. Remove wheel nuts and remove wheel and tire from lift truck. Lift truck tires and wheels are heavy.

8000 YRM 1339

Wheel and Tires

Remove Tire From Wheel WARNING Keep tire tools in firm contact with wheel. If tool slips, it can move with enough force to cause serious injury. When disassembling wheels, see Figure 55. There are several types of wheels used on these series of lift trucks.

WARNING Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses. STEP 1. Put wheel rim on bed of press. Put cage in position on tire. Use press to push tire away from side flange.

STEP 2. Put tire tool into slot between lock ring and wheel rim. Remove lock ring and side flange.

STEP 3. Turn tire over. Put a support under wheel rim. Make sure wheel rim is at least 150 to 200 mm (6 to 8 in.) from bed of press.

Wheel and Tires

8000 YRM 1339

STEP 4. Put cage in position on tire. Use press to push tire from wheel rim.

Install Tire on Wheel WARNING Damage to tire and wheel assembly and injury or death can occur if you do not do the following procedures: • Clean and inspect all parts of wheel before installing tire. • DO NOT use any damaged or repaired wheel parts. • Make sure that all parts of wheel are correct parts for that wheel assembly. • DO NOT mix parts between different types or manufacturers of wheels. • DO NOT mix types of tires, type of tire tread, or types of wheel assemblies of different manufacturers on any one lift truck. Do not use a steel hammer on wheel. Use a rubber, lead, plastic, or brass hammer to put parts together. Make sure that side ring is in correct position. Ends of side ring must not touch. Clearance at ends of lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If clearance is wrong, the wrong part has been used. When assembling wheels, see Figure 55. There are several types of wheels used on these series of lift trucks. Do not use a two-piece pneumatic wheel for solid rubber tires.

CAUTION Too much lubricant can cause tire to slide and move around wheel rim. STEP 1. Lubricate wheel rim and inner surface of tire with tire lubricant or soap.

8000 YRM 1339

Wheel and Tires

STEP 2. Put wheel rim on bed of press. Put tire over wheel rim. Put cage in position on tire. Use press to install tire on wheel rim.

STEP 3. Remove cage and put flange seat (if used), side ring, and lock ring in position on wheel rim. Install cage on tire. Use press to push tire onto wheel rim so side flange and lock ring can be installed.

STEP 4. While cage is holding tire on wheel rim, install lock ring. Use tire tool to make sure lock ring is in correct position.

Install the Wheels Install the wheel on the hub. Tighten steer wheel nuts to 225 to 280 N•m (166 to 207 lbf ft) and the drive wheel nuts to 339 to 380 N•m (250 to 280 lbf ft).

Wheel and Tires

8000 YRM 1339

SOLID RUBBER (CUSHIONED) TIRE REPAIR Remove Wheels From Lift Truck WARNING

1. The correct tools, equipment and a press ring must be used for each size of wheel. Use a press to push the wheel from the rim and tire. The capacity of the press must be approximately 355 to 1779 kN (80,000 to 400,000 lb). For the tire sizes, see the Nameplate.

The type of tire is shown on the Nameplate. Make sure the Nameplate is correct for the type of tires on the lift truck.

2. When the drive wheels are installed on the lift truck, tighten the wheel nuts to 340 to 380 N•m (251 to 280 lbf ft).

Wheels must be changed and tires repaired by trained personnel only.

3. The steering wheels are fastened to the spindle of the steering axle with a large castle nut. Make sure the inner and outer bearings are correctly lubricated with grease. Install the inner bearing assembly and wheel on the spindle. Install the outer bearing cone and castle nut.

Always wear safety glasses. NOTE: Solid rubber tires made from softer or harder material can be installed as optional equipment. The tread on solid rubber tires can be either smooth or it can have lugs. DO NOT mix types of tires or tread on lift truck. 1. Raise the lift truck as described in How to Put Lift Truck on Blocks in this manual. 2. Remove the wheel nuts and remove the wheel from the lift truck. Lift truck wheels are heavy.

Remove and Install Tire on Wheel NOTE: Make sure the tires are installed on the wheels so that the outside edges of the tire and wheel are as shown in Figure 57. Also check the Nameplate of the lift truck for the correct tire size and tread width.

4. Tighten the castle nuts of the steer wheel spindles to 68 N•m (50 lbf ft) while rotating the wheel in each direction at EACH installation. Loosen castle nuts 1/4 turn. Pull and push at top of wheel to check for movement (end play). If there is movement, tighten castle nut to 3 N•m (27 lbf in). 5. Install cotter pins at the nearest alignment positions. If cotter pin cannot be installed, tighten the castle nut to the first position where the cotter pin can be installed. Install caps for bearings. Additional torque checks are not required.

A. STEERING TIRES AND WHEELS B. DRIVE TIRES AND WHEELS

C. WIDE TREAD

1. OUTSIDE OF SOLID RUBBER TIRE 2. WHEEL

3. OVERHANG

Figure 57. Wheel and Tires

8000 YRM 1339

Lift Chain Adjustments

Lift Chain Adjustments WARNING When working on or near the mast, see Safety Procedures When Working Near Mast in this section.

Table 2. Hook-Type Carriage Chain Adjustment Class II and III

82.5 ±3 mm (3.25 ±0.12 in.)

Class IV

133.5 ±3 mm (5.26 ±0.12 in.)

Never allow anyone under a raised carriage. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the power is OFF. DO NOT try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by the pressure. During test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests. When the lift chains are correctly adjusted: • The tension will be the same on each chain of the chain set. Check tension by pushing on both chains at the same time. • The chain length will be correct. • The chains must travel freely through the complete cycle. NOTE: When the chain adjustments are complete, make sure the threads on the nuts of the chain anchors are completely engaged. Make sure all of the adjustment is not removed from the chain anchors. The chain anchors must be able to move on their mounting.

1. MAST 2. CARRIAGE 3. FORK

4. HEEL OF FORK IS 6 ±3 mm (0.24 ±0.12 in.) ABOVE FLOOR LEVEL.

Figure 58. Lift Chain Adjustment, Hook- or Pin-Type Forks

1. When adjusting lift chains on forklift trucks equipped with either pin- or hook-type forks installed, go to Step 2. If forklift truck is normally equipped with a hook-type carriage and has an attachment without forks, go to Step 3. NOTE: Prior to performing adjustment procedures, make sure the forklift truck is parked on a level surface and the mast is in the vertical position. 2. Adjust chain anchors which support the carriage until the bottom of the fork heel is 6 ±3 mm (0.24 ±0.12 in.) above floor level. See Figure 58. 3. Adjust chain anchors which support the carriage until the bottom of the lower carriage bar is above the floor level as shown in Table 2. See Figure 59.

1. MAST 2. CARRIAGE 3. DISTANCE FROM FLOOR TO LOWER CARRIAGE BAR

Figure 59. Lift Chain Adjustment, Hook-Type Carriage

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

8000 YRM 1339

11/10 (6/10)(2/10)(4/09) Printed in U.S.A.

Maintenance

STEERING SYSTEM ERP15-20VT (ERP030-040VT) [G807]

PART NO. 524295631

1600 YRM 1331

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Steering System

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Introduction ..................................................................................................................................................... Discharging The Capacitors............................................................................................................................ Steering Pressure Check..................................................................................................................................... Operation Check.................................................................................................................................................. Steering Control Unit (SCU) Repair .................................................................................................................... Remove ........................................................................................................................................................... Disassemble.................................................................................................................................................... Clean............................................................................................................................................................... Inspect............................................................................................................................................................. Assemble ........................................................................................................................................................ Install............................................................................................................................................................... Steering Wheel and Fixed Steering Column Assembly Repair ........................................................................... Remove ........................................................................................................................................................... Disassemble.................................................................................................................................................... Clean............................................................................................................................................................... Inspect............................................................................................................................................................. Assemble ........................................................................................................................................................ Install............................................................................................................................................................... Fixed Steering Column Gear Replacement .................................................................................................... Steering Wheel and Telescopic Column Assembly Repair.................................................................................. Remove ........................................................................................................................................................... Disassemble.................................................................................................................................................... Clean............................................................................................................................................................... Inspect............................................................................................................................................................. Assemble ........................................................................................................................................................ Install............................................................................................................................................................... Telescopic Steering Column Gear Replacement ............................................................................................ Hydraulic Pump and Motor .................................................................................................................................. Steering Actuator Components ........................................................................................................................... Steer Tire and Wheel Assembly...................................................................................................................... Remove....................................................................................................................................................... Install .......................................................................................................................................................... Wheel Hub Assembly ...................................................................................................................................... Remove....................................................................................................................................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Install .......................................................................................................................................................... Steering Axle Assembly .................................................................................................................................. Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Clean .......................................................................................................................................................... Inspect ........................................................................................................................................................ Assemble .................................................................................................................................................... Install .......................................................................................................................................................... Torque Specifications .......................................................................................................................................... Fixed Steering Column.................................................................................................................................... Telescopic Steering Column............................................................................................................................ Steering Control Unit....................................................................................................................................... Steer Axle........................................................................................................................................................

1 1 1 2 3 3 3 5 7 7 7 8 9 9 11 13 13 13 14 15 16 16 18 22 22 22 23 24 29 30 30 30 30 30 30 32 32 32 33 33 33 34 34 34 35 35 35 35 35 35

Table of Contents

Steering System

TABLE OF CONTENTS (Continued) This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]

1600 YRM 1331

General

General INTRODUCTION This section contains the description and repair procedures for the steering system. Components covered are the steering wheel and column assembly, steering control unit, and steering actuator. Some parts associated with the steering system are not covered in this section because they are more closely associated with other systems. See the following for information not included in this section: See Electrical System 2200 YRM 1337 section for information on wiring and power supply for hydraulic pump and motor assembly. See Hydraulic System 1900 YRM 1333 section for information on hydraulic tank and system. See Periodic Maintenance 8000 YRM 1339 manual for information on regular schedule maintenance. Throughout this section, forward will refer to travel in the direction of the forks and left and right determined by an operator sitting in the seat facing forward. See Figure 1.

to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the battery. Disconnect the battery and allow the capacitors to discharge before opening an compartment covers or inspecting or repairing the electrical system. DO NOT place tool on top of the battery. If a tool causes a short circuit, the high current flow from the battery can cause personal injury and property damage. Some checks and adjustments are performed with the battery connected. DO NOT connect the battery until the procedure instructs you to do so. Never wear any metallic items on your fingers, arms, or neck. Metal items can accidentally make an electrical connection and cause injury Before performing any tests or adjustment, block the lift truck to prevent unexpected movement. The capacitor in the transistor controller(s) can hold an electrical charge for about 10 seconds after the battery is disconnected. To prevent an electrical shock and personal injury, discharge the capacitor(s) before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Make certain the Emergency-Stop switch has not been activated. This will isolate the controller and prevent the capacitors from discharging properly. The proper way to disconnect the battery is by separating the battery connectors.

A. LEFT SIDE B. RIGHT SIDE

C. FORWARD TRAVEL

Figure 1. Truck Orientation

1. Ensure the capacitors are discharged by performing Step 2 through Step 6 below. 2. Turn key or keyless switch to OFF position. 3. Disconnect the battery by separating the connectors. 4. Block drive wheels to prevent lift truck from moving. 5. Make sure the Emergency-Stop switch HAS NOT been activated. If the Emergency-Stop switch is activated, rotate the switch to the right until it pops up. 6. Wait at least 10 seconds to be sure that the capacitors are fully discharged.

Steering Pressure Check

1600 YRM 1331

Steering Pressure Check The steering system can be evaluated by checking the system pressure. Using a hydraulic pressure gauge, tee into the steering lines and check pressure between the steering control unit (on steering column) and steering actuator (steer axle). See Figure 2.

4. Connect battery connector and turn key switch to the ON position. 5. Ensure hydraulic oil in steer cylinder is between 49 to 60°C (120 to 140°F). 6. Turn steering wheel to full left or full right position to activate steering control unit and check pressure. Maximum pressure to be 75.8 ±2.5 bar (1100 ± 36 psi). 7. If pressure is above 78.3 bar (1136 psi) replace steering control unit. See Steering Control Unit (SCU) Repair section.

A. INSERT TEE FITTING WITH GAUGE 1. LEFT STEER LINE 2. RIGHT STEER LINE 3. HOSE ASSEMBLY

4. STEERING CONTROL UNIT 5. STEER AXLE

8. If pressure is below 73.3 bar (1064 psi) check the supply pressure from hydraulic pump: a. Turn key switch to OFF position and disconnect battery connector. b. Install a gate valve (open) between steer line and tee fitting. c. Connect battery connector and turn key switch to ON position. d. Turn steering wheel to full left or full right position to activate steering control unit. e. SLOWLY close the gate valve to restrict flow of hydraulic oil until gauge rises to 73.3 bar (1064 psi), while steering wheel is in full left or full right position. f. If system pressure does not rise above 73.3 bar (1064 psi), the hydraulic pump is not performing properly. Repair or replace hydraulic pump and motor assembly. See Hydraulic System 1900 YRM 1333.

1. Remove floor mats and floor plates.

9. When pressure checks are complete, turn key switch to OFF position and disconnect the battery connector.

2. Turn key switch to the OFF position and disconnect the battery connector.

10. Remove tee fitting between steer line and hose assembly.

NOTE: Perform Step 3 through Step 11 for both right and left steer lines.

11. Reconnect steer line and hose assembly.

Figure 2. Steering Pressure Check

3. Insert a tee fitting at point A as shown in Figure 2, with gauge between steer line and hose assembly.

12. Reconnect the battery connector. 13. Install floor plates and floor mats. 14. Perform Operation Check.

1600 YRM 1331

Steering Control Unit (SCU) Repair

Operation Check The purpose of this check is to make sure steering trunnion turns the correct degrees of its rotation (approximately 180 degrees). Put the lift truck on blocks so the weight of the lift truck is removed from the steering trunnion. See How to Put Lift Truck on Blocks in either Operating Manual or Periodic Maintenance 8000 YRM 1339.

other direction. Check that steering wheel turns trunnion smoothly. The face of the wheel should be approximately parallel to the frame plate at the back of the battery compartment when the steering trunnion is rotated fully in each direction to its stops. Perform required repairs if steering system is not working correctly.

To operate steering system, rotate trunnion to its stop in one direction, then rotate trunnion to its stop in the

Steering Control Unit (SCU) Repair REMOVE NOTE: The following procedure to be used for fixed and telescopic steering columns. 1. Disconnect battery connector. 2. Discharge capacitors, for procedures see General section of this manual. NOTE: Tag all electrical connectors during removal to aid in installation. 3. Remove horn button, nut, and rod from steering wheel. See Figure 3.

4. Remove hex nut and steering wheel from steering column. If necessary, use puller tool to remove steering wheel. See Figure 4. NOTE: Follow Step 5 through Step 9 for a fixed steering column. 5. Remove steering column upper cover by pressing from both sides and pulling up. Clips should remain attached. See Figure 5. 6. Remove four capscrews and steering column lower cover. See Figure 5. 7. Remove four capscrews and steering column top cover. See Figure 5.

1. HEX NUT 2. STEERING WHEEL 1. HORN BUTTON 2. NUT

3. ROD 4. STEERING WHEEL

3. STEERING COLUMN

Figure 4. Steering Wheel

Figure 3. Horn Button Assembly and Electrical Connections

Steering Control Unit (SCU) Repair

1. STEERING COLUMN UPPER COVER 2. CLIP 3. STEERING COLUMN LOWER COVER

4. CAPSCREW 5. STEERING COLUMN TOP COVER 6. DASH PANEL 7. TILT ADJUST LEVER

Figure 5. Fixed Steering Column Covers NOTE: Tag wires prior to removal to aid in installation.

1600 YRM 1331

1. STEERING COLUMN TOP COVER 2. CLIP 3. CAPSCREW 4. STEERING COLUMN TELESCOPING COVER 5. STEERING COLUMN UPPER COVER

6. WASHER 7. STEERING COLUMN LOWER COVER 8. TILT ADJUST LEVER 9. TELESCOPIC STEERING COLUMN 10. DASH PANEL 11. TILT MEMORY LEVER

Figure 6. Telescopic Steering Column Covers

8. Disconnect the horn wires from the horn switch.

NOTE: Tag wires prior to removal to aid in installation.

9. Remove capscrews from dash panel and cowl plate. Lift dash panel over fixed steering column, maneuvering it past tilt adjust lever.

14. Disconnect the horn wires from the horn switch

NOTE: Follow Step 10 through Step 15 for a telescopic steering column. 10. Remove steering column top cover by pressing from both sides and pulling up. Clips should remain attached. See Figure 6. 11. Remove four capscrews and steering column telescoping cover. See Figure 6. 12. Remove capscrew and washer; press steering column upper cover from both sides and pull up. Clips should remain attached. See Figure 6. 13. Remove four capscrews and steering column lower cover. Maneuver steering column lower cover around tilt memory lever. See Figure 6.

15. Remove capscrews from dash panel and cowl plate. Lift dash panel over telescopic steering column, maneuvering it past tilt memory lever, adjust lever, and column locking knob. NOTE: Tag all hoses and fittings during removal to aid in installation. NOTE: Install plugs at all hose ports and hose ends to prevent foreign material from entering hydraulic system. 16. Disconnect the hydraulic hoses from the steering control unit fittings. See Figure 7. Set the hydraulic hoses aside to prevent possible damage. 17. Remove spring, e-ring, and steering direction sensor from steering column. See Figure 8. NOTE: Note placement and orientation of steering control unit prior to removal to aid in installation.

1600 YRM 1331

Steering Control Unit (SCU) Repair

18. Remove capscrews, washers, and steering control unit from tilt base bracket. See Figure 9.

1. STEERING CONTROL UNIT FITTING 2. HYDRAULIC HOSE

Figure 7. Hydraulic Hose Connections

1. 2. 3. 4.

STEERING CONTROL UNIT TILT BASE BRACKET CAPSCREW WASHER

Figure 9. Steering Control Unit

DISASSEMBLE 1. Place the steering control unit (SCU) into a soft jaw vise with the splined shaft facing down. 2. Remove hydraulic fittings, special screws, and O-rings from SCU housing. Discard O-rings. See Figure 10. 3. Remove checkball, ball stop, and emergency steering ball. Rotate SCU 90 degrees sideways in the vise. See Figure 10. 1. 2. 3. 4.

STEERING COLUMN STEERING DIRECTION SENSOR E-RING SPRING

Figure 8. Steering Direction Sensor

4. Remove the end cover, spacer, gear housing, gear, distributor plate, and O-rings from SCU. Discard O-rings. See Figure 10. 5. Remove the cardan shaft from spool assembly. See Figure 10.

Steering Control Unit (SCU) Repair

1600 YRM 1331

6. Remove the spool assembly from SCU housing.

9. Press the cross pin out of spool assembly.

NOTE: Note positioning of thrust washers on either side of the thrust bearing in the thrust bearing assembly during Step 7.

10. Press the spool from the sleeve and remove spring set from spool.

7. Remove the thrust bearing assembly from the shaft end of spool assembly. See Figure 10.

11. Remove the shaft seals from SCU housing. Discard seals.

8. Remove the retaining ring from spool assembly.

Figure 10. Steering Control Unit

1600 YRM 1331

Steering Control Unit (SCU) Repair

Legend for Figure 10 A. SPRING SET ARRANGEMENT

B. CARDAN SHAFT GEAR TEETH

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

STEERING CONTROL UNIT HOUSING SHAFT SEALS SPOOL SLEEVE SPRING SET CURVED SPRING FLAT SPRING RETAINING RING CROSS PIN THRUST BEARING ASSEMBLY THRUST WASHER THRUST BEARING EMERGENCY STEERING BALL

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety precautions.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean all parts in solvent. Dry parts with compressed air. Do not dry parts with a cloth. Make sure all surfaces are free of scratches and sharp edges.

INSPECT 1. Check all components for damage. Replace damaged components.

ASSEMBLE WARNING

BALL STOP CHECK BALL O-RING DISTRIBUTOR PLATE CARDAN SHAFT GEAR GEAR HOUSING SPACER END COVER HYDRAULIC FITTING SPECIAL SCREW O-RING CARDAN SHAFT GEAR TEETH

2. Install the spool into sleeve with key slots opposite each other. 3. Insert the curved springs between the flat springs. See Figure 10. Install spring set into spool assembly. NOTE: The retaining ring must be able to rotate unimpeded by the springs. 4. Center the springs in spool assembly and install retaining ring over sleeve. 5. Install the cross pin into spool assembly. NOTE: Thrust bearing assembly consists of two thrust washers and a single thrust bearing. See Figure 10 6. Install the thrust bearing assembly, as noted during removal, on the shaft end of spool assembly. 7. Place the SCU housing in a soft jawed vise in the horizontal position. Install the spool assembly into housing while holding cross pin in a horizontal position. 8. Rotate SCU housing to the vertical position and rotate the spool so that the cross pin in the spool is pointed to the "P" port position.

An improperly assembled steering control unit can cause uncontrollable steering wheel rotation when lift truck power is turned ON. This can cause serious injury to personnel. Be sure steering control unit is operating properly before handling the steering wheel.

9. Install the emergency steering ball, ball stop, and check ball in the "P" port.

1. Using a seal installer, install new shaft seals in SCU housing. See Figure 10.

11. Install the cardan shaft and rotate it until it is engaged with the cross pin in the spool assembly and the teeth of the gear end are aligned as shown in item B of Figure 10.

10. Install new O-ring on SCU housing and place distributor plate with holes properly aligned. See Figure 10.

Steering Control Unit (SCU) Repair 12. Install the gear onto cardan shaft. See Figure 10. 13. Install new O-rings onto gear housing, install gear housing onto distributor plate, making sure the holes are properly aligned.

1600 YRM 1331 7. Install steering column top cover and four capscrews. See Figure 5. NOTE: Check that clips are attached to steering column covers prior to installation. Replace clips if missing.

14. Place the spacer over cardan shaft and install end cover with "P" hole lined up with "P" port in SCU housing.

8. Install steering column upper cover by pressing from both sides and pushing against lower cover until snapped in place. See Figure 5.

15. Install new O-rings, hydraulic fittings, and special screws. Tighten the fittings and the special screws to 30 ±3 N•m (266 ±27 lbf in) in a cross pattern.

NOTE: Follow Step 9 through Step 14 for telescopic steering column.

INSTALL 1. Install steering control unit, washers, and capscrews onto tilt base bracket. See Figure 9. 2. Install steering direction sensor, e-ring, and spring onto steering column. See Figure 8.

9. Maneuver the dash panel down over telescopic steering column, past column locking knob, tilt adjust lever, and tilt memory lever. Install capscrews into dash panel and cowl plate. See Figure 6. 10. Maneuver steering column lower cover into place around tilt adjust lever and fasten in position with four capscrews. See Figure 6. 11. Connect the horn wires, as noted during removal, to the horn switch. NOTE: Check that clips are attached to steering column covers prior to installation. Replace clips if missing. 12. Install steering column upper cover by pressing from both sides and down against lower cover until snapped into place. Fasten in position with washer and capscrew. See Figure 6. 13. Install steering column telescoping cover and four capscrews. See Figure 6.

NOTE: Follow Step 4 through Step 8 for fixed steering column.

14. Install steering column top cover; squeeze both sides and push down until snapped into place. See Figure 6.

4. Maneuver dash panel down over fixed steering column, past tilt memory lever. Install capscrews into dash panel and cowl plate.

15. Install steering wheel and hex nut on steering column. Tighten nut to 40 to 54 N•m (30 to 40 lbf ft). See Figure 3.

5. Connect the horn wires, as noted during removal, to the horn switch.

16. Install rod, nut, and horn button in steering wheel. See Figure 3.

6. Install steering column lower cover and four capscrews. See Figure 5.

17. Connect the battery connector.

1600 YRM 1331

Steering Wheel and Fixed Steering Column Assembly Repair

Steering Wheel and Fixed Steering Column Assembly Repair REMOVE

CAUTION

NOTE: The steering column position can be adjusted up or down for different operators and is held in place by cylinder pressure and the pivot shaft. NOTE: The upper end of the steering column has splines for the steering wheel. The lower end of the steering column has splines to engage the steering control unit. NOTE: This procedure is for the removal of all components of the steering column assembly. Perform only those steps of the procedure necessary to remove the component to be replaced or repaired. NOTE: For quick access to steering column perform Step 1 through Step 5.

Horn wires could be damaged using a steering wheel puller. 4. Remove hex nut and steering wheel from steering column. If necessary, use puller tool to remove steering wheel. See Figure 12. 5. Remove steering column upper cover by pressing from both sides and pulling up. Clips should remain attached. See Figure 13. 6. Remove four capscrews and steering column lower cover. See Figure 13. 7. Remove four capscrews and steering column top cover. See Figure 13.

1. Disconnect the battery connector.

NOTE: Tag horn wires prior to disconnecting to aid in connecting.

2. Discharge capacitors, for procedures see General section of this manual.

8. Disconnect the horn wires from the horn switch.

3. Remove horn button, nut, and rod from steering wheel. See Figure 11.

9. Remove capscrews from dash panel and cowl plate. Lift dash panel over fixed steering column maneuvering it past the tilt adjust lever. See Figure 14.

1. HEX NUT 2. STEERING WHEEL 1. HORN BUTTON 2. NUT

3. ROD 4. STEERING WHEEL

3. STEERING COLUMN

Figure 12. Steering Wheel

Figure 11. Horn Button Assembly and Electrical Connections

Steering Wheel and Fixed Steering Column Assembly Repair

1. 2. 3. 4. 5. 6. 7.

1600 YRM 1331

STEERING COLUMN UPPER COVER CLIP STEERING COLUMN LOWER COVER CAPSCREW STEERING COLUMN TOP COVER TILT ADJUST LEVER DASH PANEL

Figure 13. Fixed Steering Column Covers NOTE: Tag all hoses and fittings during removal to aid in installation. NOTE: Install plugs at all hose ports and hose ends to prevent foreign material from entering the hydraulic system. 10. Disconnect hydraulic hoses from steering control unit fittings. See Figure 15. Set hydraulic hoses aside to prevent possible damage. 11. Remove spring, e-ring, and steering direction sensor from steering column. See Figure 16.

1. 2. 3. 4. 5. 6.

COWL PLATE CAPSCREW DASH PANEL FIXED STEERING COLUMN TILT ADJUST LEVER NUT

Figure 14. Fixed Steering Column Attachment

1600 YRM 1331

Steering Wheel and Fixed Steering Column Assembly Repair 2. Remove capscrews, washers, tapped plate, and horn switch from horn switch plate. See Figure 18.

1. STEERING CONTROL UNIT FITTINGS 2. HYDRAULIC HOSE

Figure 15. Hydraulic Hose Connections 12. Remove capscrews, washers, and steering control unit from tilt base bracket. See Figure 17. NOTE: Ensure electrical wires and hydraulic hoses are not damaged when steering column is removed. 13. Remove four nuts, four capscrews and fixed steering column from cowl plate. See Figure 14.

DISASSEMBLE NOTE: Perform only those steps necessary for the repair or replacement required. 1. Remove pin, retaining ring, spring, switch contact washer, and snap ring from fixed steering column. See Figure 18.

1. 2. 3. 4.

STEERING COLUMN STEERING DIRECTION SENSOR E-RING SPRING

Figure 16. Steering Direction Sensor

Steering Wheel and Fixed Steering Column Assembly Repair

1. 2. 3. 4.

1600 YRM 1331

STEERING CONTROL UNIT TILT BASE BRACKET CAPSCREW WASHER

Figure 17. Steering Control Unit

1. FIXED STEERING COLUMN 2. HORN SWITCH PLATE 3. PIN 4. RETAINING RING 5. SPRING

6. SWITCH CONTACT WASHER 7. SNAP RING 8. CAPSCREW 9. WASHER 10. HORN SWITCH 11. TAPPED PLATE

Figure 18. Horn Switch NOTE: Note position of snap rings during disassembly to aid in assembly. 3. Remove tilt adjust lever, snap rings, pivot, pin, collars, and tilt adjust cylinder from tilt base bracket and tilt adjust bracket. See Figure 19.

4. Remove nuts, tilt pins, bushings, and tilt base bracket from mount bracket and tilt adjust bracket. See Figure 20.

1600 YRM 1331

Steering Wheel and Fixed Steering Column Assembly Repair 2. Clean plastic or rubber components using warm soapy water and wipe dry with a lint free cloth.

INSPECT 1. Check all components for damage. Replace damaged components.

ASSEMBLE 1. Assemble tilt base bracket onto mount bracket and tilt adjust bracket with tilt pins, bushings, and nuts. See Figure 20.

WARNING

1. 2. 3. 4. 5. 6. 7. 8.

TILT ADJUST LEVER SNAP RING PIVOT PIN TILT ADJUST CYLINDER TILT BASE BRACKET TILT ADJUST BRACKET COLLAR

Figure 19. Tilt Adjust Lever and Cylinder

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING Compressed air is used for cleaning or drying purposes, or for clearing restrictions. Wear protective clothing (goggles/shield, gloves, etc.) to avoid injury to personnel. 1. Use cleaning solvent to clean metal components only, do not use on any component that has plastic or rubber parts. Dry with compressed air.

Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. NOTE: Ensure snap rings are positioned correctly to hold the cylinder in place, as noted during disassembly. 2. With tilt adjust cylinder end inside tilt adjust bracket, insert pivot through tilt adjust bracket holes and cylinder end; install collars and snap rings. See Figure 19. 3. Insert pin through tilt base bracket holes and top end of tilt adjust cylinder; install snap rings and tilt adjust lever. See Figure 19. 4. Install steering direction sensor, e-ring, and spring onto steering column. See Figure 16. 5. Assemble horn switch, tapped plate, washers, and capscrews; attach to horn switch plate. See Figure 18. 6. Measure gap between switch contact washer and horn switch. If gap does not meet specification shown in Figure 21 adjust as required. 7. Install snap ring, switch contact washer, spring, retaining ring, and pin on steering column. See Figure 18.

Steering Wheel and Fixed Steering Column Assembly Repair

1600 YRM 1331

WARNING The hydraulic hoses must be connected to the correct ports or the steering system will not operate as expected, which can cause damage or personal injury. Make sure the hoses are identified and connected correctly. NOTE: Remove tags from hoses and fittings after installation. 4. Remove plugs from hose ports and hose ends. Connect hydraulic hoses to steering control unit fittings, as tagged in removal. See Figure 15. 5. Install steering direction sensor, e-ring and spring on steering column. See Figure 16. 6. Maneuver dash panel down over fixed steering column past tilt adjust lever. Install capscrews into dash panel and cowl plate. See Figure 14. 7. Install steering column lower cover and four capscrews. See Figure 13. 8. Install steering column top cover and four capscrews. See Figure 13.

1. TILT BASE BRACKET 2. MOUNT BRACKET 3. TILT PIN

4. BUSHING 5. NUT 6. TILT MEMORY BRACKET

Figure 20. Brackets - Steering Column

INSTALL NOTE: Ensure electrical wires and hydraulic hoses are not damaged during installation. 1. Install fixed steering column, capscrews, and nuts onto cowl plate. Tighten capscrews to 52 N•m (38 lbf ft). See Figure 14. 2. Connect horn wires, as noted during removal, to the horn switch. 3. Install steering control unit, washers, and capscrews onto tilt base bracket. See Figure 17.

1. SWITCH CONTACT WASHER 2. HORN SWITCH

Figure 21. Horn Switch Gap

1600 YRM 1331

Steering Wheel and Fixed Steering Column Assembly Repair

NOTE: Check that clips are attached to cover prior to installation. Replace clips if missing. 9. Install steering column upper cover by pressing from both sides and pushing against lower cover until snapped in place. See Figure 13. 10. Install steering wheel and hex nut on steering column. Tighten nut to 40 to 54 N•m (30 to 40 lbf ft). See Figure 12. 11. Install rod, nut, and horn button in steering wheel. See Figure 11. 12. Connect the battery connector.

4. Remove steering control unit. See Figure 22. NOTE: The column shaft is not easily removed due to the location of the snap ring holding the shaft under the upper bearing. The best way to remove the gear is to split the gear using a hammer and chisel, allowing it to slide off. 5. Remove lower snap ring. See Figure 23. 6. Split column gear using hammer and chisel. Remove and discard gear. See Figure 23. 7. Using a press, install new column gear onto knurled shaft until against upper snap ring. See Figure 23.

FIXED STEERING COLUMN GEAR REPLACEMENT

8. Remove any displaced material from the snap ring groove area.

1. Follow steps outlined in Remove section, then perform steps below.

9. Install lower snap ring. See Figure 23.

2. Place steering column upside down in stand.

10. Install steering control unit onto tilt base bracket. See Figure 22.

3. Remove four capscrews and washers from pump mount and steering control unit. See Figure 22.

11. Install four washers and capscrews onto pump mount and steering control unit. See Figure 22. 12. Return steering column to upright position. 13. Follow steps outlined in Install section to complete steering column installation.

1. FIXED STEERING COLUMN 2. CAPSCREW 3. WASHER

4. PUMP MOUNT 5. STEERING CONTROL UNIT

Figure 22. Fixed Steering Column SCU Remove/Install

NOTE: STEERING COLUMN PLATES, BRACKETS, AND MOUNT FIXTURES NOT SHOWN FOR CLARITY. 1. LOWER SNAP RING 2. COLUMN GEAR

3. KNURLED SHAFT 4. UPPER SNAP RING

Figure 23. Column Gear

Steering Wheel and Telescopic Column Assembly Repair

1600 YRM 1331

Steering Wheel and Telescopic Column Assembly Repair REMOVE

CAUTION

NOTE: The telescopic steering column position can be adjusted up, down, forward, and back for different operators. The column is held in position by cylinder pressure, a pivot, and column locking knob. NOTE: The upper end of the steering shaft has splines for the steering wheel. The lower end of the steering shaft has splines to engage the steering control unit. NOTE: This procedure is for the removal of all components of the telescopic steering column assembly. Perform only those steps of the procedure necessary to remove the component to be replaced or repaired. NOTE: For quick access to steer column perform Step 1 through Step 7. NOTE: Tag all electrical connectors during removal to aid in installation. 1. Disconnect the battery connector. 2. Discharge capacitors, for procedures see General section of this manual. 3. Remove horn button, nut, and rod from steering wheel. See Figure 24.

1. HORN BUTTON 2. NUT

3. ROD 4. STEERING WHEEL

Figure 24. Horn Button Assembly and Electrical Connections

Horn wires could be damaged using a steering wheel puller. 4. Remove hex nut and steering wheel from steering column. If necessary use puller tool to remove steering wheel. See Figure 25. 5. Remove steering column top cover by pressing from both sides and pulling up, clips should remain attached. See Figure 26. 6. Remove capscrews and steering column telescoping cover. See Figure 26. 7. Remove capscrew and washer; press steering column upper cover from both sides and pull up, clips should remain attached; remove fold-over nut from upper bracket. See Figure 26. 8. Remove capscrews, steering column lower cover, upper bracket, and lower bracket. Steering column lower cover to be maneuvered around tilt memory lever and tilt adjust lever. See Figure 26. 9. Remove capscrews from dash panel and cowl plate. Lift dash panel over telescopic steering column, maneuvering it past the tilt memory lever, adjust lever, and column locking lever. See Figure 27.

1. HEX NUT 2. STEERING WHEEL

3. STEERING COLUMN

Figure 25. Steering Wheel

1600 YRM 1331

1. STEERING COLUMN TOP COVER 2. CLIP 3. CAPSCREW 4. STEERING COLUMN TELESCOPING COVER 5. STEERING COLUMN UPPER COVER

Steering Wheel and Telescopic Column Assembly Repair

6. WASHER 7. STEERING COLUMN LOWER COVER 8. TILT ADJUST LEVER 9. TELESCOPIC STEERING COLUMN 10. DASH PANEL 11. TILT MEMORY LEVER

Figure 26. Telescopic Steering Column Covers NOTE: Tag all hoses and fittings during disassembly to aid in assembly. NOTE: Insert plugs at all hose ports and hose ends to prevent foreign material from entering the hydraulic system. 10. Disconnect hydraulic hoses from steering control unit fittings. See Figure 28. Set hydraulic hoses aside to prevent possible damage.

1. 2. 3. 4. 5. 6. 7. 8.

DASH PANEL TELESCOPIC STEERING COLUMN TILT ADJUST LEVER TILT MEMORY LEVER COLUMN LOCKING LEVER CAPSCREW COWL PLATE NUT

Figure 27. Telescopic Steering Column Attachment NOTE: Tag horn wires prior to disconnecting to aid in installation. 13. Disconnect horn wires from the horn switch.

11. Remove spring, e-ring, and steering direction sensor from steering column. See Figure 29.

NOTE: Ensure electrical wires and hydraulic hoses are not damaged when telescopic steering column is removed.

NOTE: Note the position and orientation of steering control unit prior to removal to aid in installation.

14. Remove nuts, capscrews, and telescopic steering column assembly from cowl plate. See Figure 27.

12. Remove capscrews, washers, and steering control unit from tilt base bracket. See Figure 30.

Steering Wheel and Telescopic Column Assembly Repair

1600 YRM 1331

1. STEERING CONTROL UNIT FITTING 2. HYDRAULIC HOSE

Figure 28. Hydraulic Hose Connections 1. 2. 3. 4.

STEERING CONTROL UNIT TILT BASE BRACKET CAPSCREW WASHER

Figure 30. Steering Control Unit

DISASSEMBLE NOTE: Only perform those steps below necessary for required repair or replacement. NOTE: Note placement and orientation of components prior to disassembly to aid in assembly. 1. Remove pin, retaining ring, spring, switch contact washer, and snap ring from telescopic steering column. See Figure 31. 2. Remove capscrews, washers, tapped plate, and horn switch from horn switch plate. See Figure 31. 1. 2. 3. 4.

STEERING COLUMN STEERING POSITION SENSOR E-RING SPRING

Figure 29. Steering Position Sensor

1600 YRM 1331

Steering Wheel and Telescopic Column Assembly Repair NOTE: Note position of snap rings during disassembly to aid in assembly. 3. Remove tilt adjust lever, upper snap rings, pin, lower snap rings, collar, pivot, and tilt adjust cylinder from the tilt base bracket and tilt bracket. See Figure 32. 4. Remove cotter pin and column locking lever from pinch levers on telescopic steering column. See Figure 33.

1. TELESCOPIC STEERING COLUMN 2. HORN SWITCH PLATE 3. HORN SWITCH 4. TAPPED PLATE 5. WASHER

6. CAPSCREW 7. SNAP RING 8. SWITCH CONTACT WASHER 9. SPRING 10. RETAINING RING 11. PIN

Figure 31. Horn Switch

1. 2. 3. 4. 5. 6. 7. 8. 9.

TILT ADJUST LEVER TILT ADJUST CYLINDER PIN UPPER SNAP RING PIVOT COLLAR TILT BRACKET TILT BASE BRACKET LOWER SNAP RING

Figure 32. Tilt Adjust Cylinder - Telescopic Steering Column

Steering Wheel and Telescopic Column Assembly Repair

1600 YRM 1331 c. Remove screws, washers, and anchor bracket from tilt base bracket. See Figure 34. d. Remove pivot pin, washer, and cotter pin and remove tilt memory release lever from tilt base bracket. See Figure 34. e. Remove e-ring, cable anchor pin, and cable assembly from tilt memory bracket. See Figure 35.

1. TELESCOPIC STEERING COLUMN 2. COLUMN LOCKING LEVER

3. COTTER PIN 4. PINCH LEVER 5. WASHER

Figure 33. Column Locking Lever 5. Disassemble the cylinder, cable assembly, and tilt memory lever as indicated below: NOTE: Note cable placement during disassembly to aid in assembly. a. Disconnect cable assembly from tilt memory lever and remove from anchor bracket. See Figure 34. b. Remove spring from anchor bracket and tilt memory lever. See Figure 34.

1. CABLE ASSEMBLY 2. TILT MEMORY LEVER 3. SPRING 4. ANCHOR BRACKET

5. 6. 7. 8.

SCREW WASHER COTTER PIN TILT BASE BRACKET 9. PIVOT PIN

Figure 34. Tilt Memory Lever

1600 YRM 1331

Steering Wheel and Telescopic Column Assembly Repair Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. f.

Remove snap rings and lower pin from mount bracket and tilt memory cylinder end. See Figure 36.

g. Remove snap rings and upper pin from tilt base bracket and tilt memory cylinder end; remove cylinder. See Figure 36. 6. Remove nuts, tilt pins, bushings, and tilt base bracket from mount bracket and tilt memory bracket. See Figure 37.

1. 2. 3. 4.

CABLE ASSEMBLY E-RING CABLE ANCHOR PIN TILT MEMORY BRACKET

Figure 35. Tilt Memory Cable

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury.

1. 2. 3. 4.

SNAP RING LOWER PIN MOUNT BRACKET CYLINDER

5. UPPER PIN 6. TILT BASE BRACKET

Figure 36. Tilt Memory Cylinder

Steering Wheel and Telescopic Column Assembly Repair

1600 YRM 1331

1. Use cleaning solvent to clean metal components only, do not use on any component that has plastic or rubber parts. Dry with compressed air. 2. Clean plastic or rubber components using warm soapy water and wipe dry with a lint free cloth.

INSPECT 1. Check all components for damage. Replace damaged components.

ASSEMBLE 1. Assemble tilt base bracket onto mount bracket and tilt memory bracket with bushings, tilt pins, and nuts. See Figure 37. 2. Assemble telescopic adjust cylinder, cable assembly, and lever as indicated below: a. Attach cable assembly on tilt memory bracket with cable anchor pin and e-ring. See Figure 35.

WARNING

1. 2. 3. 4. 5. 6.

TILT BASE BRACKET MOUNT BRACKET TILT ADJUST BRACKET BUSHING NUT TILT PIN

Figure 37. Brackets - Telescopic Steering Column

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING Compressed air is used for cleaning or drying purposes, or for clearing restrictions. Wear protective clothing (goggles/shield, gloves, etc.) to avoid injury to personnel.

Install spring between adjust lever and anchor bracket. See Figure 34.

g. Position cable assembly on anchor bracket, as noted during disassembly. See Figure 34.

1600 YRM 1331

Steering Wheel and Telescopic Column Assembly Repair

h. With the lower end of the cable (non lever end) properly connected to the assembly, install the threaded end of the cable to the cable support bracket using the cable hex nut. The nut should have a final torque of 16 N•m (142 lbf in) applied. Install the cable eyelet to the lever with the small clevis pin and e-clip. See Figure 34. When properly adjusted, there should not be tension on the cable when the lever is in the relaxed position. On the other end of the cable, the large pin with the return spring should have full travel in the pin slot as the lever is actuated. Finally, with the column positioned toward the front of the truck, the cable must not uncouple from the lower base. 3. Install column locking lever by pushing lever shaft through pinch levers and inserting cotter pin. See Figure 33.

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. NOTE: Ensure snap rings are positioned correctly to hold cylinder in position. 4. With tilt adjust cylinder bottom inside tilt adjust bracket, insert pivot through bracket holes and cylinder end; install collars and snap rings. See Figure 32. 5. Insert pin through tilt base bracket holes and top end of tilt adjust cylinder; install snap rings, washers, and tilt memory lever. See Figure 32. 6. Assemble horn switch, tapped plate, washers, and capscrews; attach to horn switch plate. See Figure 31. 7. Install snap ring, switch contact washer, spring, retaining ring, and pin onto steering column. See Figure 31. 8. Measure gap between switch control washer and horn switch. If gap does not meet specification shown in Figure 38 adjust as required.

1. SWITCH CONTACT WASHER 2. HORN SWITCH

Figure 38. Horn Switch Gap

INSTALL NOTE: Ensure electrical wires and hydraulic hoses are not damaged during installation. 1. Install telescopic steering column, capscrews, and nuts to cowl plate. Tighten capscrews to 52 N•m (38 lbf ft). See Figure 27. 2. Connect horn wires, as noted during removal, to the horn switch. 3. Install steering control unit, washers, and capscrews into tilt base bracket. See Figure 30.

WARNING The hydraulic hoses must be connected to the correct ports or the steering system will not operator as expected, which can cause damage or personal injury. Make sure the hoses are identified and connected correctly. NOTE: Remove tags from hoses and fittings after installation. 4. Remove plugs from hose ports and hose ends. Connect hydraulic hoses to steering control unit fittings, as tagged during removal. See Figure 28.

Steering Wheel and Telescopic Column Assembly Repair 5. Install steering direction sensor, e-ring, and spring on steering column. See Figure 29. 6. Maneuver dash panel down over telescopic steering column, past column locking knob, adjust lever, and tilt memory lever. Install capscrews into dash panel and cowl plate. See Figure 27. 7. Maneuver steering column lower cover into place around tilt memory lever. Install upper bracket, lower bracket, and capscrews. See Figure 26. 8. Install steering column telescoping cover and capscrews. See Figure 26. NOTE: Check that clips are attached to steering column covers prior to installation. Replace clips if missing.

1600 YRM 1331

9. Install fold-over nut on upper bracket; press steering column upper cover from both sides and push down until snapped into place; fasten with washer and capscrew. See Figure 26. 10. Install steering column top cover; squeeze both sides and push down until snapped into place. See Figure 26. 11. Install steering wheel and hex nut on steering column. Tighten nut to 40 to 54 N•m (30 to 40 lbf ft). See Figure 25. 12. Install rod, nut, and horn button in steering wheel. See Figure 24. 13. Connect the battery connector.

TELESCOPIC STEERING COLUMN GEAR REPLACEMENT STEP 1. Follow steps in Remove section, then continue with steps below. STEP 2. Place steering column upside down in a stand. STEP 3. Remove four capscrews and washers from pump mount and steering control unit.

1. 2. 3. 4. 5.

TELESCOPIC STEERING COLUMN CAPSCREW WASHER PUMP MOUNT STEERING CONTROL UNIT

1600 YRM 1331

Steering Wheel and Telescopic Column Assembly Repair

STEP 4. Remove steering control unit from tilt base bracket.

1. TILT BASE BRACKET 2. STEERING CONTROL UNIT STEP 5. Remove tube with column gear from telescopic steering column.

1. TELESCOPIC STEERING COLUMN 2. TUBE 3. COLUMN GEAR

Steering Wheel and Telescopic Column Assembly Repair STEP 6. Remove lower snap ring from tube.

1. LOWER SNAP RING 2. TUBE STEP 7. Remove and discard column gear from tube.

1. COLUMN GEAR 2. TUBE

1600 YRM 1331

Steering Wheel and Telescopic Column Assembly Repair

STEP 8. Install new column gear onto tube until it contacts washer.

1. COLUMN GEAR 2. TUBE 3. WASHER STEP 9. Remove any displaced plastic material from snap ring groove and install lower snap ring onto tube.

1. TUBE WITH COLUMN GEAR 2. LOWER SNAP RING

Steering Wheel and Telescopic Column Assembly Repair

1600 YRM 1331

STEP 10. Install tube with column gear into telescopic steering column.

1. TELESCOPIC STEERING COLUMN 2. TUBE WITH COLUMN GEAR STEP 11. Install steering control unit onto tilt base bracket.

1. TILT BASE BRACKET 2. STEERING CONTROL UNIT

1600 YRM 1331

Hydraulic Pump and Motor

STEP 12. Install four washers and capscrews onto pump mount and steering control unit.

1. 2. 3. 4. 5.

TELESCOPIC STEERING COLUMN CAPSCREW WASHER PUMP MOUNT STEERING CONTROL UNIT

STEP 13. Return steering column to upright position. STEP 14. Follow steps in Install section to complete installation.

Hydraulic Pump and Motor Information for removal, disassembly, repair, and installation of hydraulic pump and motor assembly can be found in Hydraulic System 1900 YRM 1333.

Steering Actuator Components

1600 YRM 1331

Steering Actuator Components The steering actuator assembly has a horizontal shaft and gear assembly (pinion) that extends through the gear housing, which is mounted in the bottom of the counterweight. The pinion is rotated by the horizontal movement of a hydraulic-driven gear rack. The hydraulic pump feeds hydraulic oil to the steering control unit, which directs the oil into either end of the gear housing. The housing acts as a cylinder tube. Pistons, at each end, control the movement of the gear track.

STEER TIRE AND WHEEL ASSEMBLY Remove WARNING Before attempting to remove the steer tire and wheel assemblies from the steering axle, put blocks under each side of the frame. The blocks must prevent the lift truck from falling and causing injury or damage.

Truck on Blocks in either Operating Manual or Periodic Maintenance 8000 YRM 1339. 4. Loosen wheel nuts retaining steer tire and wheel assembly. 5. Remove wheel nuts and steer tire and wheel assembly from steer axle wheel bolts.

Install WARNING Lifting and carrying of tires is not recommended because their weight could be in excess of 45 kg (100 lb). Where applicable, use a wheel or tire dolly to assist in the removal and installation of the wheel. Follow the instructions in Periodic Maintenance 8000 YRM 1339 or Operating Manual. 1. Align steer tire and wheel assembly with steer axle wheel bolts and install on wheel hub.

NOTE: Perform the following procedures for each steer tire and wheel assembly.

2. Install wheel nuts on wheel bolts to retain steer tire and wheel assembly. Tighten nuts snugly.

1. Turn steering wheel so steer tire and wheel assembly to be removed is accessible. Turn key switch to the OFF position and disconnect battery connector.

3. Lower lift truck to floor. Tighten wheel nuts, in a diametrically opposed pattern, to 170 N•m (125 lbf ft).

2. Block drive wheels to prevent unexpected movement and apply parking brakes.

4. Remove blocks from drive wheels. Connect battery connector.

WHEEL HUB ASSEMBLY WARNING DO NOT place jacking equipment under counterweight. 3. Place rear of lift truck frame on blocks to suspend steer tires of the ground. See How to Put Lift

Remove 1. Remove wheel and tire assembly. See Steer Tire and Wheel Assembly. 2. Remove hub cap. See Figure 39.

Legend for Figure 39 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

HUB CAP CASTLE NUT COTTER PIN WASHER OUTER BEARING CONE OUTER BEARING CUP WHEEL HUB SEAL RING AXLE SHAFT AXLE SUPPORT STEER PINION NILOS RING WEAR RING

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

UPPER HOUSING SNAP RING SHIM LOCKWASHER SLOTTED NUT SOCKET-HEAD SCREW MAGNET STEERING DIRECTION SENSOR COVER PLATE GEAR RACK O-RING PISTON PISTON RING

28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38.

WIPER RING CYLINDER CAP FITTING PLUG WHEEL BOLT LOCKING SOCKET-HEAD SCREW YOKE INNER BEARING CONE INNER BEARING CUP BEARING CONE BEARING CUP

1600 YRM 1331

Steering Actuator Components

Figure 39. Steer Axle Assembly

Steering Actuator Components 3. Remove and discard cotter pin. See Figure 39. NOTE: Hub assembly consists of wheel hub, outer bearing cup, inner bearing cup, outer bearing cone, inner bearing cone, seal, and ring. NOTE: Inner bearing cone, seal, and ring may stay on axle shaft when hub assembly is removed. 4. Remove castle nut, washer, and hub assembly from axle shaft. See Figure 39. 5. Remove outer bearing cone from wheel hub. See Figure 39. NOTE: For correct orientation during installation, note the position of seal during removal. 6. Remove ring, seal, and inner bearing cone from wheel hub or axle shaft. See Figure 39. NOTE: Bearing cones are to be replaced as sets. If one bearing cone has been determined to be unserviceable, then both must be replaced. 7. If bearing cones are to be replaced, use a brass drift pin to remove inner and outer bearing cups from wheel hub. See Figure 39. 8. Repeat Step 1 through Step 7 for opposite wheel.

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

1600 YRM 1331 4. After cleaning, dry bearing cones with compressed air. Take care to prevent spinning the bearing cones when using a compressed air jet. 5. Immediately wrap bearing cones in a lint-free cloth to protect them from dust and other foreign matter.

Inspect 1. Inspect bearing cones for burned or damaged rollers. If either condition exists, replace both sets of bearing cones and bearing cups. 2. Inspect bearing cups for signs of overheating or scoring. If either condition exists, replace both sets of bearing cones and bearing cups. 3. Inspect the seal and ring for any damage. Replace if damaged. 4. Inspect wheel bolts. Replace if damaged. 5. Inspect the remainder of axle assembly for damage, and repair or replace as necessary.

Install 1. Prior to installation, pack bearings, seal, and ring with grease. See Periodic Maintenance 8000 YRM 1339 or Operating Manual for recommended grease. 2. If removed, use a press to install new inner and outer bearing cups into wheel hub. See Figure 39. 3. Install inner bearing cone, seal, and ring into wheel hub. See Figure 39. 4. Install outer bearing cone into wheel hub. See Figure 39. NOTE: Hub assembly consists of wheel hub, outer bearing cup, inner bearing cup, outer bearing cone, inner bearing cone, seal, and ring. 5. Install hub assembly, washer, and castle nut onto axle shaft. Tighten nut to 47 N•m (35 lbf ft). Rotate wheel while tightening nut. See Figure 39. 6. Install new cotter pin into castle nut and axle shaft. If necessary, tighten nut to align with hole in axle shaft. See Figure 39.

2. Clean remaining metal components with solvent.

7. Install hub cap. See Figure 39.

3. Clean seal and other rubber components in warm soapy water. Rinse with clean warm water and allow to air dry.

8. Install wheel and tire assembly. See Steer Tire and Wheel Assembly.

1600 YRM 1331

STEERING AXLE ASSEMBLY Remove WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the mast, drive axle, battery, or counterweight will cause large changes in the center of gravity. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: If the mast and drive axle are removed, put blocks under the counterweight so that the lift truck cannot fall backward. If the counterweight is removed, put blocks under the mast assembly so that the lift truck cannot fall forward.

Steering Actuator Components 6. Remove three nuts, three washers, and three steer mounting studs from steer plate and axle housing. 7. Carefully lower floor jack enough to remove steer axle from under lift truck. Disconnect steering direction sensor cable from steering direction sensor and move cable aside to prevent damage. Move steer axle clear of lift truck 8. Remove both steer tire and wheel assemblies, for procedures see Steer Tire and Wheel Assembly section.

Disassemble 1. Remove fitting from cylinder cap. See Figure 39. 2. Unscrew cylinder cap from upper housing. Remove and discard O-ring from upper housing. See Figure 39.

Put lift truck on blocks on a solid, even, level surface. Verify the blocks or stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Verify the lifting devices used during repairs can lift the weight of the part and assemblies.

3. Remove piston from inside cylinder cap. See Figure 39.

See the Operating Manual or Periodic Maintenance section for your lift truck model, for the procedures to put the lift truck on blocks.

6. Remove gear rack from upper housing. See Figure 39.

NOTE: The steering axle can be removed without removing the counterweight.

NOTE: Axle shaft assembly consists of the axle support and steering pinion. Yoke assembly consists of the upper housing and yoke.

1. Place lift truck on blocks. The procedure for placing lift truck on blocks may be found in the Operating Manual or Periodic Maintenance 8000 YRM 1339 manual.

7. Remove eight locking socket-head screws that fasten axle shaft assembly and yoke assembly. Separate axle shaft assembly from yoke assembly.

2. Disconnect the battery connector.

8. Remove steering pinion from axle support. See Figure 39.

3. Discharge capacitors, for procedures see Introduction section.

9. Remove wheel hubs; follow procedures in Wheel Hub Assembly section.

4. Slide floor jack under steering axle. Raise lifting device until it holds the weight of the axle assembly.

10. Remove two socket-head screws, two lockwashers, and cover plate from the top of upper housing. Discard lockwashers. See Figure 39.

NOTE: Tag steer lines prior to disconnecting from steering cylinder to aid in correct connection during installation. 5. Disconnect steer line at fitting on cylinder cap and drain hydraulic oil from hose. See Figure 39. Cap steer line. Repeat for opposite steer line.

4. Remove piston ring and wiper ring from piston. Discard wiper ring. See Figure 39. 5. Repeat Step 1 through Step 4 for opposite cylinder cap

11. Remove socket-head screw and steering direction sensor with magnet from upper housing. See Figure 39. 12. Remove slotted nut, lockwasher, shims, and nilosring from top of upper housing. Discard lockwasher. See Figure 39.

Steering Actuator Components NOTE: Bearing cones are to be replaced as sets. If one bearing cone has been determined to be unserviceable, then both must be replaced. 13. Remove bearing cone, shim, snap ring, and seal from top of upper housing. See Figure 39. NOTE: For correct orientation during installation, note the position of the seal during removal.

1600 YRM 1331 5. Immediately wrap bearing cones in a lint-free cloth to protect them from dust and other foreign matter.

Inspect 1. Inspect bearing cones for burned or damaged rollers. If either condition exists, replace both sets of bearing cones and bearing cups.

14. Remove nilosring, bearing cone, wear ring, and seal from bottom of upper housing. See Figure 39.

2. Inspect bearing cups for signs of overheating or scoring. If either condition exists, replace both sets of bearing cones and bearing cups.

15. If bearing cones are to be replaced, use a brass drift pin to remove bearing cups from upper housing. See Figure 39.

3. Inspect the remaining components for damage. Repair or replace as necessary.

16. Remove plug from upper housing. See Figure 39.

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to eyes. 1. Clean bearing cones by placing them in a wire basket and immersing in a container of fresh solvent. Agitate the bearing cones in the solvent to remove all traces of old lubricant. 2. Clean all remaining components, except seals, with solvent. 3. Clean seals in warm soapy water. Rinse with clean warm water and allow to air dry. 4. After cleaning, dry bearing cones with compressed air. Take care to prevent spinning the bearing cones when using a compressed air jet.

Assemble 1. Prior to installation, pack bearings, seals, and rings with grease. See Periodic Maintenance 8000 YRM 1339 or Operating Manual for recommended grease. 2. Install plug in upper housing. See Figure 39. 3. If removed, use a press to install new bearing cups into upper housing. See Figure 39. 4. Install seal, wear ring, bearing cone, and nilosring into bottom of upper housing. See Figure 39. 5. Install seal, snap ring, shim, and bearing cone into top of upper housing. See Figure 39. 6. Install nilosring, shims, lockwasher, and slotted nut into top of upper housing. See Figure 39. 7. Install steering direction sensor with magnet and socket-head screw into upper housing. See Figure 39. 8. Install cover plate, two lockwashers, and two socket-head screws onto upper housing. See Figure 39. 9. Install wheel hubs; follow procedures in Wheel Hub Assembly section. 10. Install steering pinion onto axle support. See Figure 39.

1600 YRM 1331

Torque Specifications

NOTE: Axle shaft assembly consists of the axle support and steering pinion. Yoke assembly consists of the upper housing and yoke. 11. Place axle shaft assembly below yoke assembly. Install eight locking socket-head screws, fastening axle shaft assembly and yoke assembly. Tighten locking socket-head screws to 130 N•m (96 lbf ft). See Figure 39. 12. Install gear rack into upper housing. See Figure 39. 13. Install wiper ring and piston ring onto piston. See Figure 39. 14. Install piston into cylinder cap. See Figure 39. 15. Install O-ring in upper housing. See Figure 39.

Install 1. Install both steer tire and wheel assemblies, for procedures see Steer Tire and Wheel Assembly section. 2. Using floor jack, position steer axle under frame. 3. Connect steering direction sensor cable to steering direction sensor. 4. Using a lifting device, lift steer axle into position on lift truck frame. 5. Prior to installation, coat steer mounting studs with sealant. See Periodic Maintenance 8000 YRM 1339 or Operating Manual for correct sealant.

16. Screw cylinder cap onto upper housing. See Figure 39.

6. Install three steer mounting studs, three washers, and three nuts onto steer plate and axle housing. Tighten nuts to 270 N•m (200 lbf ft).

17. Repeat Step 13 through Step 16 for opposite cylinder cap.

7. Remove floor jack from under lift truck. Connect battery connector. Remove lift truck from blocks.

18. Install fitting on cylinder cap. Repeat for opposite fitting. See Figure 39.

8. Operate steering system to remove air from system. Turn steering wheel several times from one stop to the other. Check for hydraulic leaks.

Torque Specifications FIXED STEERING COLUMN

STEER AXLE

Column to Cowl Plate Capscrews 52 N•m (38 lbf ft)

Steer Wheel Nuts 170 N•m (125 lbf ft)

TELESCOPIC STEERING COLUMN

Wheel Hub Castle Nut 47 N•m (35 lbf ft)

Column to Cowl Plate Capscrews 52 N•m (38 lbf ft)

STEERING CONTROL UNIT Column to Cowl Plate Capscrews 52 N•m (38 lbf ft)

Steer Axle Housing Locking Socket-Head Screws 130 N•m (96 lbf ft) Steer Axle Mounting Nuts 270 N•m (200 lbf ft)

Hydraulic Fittings 30 ±3 N•m (266 ±27 lbf in)

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

1600 YRM 1331

11/10 (2/10)(7/08) Printed in U.S.A.

Maintenance

TRANSAXLE ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

PART NO. 524295630

1300 YRM 1330

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Transaxle

Table of Contents

1 2 2 3 3 3 4 5 6 6 7 7 8 9 10 11 13 13 14 14 14 15 16

This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

1300 YRM 1330

General

General CAUTION DO NOT remove the cover from the transaxle housing during the warranty period. Removing the cover from the housing will void the transaxle warranty. The transaxle warranty period may vary from truck hours or other warranties. Contact Yale Company Contact Management if you have questions about warranty status.

CAUTION Use only transmission fluid from approved vendors. Using fluid from unapproved vendors will void the warranty. Contact Yale Company Contact Management if you have questions about warranty status. This section contains the removal, repair, inspection, and installation instructions for the transaxle assemblies used on these models.

A. LEFT SIDE B. RIGHT SIDE C. FORWARD TRAVEL

Figure 1. Truck Orientation (Three-Wheel Trucks)

WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the battery. Throughout this section, forward will refer to travel in the direction of the forks and left and right will be determined by sitting in the seat facing forward. See Figure 1 or Figure 2. A. LEFT SIDE B. RIGHT SIDE C. FORWARD TRAVEL

Figure 2. Truck Orientation (Four-Wheel Trucks)

General

1300 YRM 1330 4. Block drive wheels to prevent lift truck from moving. 5. Make sure the Emergency Disconnect Switch HAS NOT been activated. If the Emergency Disconnect Switch is activated, rotate the switch to the right until it pops up. 6. Press horn button. Wait 30 seconds to be sure capacitors are fully discharged.

SPECIAL TOOLS Special tools are necessary to properly perform some repairs. These tools are available from your Yale dealer. Warranty will not cover damage resulting from work done using improper tools. Refer to Table 1.

Table 1. Yale Special Tools

Input Seal Driver Yale Part No. 582000161

Before performing any tests or adjustments, block the lift truck to prevent unexpected movement. The capacitor in the transistor controller(s) can hold an electrical charge for about 10 seconds after the battery is disconnected. To prevent an electrical shock and personal injury, discharge the capacitor(s) before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected.

Breather Set Tool Yale Part No. 582000187

DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Make certain the Emergency Disconnect Switch has not been activated. This will isolate the controller and prevent the capacitors from discharging properly. The proper way to disconnect the battery is by separating the battery connectors. 1. Ensure the capacitors are discharged by performing Step 2 through Step 6 below. 2. Turn the key or keyless switch to the OFF position. 3. Disconnect the battery by separating the connectors.

Wheel Stud Tool Yale Part No. 582000162

1300 YRM 1330

Transaxle Assembly

Transaxle Assembly REMOVE TRANSAXLE FROM FRAME WARNING The lift truck must be put on blocks for some types of maintenance and transaxle repair. The removal of the battery, mast, transaxle, or the counterweight will cause large changes in the center of gravity. Position additional blocks under the frame when the lift truck is on blocks, so the lift truck cannot tip over. 1. Remove the mast assembly. Refer to the section Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 for European lift truck models ERP15-20VT (G807) and ERP16-20VF (A955) or Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405 for European and American lift truck models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) for mast removal instructions. 2. Turn the key switch to the OFF position and disconnect the battery. 3. Position the lift truck frame on blocks so the drive tires are suspended off the floor. Refer to section Periodic Maintenance 8000 YRM 1373 for lift truck models ERP16-20VF (ERP30-40VF) (A955) or Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15-20VT (ERP030-040VT) (G807) for instructions on putting the lift truck on blocks. 4. Remove the drive tire lug nuts and remove the drive tire. 5. Disconnect the transaxle speed sensor from the main wiring harness. 6. Disconnect the electric park brake connector from the main wiring harness. 7. Disconnect the manual override cable from the parking brakes. 8. Tag and disconnect the motor leads from the terminals on the traction motor. 9. Disconnect the traction motor temperature sensor at the traction motor. 10. Disconnect the service brake line from the port on the transaxle. Cap the brake line and plug the port on the transaxle to reduce the possibility of contamination entering the brake system.

11. Loosen, but do not remove, the five mounting capscrews and nuts that hold the transaxle assembly to the lift truck.

WARNING The transaxle and traction motor assemblies are heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the transaxle and traction motor. 12. Position a floor jack under the transaxle assembly. Make sure the assembly is properly balanced on the floor jack so it will not fall once the mounting capscrews have been removed.

CAUTION Check that cables, hoses, and wires do not interfere with the removal of the transaxle assembly. 13. Remove the five capscrews and washers securing the transaxle to the lift truck frame. Carefully lower the transaxle assembly from the lift truck frame using the floor jack.

WARNING The transaxle and traction motor assemblies are heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the transaxle and traction motor. 14. Transfer the transaxle assembly from the floor jack to clean workbench using an appropriate sling and overhead lifting device.

REMOVE PARKING BRAKE AND TRACTION MOTOR WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

Transaxle Assembly 2. Remove the parking brake assembly from the traction motor: a. Remove the four capscrews, lockwashers, and washers securing the brake assembly to the traction motor. See Figure 3. b. Pry evenly on opposite sides to remove the brake assembly from the brake hub. Remove brake by hand. c. Remove the snap ring securing the brake hub to the traction motor shaft. Slide the hub from the shaft. Remove the snap ring and the woodruff key from beneath the hub.

1300 YRM 1330 3. Remove the traction motor from the transaxle: a. Install an eyebolt to the traction motor shaft and attach an overhead lifting device of adequate capacity to the eyebolt. b. Remove the four capscrews and washers mounting the traction motor to the transaxle. c. Lift the traction motor from the transaxle using the overhead lifting device.

INSTALL PARKING BRAKE AND TRACTION MOTOR WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING The traction motor is heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the traction motor. 1. Position the transaxle on blocks with the studs down. Securely support in this position. 2. Install the traction motor to the transaxle: a. Install an eyebolt to the traction motor shaft and attach an overhead lifting device of adequate capacity to the eyebolt.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

CAPSCREW LOCKWASHER WASHER PARKING BRAKE ASSEMBLY TRACTION MOTOR CAPSCREW WASHER MOTOR SHAFT TRANSAXLE INPUT SEAL

Figure 3. Traction Motor and Parking Brake

b. Lightly lubricate the inside lip of the transaxle input shaft with multipurpose grease to ensure the seal seats properly on the traction motor shaft. It is not necessary to lubricate the traction motor shaft as it is lubricated internally within the transaxle. See Figure 4. c. Lift the traction motor and position it to the transaxle using the overhead lifting device. Guide the traction motor shaft into the transaxle through the input seal. Align the motor with the transaxle as removed. d. Install the four capscrews and washers mounting the traction motor to the transaxle. Tighten to 48 N•m (35 lbf in). e. Remove the eyebolt from the traction motor shaft.

1300 YRM 1330

Transaxle Assembly

INSTALL TRANSAXLE TO FRAME 1. Check that the dowels are installed in the transaxle housing and are in good condition. Replace as necessary.

WARNING The transaxle and traction motor assembly are heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the transaxle and traction motor. 2. Move the transaxle assembly onto a floor jack using an appropriate sling and lifting device. Make sure the assembly is balanced and properly supported so it will not fall during installation. 3. Carefully position the transaxle to the frame using the floor jack. Align the transaxle mounting dowels with their mounting holes in the frame. 4. Apply Loctite® 271 to the five socket head capscrews and washers. Install capscrews with washers through the transaxle and into the mounting holes in the frame. Torque to 220 N•m (162 lbf ft). 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

CAPSCREW LOCKWASHER WASHER PARKING BRAKE ASSEMBLY TRACTION MOTOR CAPSCREW WASHER MOTOR SHAFT TRANSAXLE INPUT SEAL

5. Remove the cap and plug from the service brake line and service brake port. Install the service brake line to the service brake port. Tighten to 12 to 16 N•m (108 to 192 lbf in). 6. Install the power cables to the traction motor studs as removed. Tighten to 8 N•m (71 lbf in).

Figure 4. Traction Motor and Parking Brake

7. Connect the traction motor temperature sensors to the main wiring harness as removed.

3. Install the parking brake assembly to the traction motor:

8. Connect the parking brake to the main wiring harness as removed.

a. Install the lower snap ring and woodruff key to the traction motor shaft. Align the groove in the hub with the woodruff key and slide the hub onto the shaft. Install the upper snap ring securing the brake hub to the traction motor shaft.

9. Connect the manual override cable to the parking brakes as removed.

b. Position the brake assembly onto the brake hub. Align the splines and seat the brake to the traction motor end head as removed. c. Install the four capscrews, lockwashers, and washers to secure. Tighten to 8 N•m (71 lbf in).

10. Connect the transaxle speed sensor to the main wiring harness as removed.

CAUTION Make sure the lift truck is blocked at the same height as with the drive tire installed to ensure the proper fluid level reading. 11. Bleed the service brakes. Refer to the section Brake System 1800 YRM 1332.

Maintenance and Repair

1300 YRM 1330 models ERP16-20VF (ERP30-40VF) (A955) or Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15-20VT (ERP030-040VT) (G807).

12. Check the fluid level in the transaxle. Fill as necessary. See Fluid Level Check. 13. Install the drive tire and wheel assembly to the wheel hub. Install lug nuts and torque to 170 N•m (125 lbf ft). 14. Connect the battery connector, turn the key switch to the ON position, and test the lift truck for proper operation. 15. Lower lift truck from the blocks. Refer to section Periodic Maintenance 8000 YRM 1373 for lift truck

16. Install the mast to the lift truck. Refer to the section Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 for European lift truck models ERP15-20VT (G807) and ERP16-20VF (A955) or Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405 for European and American lift truck models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955).

Maintenance and Repair SPEED SENSOR REPAIR The speed sensor monitors the speed of the transaxle and relays the information to the controller. The speed sensor can be replaced with the transaxle installed to the lift truck.

11. Reconnect the battery and test lift truck for proper operation.

1. Park the lift truck on a level surface. Turn the key switch to the OFF position and unplug the battery connector. 2. Discharge the capacitors. See Discharging the Capacitors, in this section. 3. Remove the floormat and floor plates from the operator compartment to access the top of the transaxle(s). 4. Disconnect the sensor wiring harness from the main wiring harness.

CAUTION Use a brush to clean around the sensor before removing to avoid contaminating the transaxle. 5. Remove the capscrew securing the sensor to the transaxle using a 5mm Allen wrench. See Figure 5. 6. Pull the sensor out of the transaxle. 7. Insert the new sensor into the transaxle. 8. Align the screw holes and install the capscrew. Torque to 9.5 N•m (84.0 lbf in). 9. Connect the sensor wiring harness to the main wiring harness. 10. Replace the floor plates and floormat.

1. 2. 3. 4. 5. 6.

CAPSCREW SPEED SENSOR FILL PLUG TRANSAXLE COVER COVER CAPSCREWS DRAIN PLUG

Figure 5. Speed Sensor

1300 YRM 1330

TRUNNION CAP REPAIR To repair the trunnion cap: 1. Remove the load from the forks and park the lift truck on a level surface. Adjust the mast to a vertical position, then turn the key switch to the OFF position and separate the battery connectors. 2. Remove the four capscrews securing the trunnion cap to the transaxle housing. Remove the trunnion cap. See Figure 6. 3. Wipe away any dirt or grease near the mounting holes. Clean the holes with a proper sized tap and tap wrench as necessary. 4. Position the new cap over the mast pin and onto the transaxle. 5. Apply Loctite® 242 to the threads and install the four capscrews and tighten alternately in small increments. Torque to 24 N•m (216 lbf in). 6. Grease the fitting in the mast stub shaft to lubricate the trunnion cap.

Maintenance and Repair 7. Connect the battery, turn the key to the ON position and test for proper operation.

FLUID LEVEL CHECK CAUTION Use only transmission fluid from approved vendors. Using fluid from unapproved vendors will void the warranty. Contact Yale Company Contact Management if you have questions about warranty status. Each transaxle has a separate fluid supply which must be checked every 2000 hours or 1 year or when other maintenance procedures require the fluid level to be checked. Make sure the transaxle is installed to the lift truck and the lift truck is positioned on a level surface when checking fluid levels for an accurate reading.

CAUTION Clean around the fill and check plugs with solvent before removal to prevent contamination of the system.

CAUTION Blocking the lift truck higher or lower or at a different angle than it normally sits with the drive tire installed will result in an incorrect fluid level check. 1. Remove the drive tire and block the lift truck frame to position the transaxle at the same height and position as with the drive tire installed. See Periodic Maintenance 8000 YRM 1373 for lift truck models ERP16-20VF (ERP30-40VF) (A955) or Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15-20VT (ERP030-040VT) (G807). 2. Remove the check plug. The fluid should be level with the bottom of the check hole. 3. If necessary, remove the fill plug and add fluid through the fill hole until level with the bottom of the check hole. Each transaxle holds approximately 0.60 liter (0.63 qt) of transmission fluid. 1. 2. 3. 4.

CAPSCREWS TRUNNION CAP THREADED MOUNTING HOLES TRANSAXLE HOUSING

Figure 6. Trunnion Cap

NOTE: New sealing rings must be installed with the drain, fill, and check plugs. 4. Replace check plug (and fill plug if removed) and tighten to 22 N•m (192 lbf in). See Figure 7.

Maintenance and Repair

1300 YRM 1330

CAUTION Clean around the fill and check plugs with solvent before removal to prevent contamination of the system. NOTE: Install new sealing rings on the plugs anytime the drain, check, or fill plugs are removed. NOTE: Operate the lift truck for 5 minutes or until the transaxle is warm to the touch. Transaxle fluid will drain easier and more thoroughly when it is warm. Each transaxle uses separate, self-contained fluid supplies.

1. 2. 3. 4.

FILL PLUG WHEEL HUB DRAIN PLUG CHECK PLUG

Figure 7. Transaxle Plug Locations 5. Reinstall drive tire and torque lugs to 170 N•m (125 lbf ft). Remove truck from blocks. 6. Repeat for the other transaxle. Check the fluid level in each transaxle every 2000 hours or one year.

FLUID CHANGE CAUTION

1. Remove the transaxle tire and block the lift truck frame to position the transaxle at the same height and position as with the tire installed. See Periodic Maintenance 8000 YRM 1373 for lift truck models ERP16-20VF (ERP30-40VF) (A955) or Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15-20VT (ERP030-040VT) (G807). 2. Turn the key switch to the OFF position and disconnect the battery. Block the wheels to prevent unexpected movement. 3. Place a drip pan with at least a 3.0 liter (3.3 qt) capacity under the transaxle.

CAUTION

Use only transmission fluid from approved vendors. Using fluid from unapproved vendors will void the warranty. Contact Yale Company Contact Management if you have questions about warranty status.

Clean around plugs with solvent before removal to prevent contamination of the transaxles.

The fluid is not normally changed unless contamination is suspected or other maintenance procedures require draining the transaxle. If changing the fluid is necessary, refer to the following procedures.

5. Remove the check plug.

4. Remove the fill plug on the transaxle. Inspect the breather for proper operation. Clean or replace as necessary. See Breather Repair.

6. Remove the drain plug. Clean the drain plug thoroughly, removing any metallic debris that has collected on the drain plug magnet.

WARNING The fluid is hot at normal operating temperatures. Be careful when draining the transaxles.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

CAUTION Blocking the lift truck higher or lower or at a different angle than it normally sits with the drive tire installed will result in an incorrect fluid level check.

CAUTION The drain plug must not be interchanged with the fill or check plugs. Use only an approved magnetic type drain plug to prevent damage to the transaxle.

1300 YRM 1330 NOTE: It may take as long as 10 minutes for the transaxle to drain completely depending on temperature and contaminants. Allow the transaxle to drain completely before continuing.

Maintenance and Repair

CAUTION A special tool is require to set the proper gap between housing and breather head. DO NOT drive the breather flush against the housing.

7. After the transaxle has drained completely, install the drain plug into the transaxle as removed. Tighten to 22 N•m (192 lbf in). Remove the drip pan and dispose of waste fluid properly.

6. Drive the breather into the housing using the Breather Set Tool (refer to Special Tools in this section) and a nylon faced hammer. See Figure 10.

NOTE: Use a funnel or a funnel with a tube attached to add fluid to the transaxle. Pour slowly.

7. Reinstall drive tire and torque lugs to 170 N•m (125 lbf ft). Remove truck from blocks.

8. Fill the transaxle with fluid until level with the bottom of the check hole. Each transaxle should be filled with approximately 0.60 liter (0.63 qt) of fluid. 9. When the fluid reaches the bottom of the check hole, install the check plug and the fill plug and tighten each to 22 N•m (192 lbf in).

BREATHER REPAIR The breather can be repaired with the transaxle installed to the lift truck and the drive tire removed. The breather equalizes air pressure inside the transaxle with the air pressure outside. If the breather is visibly damaged then the breather should be replaced. 1. Remove the drive tire and block the lift truck frame to position the transaxle at the same height and position as with the drive tire installed. See Periodic Maintenance 8000 YRM 1373 for lift truck models ERP16-20VF (ERP30-40VF) (A955) or Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15-20VT (ERP030-040VT) (G807).

Figure 8. Remove Breather Cap

2. Remove breather cap by shearing of with a flat screwdriver. See Figure 8. 3. Remove spring by hand. A small breather ball is located under the spring. Blow into the breather at a slight angle with compressed air to force the breather ball out. 4. Install a 6mm thread tap into the breather using a tap wrench, and pull the breather out of the housing. See Figure 9. 5. Position the new breather into the housing by hand.

Figure 9. Extracting the Breather

Maintenance and Repair

Figure 10. Installing the Breather

1300 YRM 1330

Figure 11. Drilling the Stud

STUD REPAIR Stud repair can be performed with the transaxle installed to the lift truck or removed. 1. Remove the drive tire and block the lift truck frame to position the transaxle at the same height and position as with the drive tire installed. See Periodic Maintenance 8000 YRM 1373 for lift truck models ERP16-20VF (ERP30-40VF) (A955) or Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15-20VT (ERP030-040VT) (G807). 2. Remove the damaged stud using adjustable grip pliers. 3. If the stud is sheared off:

Figure 12. Removing the Stud a. Mark the center of the stud with a center punch and nylon faced hammer. b. Drill into the center of the stud with a 3mm drill bit. See Figure 11. c. Drill the hole larger with a 7mm drill bit. d. Lightly tap an easy-out into the hole in the stud. Install the tap wrench and unscrew the stud from the hub. See Figure 12. 4. Run a thread tap (size M14 x 1.5) into the stud hole to clean and repair any damaged threads.

5. Test the threads with a thread plug gauge (size M14 x 1.5 - 6H). 6. If the threads are within specification, install the new stud using the Stud Installation Tool (refer to Special Tools in this section). 7. Torque studs to 80 N•m (59 lbf ft). See Figure 13. 8. Reinstall drive tire and torque lugs to 170 N•m (125 lbf ft). Remove truck from blocks.

1300 YRM 1330

Maintenance and Repair Recover the spring from beneath the cap. Remove the seal from the cap and cut it in two to prevent accidental reuse. See Figure 15. 5. Using a grind stone, slightly bevel the end of a 7/16 x 2 inch roll pin. Allow the pin to cool. 6. Carefully position the roll pin to the piston. Drive the roll-pin into the cavity of the piston with a nylon faced hammer. NOTE: It may be helpful to apply compressed air to the service brake line port (as with removing the cap) AFTER the piston has been pulled to the top end of the brake cylinder.

Figure 13. Stud Installation

BRAKE CYLINDER REPAIR

NOTE: Make note of the piston and seal orientation during removal. 7. Pull the roll-pin (and piston) from the cylinder using pliers.

WARNING Always wear eye protection and use the proper tools when installing/removing snap rings. The service brake pedal in the operator compartment actuates the master cylinder sending pressurized fluid to the brake pistons in the transaxles through the service brake lines. 1. Remove the transaxle from the lift truck. Disassemble the parking brake and traction motor from the transaxle. See Remove Transaxle From Frame in this section. 2. Drain the oil from the transaxle. 3. Remove the snap ring in the brake cylinder. See Figure 14.

CAUTION Cover the cap with a cloth to control it in case it is ejected from the piston. NOTE: Make note of the piston and cap orientation as well as the orientation of the seal on the piston before removal.

1. 2. 3. 4.

CYLINDRICAL PIN PISTON SEAL PISTON SPRING

5. O-RING 6. CAP 7. SNAP RING

Figure 14. Brake Piston Assembly

4. Direct pressurized air into the service brake line port in the cover to force the cap out of the cylinder.

Maintenance and Repair

1300 YRM 1330 NOTE: Make sure the cap is oriented as noted when removed. 15. Install the cap into the brake cylinder. 16. Press the cap into cylinder to expose the snap ring groove, and install the snap ring to the brake piston. NOTE: It is recommended to verify the torque on the transaxle cover capscrews before reinstalling the traction motor. See Cover to Housing Seal. 17. Assemble the brake and traction motor to the transaxle, and install the transaxle to the lift truck as removed. See Install Transaxle to Frame in this section.

Figure 15. Removing the Cap NOTE: Make note of the cylindrical pin orientation during removal. 8. Remove the cylindrical pin from beneath the piston. 9. Inspect the cylinder walls for pits, cracks, and other damage. NOTE: Install the cylindrical pin in the orientation noted during removal.

CAUTION Make sure the lift truck is blocked at the same height as with the drive tire installed to ensure the proper fluid level reading. 18. Check the transaxle fluid level. See Fluid Level Check. 19. Install the drive tire (170 N•m (125 lbf ft)) and test truck for proper operation.

10. Lightly lubricate the cylindrical pin with multipurpose grease and install into the brake cylinder as removed. NOTE: A new brake piston and new seal should be used when repairing the brake cylinder assembly. Make sure the new piston and new seal are oriented as noted when removed. 11. Lightly lubricate the new piston seal with multipurpose grease and install to the new brake piston as removed. See Figure 16. 12. Install the new brake piston (and seal) into the brake cylinder. 13. Place the spring into the cavity in the piston by hand. 14. Lightly lubricate the new O-ring with multipurpose grease and install to the cap as removed.

1. SNAP RING 2. CAP 3. O-RING

4. PISTON 5. SEAL 6. SPRING

Figure 16. Piston Seal Orientation

1300 YRM 1330

INPUT SEAL REPAIR The input seal is located between the traction motor and the transaxle. The seal covers the transaxle input bearing and input pinion. The traction motor shaft slides through the center of the seal into the input pinion. To replace the input seal:

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING The traction motor is heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the traction motor. 1. Remove the transaxle from the lift truck, and remove the parking brake and traction motor from the transaxle. See Remove Transaxle From Frame in this section.

CAUTION The transaxle is heavy and can be difficult to stabilize when positioned with the studs down. Securely support the transaxle in a stable position during these procedures. 2. Carefully position the transaxle with the drive tire mounting studs down. Support the transaxle with wooden blocks to stabilize. 3. Use solvent to clean the outside of the transaxle before removing the seal. NOTE: Removal is destructive to the seal. 4. Puncture the seal with a flat screwdriver (carefully near the center of the seal to avoid damaging the bearing) and pry around the edge under the seal to remove from the cover.

Maintenance and Repair 5. Clean around the flange to remove any dirt or debris. 6. Install the input seal using the Yale input seal installation tool (refer to Special Tools in this section). NOTE: It is recommended to verify the torque on the transaxle cover capscrews before reinstalling the traction motor. See Cover to Housing Seal. 7. Lightly lubricate the center of the input seal with multipurpose grease to allow the seal to seat properly on the motor shaft. It is not necessary to lubricate the traction motor shaft. Install the traction motor to the transaxle. 8. Install the brake to the traction motor, and install the transaxle to the lift truck as removed. See Install Transaxle to Frame in this section.

COVER TO HOUSING SEAL CAUTION DO NOT remove the cover from the transaxle housing during the warranty period. Removing the cover from the housing will void the transaxle warranty. The transaxle warranty period may vary from truck hours or other warranties. Contact Yale Company Contact Management if you have questions about warranty status. The transaxle cover is mated to the housing using an anaerobic sealant and secured in place with ten socket-head capscrews. DO NOT remove the cover from the housing during the transaxle warranty period. THIS WILL VOID THE WARRANTY. Internal parts of the transaxle are press fit and cannot be repaired or properly preloaded without specialized equipment. If a leak develops from between the cover and the housing, different procedure are required depending on whether your transaxle is within the warranty period or beyond the warranty period. Refer to During the Transaxle Warranty Period or After the Transaxle Warranty Period.

Maintenance and Repair

During the Transaxle Warranty Period CAUTION DO NOT remove the cover from the transaxle housing during the warranty period. Removing the cover from the housing will void the transaxle warranty. The transaxle warranty period may vary from truck hours or other warranties. Contact Yale Company Contact Management if you have questions about warranty status.

1300 YRM 1330 2. Drain the fluid from the transaxle. 3. Remove the ten socket-head capscrews securing the cover to the housing. See Figure 18. NOTE: The cover is aligned to the housing with internal components of the transaxle. Carefully pry the cover from the housing by levering equally on each side. 4. Separate the cover from the housing by tapping around the seam of the cover and housing using a thin flat chisel. Gently pry around the cover in small equal increments to remove from the housing.

CAUTION The transaxle is heavy and can be difficult to stabilize when positioned with the studs down. Securely support the transaxle in a stable position during these procedures. 1. Remove the transaxle from the lift truck and remove the parking brake and traction motor. See Remove Transaxle From Frame. 2. Tighten the capscrews to 110 N•m (81 lbf ft). See Figure 17. 3. Install the brake and traction motor to the transaxle, and install the transaxle to the lift truck. See Install Transaxle to Frame. 4. If the leak persists, the unit must be reported to Yale Company Contact Management.

After the Transaxle Warranty Period Removing the Cover

1. SOCKET-HEAD SCREW 2. SPEED SENSOR 3. FILL PLUG

4. COVER 5. SOCKET-HEAD CAPSCREW 6. DRAIN PLUG

Figure 17. Cover Assembly

1300 YRM 1330

Maintenance and Repair contaminated when the cover is turned over to be assembled. 2. Apply a continuous coating of Loctite® 5188 completely around the housing flange using a clean, lint free paint roller to ensure a proper seal. See Figure 19. NOTE: The cover is aligned to the housing with internal components of the transaxle. Carefully align the cover to the housing and lower equally on every side until it is mated. Dowel pins inside the housing must be aligned with the cover during installation. 3. Position the cover to the transaxle and slowly lower into position. Turn the assembly while beginning to lower to ensure that the internal components seat properly and do not bind. Make sure the assembly holes and dowels are aligned as the cover and the housing meet. Lightly tap evenly around the cover with a rubber mallet to seat the cover onto the housing.

CAUTION

1. SOCKET-HEAD SCREW 2. SPEED SENSOR 3. FILL PLUG

4. COVER 5. SOCKET-HEAD CAPSCREW 6. DRAIN PLUG

Figure 18. Cover Assembly Installing the Cover

DO NOT install the capscrews until the cover is Tightening capscrews can completely seated. damage internal components if the cover is not properly seated. 4. When the cover is completely seated onto the housing, install the ten socket head screws securing the cover to the housing. Incrementally tighten in a non-concentric pattern to 110 N•m (81 lbf ft). See Figure 20.

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

CAUTION Make sure the cover has been thoroughly drained of any fluid so the new sealant is not contaminated when the cover is turned over to be assembled. 1. Clean the housing flange and cover flange thoroughly before reassembly. The flanges must be clean of oil, dirt, and old sealant to ensure a proper seal. Make sure the cover has been thoroughly drained of any oil so the new sealant is not

Figure 19. Applying Sealant to the Flange

Maintenance and Repair

1300 YRM 1330 c. Install the check and fill plugs with new sealing rings and tighten to 22 N•m (192 lbf in).

WET BRAKES The wet brake disc can be replaced after the warranty period. To replace the brake discs:

CAUTION DO NOT remove the cover from the transaxle housing during the warranty period. Removing the cover from the housing will void the transaxle warranty. The transaxle warranty period may vary from truck hours or other warranties. Contact Yale Company Contact Management if you have questions about warranty status.

CAUTION The transaxle is heavy and can be difficult to stabilize when positioned with the studs down. Securely support the transaxle in a stable position during these procedures.

1. SOCKET-HEAD SCREW 2. ENCODER SENSOR 3. FILL PLUG

4. COVER 5. SOCKET-HEAD CAPSCREW 6. DRAIN PLUG

1. Remove the transaxle from the lift truck and remove the parking brake and traction motor. See Remove Transaxle From Frame. 2. Drain the fluid from the transaxle. 3. Remove the cover from the transaxle. Refer to Removing the Cover in this section.

Figure 20. Cover Assembly 5. Install the brake and traction motor to the transaxle, and install the transaxle to the lift truck. See Install Transaxle to Frame.

CAUTION Make certain to use the proper magnetic plug for the drain plug. The drain plug is not interchangeable with the fill and check plugs. 6. Fill the transaxle with fluid to the proper level:

CAUTION Always replace the full set of inner and outer splined brake discs. NOTE: Make note of the orientation of the brake discs during removal. 4. Remove the 4 brake discs (outer spline) and 3 brake discs (inner spline) from the transaxle by hand. Remove the pressure plate from the transaxle by hand. See Figure 21.

a. Install the drain plug with new sealing ring and tighten to 22 N•m (192 lbf in).

5. Install the pressure disc into the transaxle housing by hand as removed.

NOTE: Each transaxle requires approximately 0.60 liter (0.63 qt) of transmission fluid.

6. Soak the new brake discs in clean transaxle fluid before installing.

b. Fill the transaxle until the fluid begins to emerge from the check hole.

7. Install a brake disc (external spline) against the pressure disk in the transaxle.

1300 YRM 1330

1. 2. 3. 4. 5. 6. 7. 8. 9.

Maintenance and Repair

PRESSURE DISC BRAKE DISC (OUTER SPLINED) BRAKE DISC (INNER SPLINED) PLUG SEALING RING SCREW INPUT SEAL SNAP RING COVER

10. 11. 12. 13. 14. 15. 16. 17. 18.

O-RING SPRING PISTON RING PIN BLEEDER VALVE PLUG SPEED SENSOR SCREW

Figure 21. Brake Discs

CAUTION Brake discs with internal splines should be installed in the transaxle housing so that the rounded off side of teeth point upward. 8. Install a brake disc (internal spline) against the brake disc (external spline) with the rounded off side of teeth pointing upward. 9. Install the remainder of the brake discs alternating between internal and external splined discs. The disc pack should have a total of 1 pressure disc,

4 brake discs (external spline) and 3 brake discs (internal spline). 10. Align the splines of the internal discs using a screwdriver. 11. Install the cover to the transaxle. Refer to Installing the Cover in this section. 12. Install the traction motor and brake to the transaxle, and install the transaxle to the lift truck. See Install Transaxle to Frame.

Maintenance and Repair

CAUTION

1300 YRM 1330 NOTE: Each transaxle requires approximately 0.60 liter (0.63 qt) of transmission fluid.

Make certain to use the proper magnetic plug for the drain plug. The drain plug is not interchangeable with the fill and check plugs.

b. Fill the transaxle until the fluid begins to emerge from the check hole.

13. Fill the transaxle with fluid to the proper level:

c. Install the check and fill plugs with new sealing rings and tighten to 22 N•m (192 lbf in).

a. Install the drain plug with new sealing ring and tighten to 22 N•m (192 lbf in).

14. Connect the battery connectors, turn the key switch to the ON position, and test for proper operation.

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

1300 YRM 1330

3/11 (2/10)(2/09) Printed in U.S.A.

Maintenance

USER INTERFACE SERVICE TECHNICIAN ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]; ERC22-35VG (ERC045-070VG) [A968]; ERC16-20VA (ERC030-040VA) [A969]; ERP22-35VL (ERP045-070VL) [A976]

PART NO. 524319498

2200 YRM 1336

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

User Interface

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Description ...................................................................................................................................................... Display Panel Menu Access ............................................................................................................................ Menu Flowchart................................................................................................................................................... Technician Menu Flowchart............................................................................................................................. Menu Navigation.................................................................................................................................................. Main Menu Structure .................................................................................................................................. Screens and Title Screens.......................................................................................................................... Submenus................................................................................................................................................... Returning to the Main Menu ....................................................................................................................... Icons and Settings ...................................................................................................................................... Soft Keys..................................................................................................................................................... Entering Numbers....................................................................................................................................... Icon Glossary ...................................................................................................................................................... Introduction ..................................................................................................................................................... Soft Key Icons ................................................................................................................................................. Overlay Icons .................................................................................................................................................. System Off Screen and Alert Screens ............................................................................................................ Main Menu Title Screens ................................................................................................................................ Submenu Icons Grouped by Menu.................................................................................................................. Operating Screen Icons .............................................................................................................................. Password Screen Icons .............................................................................................................................. Activity Log Submenu Icons........................................................................................................................ Calibration Submenu Icons......................................................................................................................... Display Submenu Icons .............................................................................................................................. Status Submenu Icons................................................................................................................................ Truck Setup Submenu Icons ....................................................................................................................... Diagnostics Submenu Icons ....................................................................................................................... Operating Screen ................................................................................................................................................ Introduction ..................................................................................................................................................... Performance Mode Controls ........................................................................................................................... Status and Warning Icons ............................................................................................................................... Battery Discharge Indicator............................................................................................................................. Direction and Parking Brake Indicators ........................................................................................................... Hazard Flashers and Lighting Controls........................................................................................................... Tire Angle Indicator ......................................................................................................................................... System Time ................................................................................................................................................... Load Weight Indicator ..................................................................................................................................... System Off/Alert Screens .................................................................................................................................... Introduction ..................................................................................................................................................... System Off Screen .......................................................................................................................................... Alert Screens .................................................................................................................................................. Password Screen................................................................................................................................................. Introduction ..................................................................................................................................................... Password Screen ............................................................................................................................................ Service Technician Password Setup ........................................................................................................... Adding/Removing/Changing Passwords ......................................................................................................... Password Log.................................................................................................................................................. Activity Log Menu ................................................................................................................................................ Introduction ..................................................................................................................................................... Operator Checklist Log ...................................................................................................................................

1 1 1 2 2 8 8 8 9 10 10 10 11 11 11 11 13 13 16 18 18 19 19 20 23 25 28 40 48 48 49 49 50 51 51 51 51 51 52 52 52 52 53 53 53 54 55 56 58 58 58

Table of Contents

User Interface

TABLE OF CONTENTS (Continued) Password Log.................................................................................................................................................. Impact Events Log .......................................................................................................................................... Calibration Menu ................................................................................................................................................. Introduction ..................................................................................................................................................... Load Weight Calibration .................................................................................................................................. Return to Set Tilt Stop Point Calibration.......................................................................................................... E-Hydraulic and Manual Valve Threshold Calibration ..................................................................................... Steering Wheel Knob Center Point Calibration ............................................................................................... Steer Axle Position Calibration........................................................................................................................ Manual Hydraulics Calibration......................................................................................................................... Display Menu....................................................................................................................................................... Introduction ..................................................................................................................................................... Set Date and Time Format Menu.................................................................................................................... Set Daylight Saving Time Menu ...................................................................................................................... Procedure for Setting Up Automatic Daylight Savings Time ....................................................................... Set Time and Date Menu ................................................................................................................................ Procedure for Setting Time and Date ......................................................................................................... Set Units Menu................................................................................................................................................ Status Menu ........................................................................................................................................................ Introduction ..................................................................................................................................................... VSM Versions.................................................................................................................................................. Display Versions.............................................................................................................................................. Truck Serial Number........................................................................................................................................ Hour Meters .................................................................................................................................................... E-Hydraulic Controller Versions ...................................................................................................................... Pump Motor Controller Versions ..................................................................................................................... Traction Motor Controller 1 Versions ............................................................................................................... Traction Motor Controller 2 Versions ............................................................................................................... Light Controller Versions ................................................................................................................................. Impact Sensor Versions .................................................................................................................................. Truck Setup Menu................................................................................................................................................ Introduction ..................................................................................................................................................... Add/Remove Password ................................................................................................................................... Motor Braking.................................................................................................................................................. Changing the Motor Braking Settings ......................................................................................................... Battery Setup .................................................................................................................................................. BDI Adjustment Setting ................................................................................................................................... Acceleration Rates .......................................................................................................................................... Hour Meter Initialization .................................................................................................................................. Impact Monitor Shutdown ............................................................................................................................... Operator Checklist .......................................................................................................................................... Minimum Pump Standby Flow Rate ................................................................................................................ Scheduled Maintenance Reminder ................................................................................................................. Traction Speed Limit........................................................................................................................................ Return to Set Tilt ............................................................................................................................................. Auto Power-Off Time Delay ............................................................................................................................. Impact Monitor Settings .................................................................................................................................. Impact Detection ......................................................................................................................................... Setting Adjustments .................................................................................................................................... Initial Adjustment of Soft and Hard Impact Settings ................................................................................... Readjustment of Soft and Hard Impact Settings.........................................................................................

60 62 64 64 65 65 66 66 67 67 68 68 68 70 70 72 73 73 74 74 74 75 75 75 75 75 76 76 76 76 76 76 77 77 78 78 80 80 81 81 81 82 82 84 84 84 85 85 85 85 86

User Interface

Table of Contents

TABLE OF CONTENTS (Continued) Motion Alarm ................................................................................................................................................... Lift Hydraulic Function Maximum Speed and Ramp Times ............................................................................ Lower Hydraulic Function Maximum Speed and Ramp Times ....................................................................... Tilt Forward Hydraulic Function Maximum Speed and Ramp Times .............................................................. Tilt Backward Hydraulic Function Maximum Speed and Ramp Times............................................................ Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times .............................................................. Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times .............................................................. Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times .............................................................. Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times .............................................................. Optional Hydraulic Functions .......................................................................................................................... Rear Lights Control ......................................................................................................................................... Restore Default Settings ................................................................................................................................. Diagnostics Menu ................................................................................................................................................ Introduction ..................................................................................................................................................... Fault Code Log................................................................................................................................................ Fault Log Details ......................................................................................................................................... Speedometer................................................................................................................................................... Direction Switch .............................................................................................................................................. Traction Motor 1 Status ................................................................................................................................... Traction Motor 2 Status ................................................................................................................................... Occupancy Sensor.......................................................................................................................................... Brake System Sensors.................................................................................................................................... Pump Status.................................................................................................................................................... Hydraulic Control Inputs.................................................................................................................................. E-Hydraulic Valves .......................................................................................................................................... Hydraulic Sensors ........................................................................................................................................... System Voltages ............................................................................................................................................. Steering Position Sensors ...............................................................................................................................

86 86 87 87 87 87 87 87 88 88 88 89 89 89 90 90 91 91 91 92 92 92 92 93 93 94 95 95

This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]; ERC22-35VG (ERC045-070VG) [A968]; ERC16-20VA (ERC030-040VA) [A969]; ERP22-35VL (ERP045-070VL) [A976]

iii

2200 YRM 1336

General

General DESCRIPTION This topic describes the functions of the display panel that are available to the Service Technician. With a proper service technician password, a Service Technician can access menu items that are not visible at Operator or Supervisor password-level access.

Legend for Figure 1 1. 2. 3. 4. 5. 6. 7. 8.

2 AND 3 KEYS SCROLL FORWARD KEY (RIGHT ARROW) 5, 6, 7, 8, 9, AND 0 KEYS KEYLESS START SWITCH OR KEY SWITCH SCROLL BACK KEY (LEFT ARROW) 1 AND 4 KEYS POUND KEY (# KEY) ENTER KEY (* STAR KEY)

The operator password screen appears at startup as shown in Figure 2 if Operator Passwords are enabled. Use the number keys on the Display Panel to enter your five-digit Service Technician password. If a non-service technician password has already been entered at the initial password screen, you can navigate to the Password Screen by pressing the Enter Key (*) to go to the Main Menu, then press either the Scroll Back Key ( —) or the Scroll Forward Key (— ) to access the Password Screen. Refer to the Main Menu Structure topic for orientation on the Main Menu title screens (the main level menus).

Figure 1. Lift Truck Display Panel Figure 2. Password Screen

Menu Flowchart

2200 YRM 1336

Menu Flowchart TECHNICIAN MENU FLOWCHART NOTE: Depending upon how the lift truck is equipped, some of the functions described in this section may not be included in the on-board menu structure for a particular lift truck. NOTE: The icons displayed on the Operating Screen vary from any one time to another, depending on the current operation of the lift truck and other factors. The Battery Discharge Indicator, system time, and direction indicator are always displayed.

All available menus are grouped by function under the main menu screens, which are also called top-level title menus. When you select a main menu screen, the system then presents submenus, also known as second-level menus, that you can cycle through using the UP ↑ or DOWN ↓ keys until you find the one you want on the Display Panel. Two main menu screens, the Operating Screen and the Password screen, have no associated submenus, but the other main menus lead to submenus. The following flowchart is for the Technician use only. See Figure 3 and Table 1.

2200 YRM 1336

Menu Flowchart

Figure 3. Technician Flowchart (Sheet 1 of 4)

Menu Flowchart

2200 YRM 1336

Figure 3. Technician Flowchart (Sheet 2 of 4)

2200 YRM 1336

Menu Flowchart

Figure 3. Technician Flowchart (Sheet 3 of 4)

Menu Flowchart

2200 YRM 1336

Figure 3. Technician Flowchart (Sheet 4 of 4)

2200 YRM 1336

Menu Flowchart

Table 1. Technician Menu Flowchart A

Operating Screen

Password Entry

Activity Log

Calibration

Diagnostics

Truck Setup

Truck Status

Display Adjustment

Operator Checklist

Load Weight

Fault Code Log

Add/Remove Password

VSM Version

Set Date and Time Format

Impact Events

Manual Hydraulics

Steering Position Sensor

Restore Default

Impact Sensor Version

Set Units

Password

Steering Axle Position

System Voltages

Rear Lights

Light Controller Version

Set Time and Date

Steering Wheel Knob Center Point

Hydraulic Sensors

Optional Hydraulics Function

Traction Motor Controller 2 Version

Set Daylight Saving Time

Valve Threshold

E-Hydraulic Sensors

AUX 2B Adjustments

Traction Motor Controller 1 Version

Hydraulic Control Inputs

AUX 2A Adjustments

Pump Motor Controller Version

Pump Status

AUX 1B Adjustments

E-Hydraulic Controller Version

SHEET 1

Return to Set Tilt Stop

Brake System Sensors

AUX 1A Adjustments

Hour Meters

Occupancy Sensor

Tilt Back Adjustments

Truck Serial Number

Traction Motor 2 Status

Tilt Forward Adjustments

Display Version

Traction Motor 1 Status

Lift Adjustments

Direction Switch

Lower Adjustments

Speedometer

Motion Alarm

SHEET 2

Impact Monitor Settings

Auto Power-Off Time Delay

17 18 19

Return to Set Tilt Traction Speed Limit

SHEET 3

Scheduled Maintenance Required

Minimum Pump Standby

Operator Checklist

Interlock Screen

Impact Monitor Shutdown

Cycle the Key

Traction Switch

Hour Meter Initialization

Secure Battery

Hydraulic Switch

Acceleration Rates

Release Park Brake

Temperature Too High

BDI Adjustment

Operator out of Seat

Lift Limit Exceeded

Battery Setup

Release Accelerator

Charge Battery

Motor Braking

Release Hydraulic Input

Impact DetectedEnter Service/ Supervisor Password

SHEET 4

Menu Navigation

2200 YRM 1336

Menu Navigation This topic explains how to use the keys on the Display Panel, shown in Figure 4, to navigate from one menu to another and change settings.

When a title screen or a menu screen is displayed on the LCD screen, the screen is still referred to as the “screen” in a generic way, but the actual Operating Screen is shown in Figure 4. See the Operating Screen section for details. When the Operating Screen is displayed, pressing the Scroll Forward Key (— ) causes the system to display the Password Screen. If you press the Scroll Forward Key a second time, the system displays the Activity Log Title Screen, shown in Figure 5, on the LCD screen.

1. LCD SCREEN 2. DISPLAY PANEL

Figure 4. Display Panel with Operating Screen Displayed Keys used for menu navigation include: • The 1, 2, 3, 4, and # keys. • The Enter Key (*) which is also called the star key because of its * label. • The Scroll Back Key ( —) and the Scroll Forward Key ( — ). These keys are explained in detail in the General section of this document. The Password Screen, discussed in the Adding/Removing/Changing Passwords topic in the Password Screen section, is the first screen displayed when the key switch or keyless switch is turned to the On position unless Operator Passwords are deactivated (in this case, the Activity Log Title Screen appears). After entering your password successfully, the system displays the Operating Screen on the orange 1.5 x 2.5 inch LCD screen of the Display Panel as shown in Figure 4.

Figure 5. Activity Log Title Screen

Main Menu Structure The main menus (top-level menus) appear on the screen in the order shown in Figure 6. Use the Scroll Back Key or the Scroll Forward Key to move from one title screen to another. Press the Enter Key to enter one of these main menus.

Screens and Title Screens The main menu has eight menus, or screens, which are shown in Figure 6. Press the Scroll Forward Key to advance through all of them. If you press the Scroll Forward Key after reaching the Display Title Screen, the system returns (loops back) to the Operating Screen. Press the Scroll Forward Key again to scroll through the screens again. Alternatively, use the Scroll Back Key to scroll through the screens in the reverse direction.

2200 YRM 1336

1. 2. 3. 4.

Menu Navigation

OPERATING SCREEN PASSWORD SCREEN ACTIVITY LOG TITLE SCREEN CALIBRATION TITLE SCREEN

5. 6. 7. 8.

DIAGNOSTICS TITLE SCREEN TRUCK SETUP TITLE SCREEN STATUS TITLE SCREEN DISPLAY TITLE SCREEN

Figure 6. Main Menu Structure The Password Screen and Operating Screen do not have submenus below them. The other title screens are all main menus which have submenus under them. Submenus can also be called second-level menus. Figure 5 is an example of a main menu screen. Service Technicians have access to all title screens while Supervisors have access to the Activity Log, Calibration, Display, Status, and Truck Setup Title Screens. Operators can use only the Password Screen, Operating Screen, and Calibration Title Screen.

Submenus Submenus are the “branches” of a main menu. The Activity Log Menu has only three submenus, while the Truck Setup Menu has 27 submenus. Each submenu is represented by a title screen. When the title screen of the submenu you want is displayed on the screen, press the Enter Key to enter that submenu. For example, if

you enter the Operator Checklist Log submenu, shown in Figure 7, the system displays the menu shown in Figure 8. When viewing a submenu title screen, you can return to the main menu at any time by pressing the Scroll Back Key or the Scroll Forward Key. Menu navigation is possible through the use of soft keys, which are explained in the Soft Keys topic. For example, if you scroll to the Activity Log Title Screen and have it displayed on the screen as shown in Figure 5, press the Enter Key (*) to enter the Activity Log menu. The system will display the first submenu in the Activity Log menu, which is shown in Figure 7. Press the Enter Key again and the system will display the Operator Checklist Log, shown in Figure 8. The Activity Log Icon in the upper left corner of this submenu indicates you are in the Activity Log main menu.

Menu Navigation

2200 YRM 1336 icon represents: 1) a setting that can be changed, or 2) a status value that can be viewed, such as a truck’s serial number, or 3) an action that can be taken, such as clearing the fault log. Only a logged in user who has the proper privileges can change a setting, view a status value, or take an action.

Figure 7. Operator Checklist Log Title Screen

A setting is a value that controls the operation of a lift truck in some way. For example, there are four values for the performance mode setting, 1, 2, 3, and 4. Some settings have only two values, such as Enabled and Disabled, while other settings may present a series of values you can select from by using the soft keys. In some cases, you need to enter a numerical value that is within an acceptable range for a setting. In this case, you key in the value using the number keys. This is discussed in the Entering Numbers topic at the end of this section. On submenus that have two or more icons, the icons correspond to related settings. To change settings you need to use the buttons called soft keys, which are explained in the next topic.

Soft Keys

Figure 8. Operator Checklist Log Menu

Returning to the Main Menu To return to the main menu from a submenu, press the Scroll Forward Key ( — ). This returns you to the title screen of the submenu (second-level menu) you are using. If you press the Scroll Forward Key a second time, the system returns you to the main menu. You can also return to the main menu, or back out of a submenu, by pressing the Scroll Back Key. Press the Enter Key to save any changes you make in a submenu before exiting from the submenu. If you return to the main menu before saving a change, the system does not store the change.

Icons and Settings An icon is a simple graphic that represents an object, such as a clock, or a setting such as battery voltage. Each submenu has at least one icon on it, and each

Certain keys on the Display Panel called "soft keys" make it possible to navigate from one menu to another, change settings, delete a log entry, or take other actions. A soft key is a key that has been programmed to serve more than one function, and the function it serves depends on which menu is active. For example, when the Operating Screen is displayed, the # key lets you turn the Hazard Flashers On or Off, but when you are in the Activity Log Checklist menu, the # key can be used to delete a log entry. The soft keys include the 1 and 4 keys on the left, the 2 and 3 keys on the right, and the # and * keys below the Operating Screen. There are no icon indicators for the soft keys. The * soft key serves as an Enter Key in all menus except when using the Operator Checklist (see the Operator Checklist topic in the Truck Setup Menu section). In a lot of menus, the 2 and 3 soft keys are programmed for navigating up or down in the menu to the setting value you want to change. Also, in most but not all menus, the 2 and 3 soft keys are programmed for moving up or down though the available values or options for the currently selected setting. When this is the case, the up and down arrows are displayed on the right side of the screen.

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Icon Glossary

The following example shows how to use the soft keys. How to Change the Battery Voltage Setting 1. Starting from the main menu, use the Scroll Back Key ( —) or Scroll Forward Key (— ) to navigate to the Truck Setup Title Screen and press the Enter Key (*). 2. Use the 2 or 3 arrow soft keys to step through the menus to the Battery Setup submenu (the title screen of this submenu has a battery icon on it) and press the Enter Key. 3. Press the 2 or 3 arrow soft key to "move to" the value located to the right of the top icon and the system will place a "selection box" around the value. This number indicates the current battery voltage, such as 36. 4. With the selection box around the battery voltage value, press the Enter Key. 5. Use the 2 and 3 arrow soft keys to move up or down though the available values (36, 48, 72, and 80) until 48 is displayed, then press the Enter Key. The system stores the 48 Volt value and begins using it as the new battery voltage setting.

NOTE: While changing a setting, all other sub-items (setting items) disappear.

Entering Numbers The preceding example shows how the system allows a user to select one value out of a series of values. In some menus, you will use the number keys (0 through 9) to enter a value directly. These are: • The 1, 2, 3, and 4 soft keys. These keys can be used as number keys only in the menus that accept numerical input. These keys are programmed for use as soft keys in most menus. • The 5, 6, 7, 8, 9, and 0 keys. These keys can be used to enter numbers in menus that allow numerical input. These keys are not soft keys in any menu. Passwords are a special case of entering numbers. The user is required to enter a five digit “password” number, such as 15324, on the Password Screen. This number must consist only of the numbers 1, 2, 3, 4, 5, 6, 7, 8, and 9 and is entered using the 1, 2, 3, 4, 5, 6, 7, 8, and 9 keys. Pressing any other numeric key has no effect.

Icon Glossary INTRODUCTION An icon is a symbol that conveys a unique meaning without words, such as an arrow. The Operating Screen on this lift truck presents information to an operator solely through the use of symbols which are mostly icons, along with some numbers and a few text characters. Icons make it possible to simultaneously display up to 12 kinds of information graphically in a small space. In addition, the use of icons reduces the difficulty of communicating with operators who speak different languages. The meaning of some icons is apparent when the icon appears by itself, such as the seat belt icon. Other icons need to have numeric information displayed alongside them to present information, such as when 24 appears beside the clock icon to indicate the times are being displayed using the 24-hour clock system. Sometimes two icons are displayed side by side to convey information, such as when the icon that means "enabled" is shown beside the rear lights icon. Also, two icons can be displayed at the same time, one over the other, which is discussed in the Overlay Icons topic.

The icons and their meanings are presented in these categories: • Soft Key Icons • Overlay Icons • Icons on System Off Screen and Alert Screens • Main Menu Screens • Submenu Icons Grouped by Menu

SOFT KEY ICONS Some of the icons on the Operating Screen are called soft key icons because they associate an operation or function with a nearby key (1, 2, 3, 4, #, or *) on the Display Panel. The result of pressing one of these keys depends on which menu is currently active, because the icons nearest these keys change from one menu to another. The soft keys are programmed to function in relation to the current menu context. Table 2 shows the soft key icons that appear on the Display Panel along with a short description of each one’s purpose.

Icon Glossary

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Table 2. Soft Key Icons Icon

Description Hare Performance Mode "increase" Icon. Press the 1 soft key (or the # soft key in some cases) to increase performance. Tortoise Performance Mode “decrease” Icon. Press the 3 soft key to decrease performance. Trash Can Icon. Used to delete all entries in a log. Press the 4 soft key (or the # soft key in some cases) to empty a log. Up Arrow soft key. Press 2 to scroll up in most screens. Also used to view next log entry in log screen. Down Arrow soft key. Press 3 to scroll down in most screens. Also used to view next log entry in log screen. View Next Device Log Icon. Press the # key for previous. View Previous Device Log Icon. Press the * key for next.

This icon points to the * key (the soft Enter Key) and is used to accept a value, command a calibration action, or restore defaults, depending on the context when the * key is pressed.

Table 2. Soft Key Icons (Continued) Icon

Description Enable Current Item Icon. When the * key is pressed, the current item displayed will appear during the Operator Checklist sequence. Deactivate Soft Key Icon. Indicates function is deactivated. Press the * key to deactivate. “Enable” Traction and Hydraulics for Forklift Icon. Press the 2 key to enable.

“Disable” Traction and Hydraulics for Forklift Icon. Press the 4 key to disable.

Hazard Flashers Icon. Press the # key to toggle the hazard flashers on and off. Select system time for Fault Log event. Press the 1 key to select system time (this soft key toggles between system times and hour meters). Front Truck Lights Icon. Only available with CAN light controller. Press the 4 key to turn truck lights on. Rear Truck Lights Icon. Only available with CAN light controller. Press the 2 key to turn truck lights off.

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Icon Glossary

OVERLAY ICONS

Table 4. Alert Screen Icons

Icons that look like they are placed over another icon are called overlay icons. This type of icon always appears in conjunction with another icon, not by itself. Table 3 shows the overlay icons and describes how they are used.

Icon

Description Alert

Table 3. Overlay Icons Icon

Description Null Symbol Icon. When this icon overlays another icon it indicates that a setting value is invalid or out-of-range. X Icon. This icon indicates that a feature has been deactivated (disabled).

Example of a Fault Screen Traction Icon

SYSTEM OFF SCREEN AND ALERT SCREENS The System Off Screen and the various Alert Screens show interlocks, such as operator not in seat. These screens appear only briefly. Refer to System Off/Alert Screens for more information on these screens. The icons used in alert screens identify either status or warning conditions as shown in the examples in Table 4.

Forklift Truck Icon

Service Required Icon

Hydraulics Icon

Icon Glossary

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Table 4. Alert Screen Icons (Continued) Icon

Description Alert

Table 4. Alert Screen Icons (Continued) Icon

Description Alert

Alert Screens

Operator Out of Seat Cycle the Key

Release Pedal Secure Battery

Release Hydraulic Input Release Park Brake

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Icon Glossary

Table 4. Alert Screen Icons (Continued) Icon

Description

Table 4. Alert Screen Icons (Continued) Icon

Description

Alert

Traction Switch

Lift Limit

Hydraulic Switch

Charge Battery

Temperature Too High

Icon Glossary

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Table 4. Alert Screen Icons (Continued) Icon

Description Alert

Password screen, have no associated submenus, but the other main menus lead to submenus. When you are at the main menu level, pressing the Scroll Back Key takes you to the previous main menu screen. Pressing the Scroll Forward Key takes you to the next main menu screen. If you are in a submenu, pressing the Scroll Back Key or Scroll Forward Key returns you to the main menu screens. Table 5 presents the main menu screens.

Table 5. Main Menu Title Screens Operating Screen

Truck Locked — Impact Detected — See Supervisor to Unlock

NOTE: Icons for Front and Rear Lights are shown. These are optional features. Password Screen

Fault Detected

MAIN MENU TITLE SCREENS All available menus are grouped by function under the main menu screens, which are also called top-level title menus. When you select a main menu screen, the system then presents submenus, also known as secondlevel menus, that you can cycle through until you find the one you want by pressing the Scroll Back Key ( —) or Scroll Forward Key (— ) on the Display Panel. Two main menu screens, the Operating Screen and the

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Icon Glossary

Table 5. Main Menu Title Screens (Continued)

Activity Log Title Screen

Status Title Screen

Calibration Title Screen

Display Title Screen

Truck Setup Title Screen

Diagnostics Title Screen

Icon Glossary

2200 YRM 1336

SUBMENU ICONS GROUPED BY MENU This topic presents the icons used in submenus in groups, with one table for each title screen of the main menu.

Operating Screen Icons Table 6 shows the icons that appear on the Operating Screen. Normally the icons convey status or operating information such as battery charge level, tire angle, front and rear work light soft keys, and system time. Sometimes icons are displayed to provide critical information, such as warnings. Refer to the Operating Screen topic for more information. NOTE: The icons displayed on the Operating Screen vary from any one time to another, depending on the current operation of the lift truck and other factors. The Battery Discharge Indicator, system time, and direction indicator are always displayed.

Table 6. Operating Screen Icons Icon

Description Hare Performance Mode Icon. Press the 4 key to increase performance. (The soft key to use depends on the currently displayed menu.) Tortoise Performance Mode Icon. Press the 1 key to decrease performance.

Table 6. Operating Screen Icons (Continued) Icon

Description Temperature High Warning Icon

Hydraulic Fluid Level Low Warning Icon. (Displayed only on trucks that have the Hydraulic Fluid Level Monitoring option.) Hydraulic Filter Warning (restriction) Icon. (Displayed only on trucks that have the Hydraulic Filter Monitoring option.) Service Due Soon Warning Icon or Fault

Hazard Flashers Icon. See Table 2 for more information.

Forward Direction Indicator Icon

Battery Discharge Indicator (BDI) Icon Neutral Indicator Icon

Seat Belt Warning Icon Reverse Direction Indicator Icon Brake Fluid Low Warning Icon

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Icon Glossary

Table 6. Operating Screen Icons (Continued) Icon

Description Park Brake On Icon

screen to appear when you turn on the key switch or turn the keyless switch to the On position. See the Password Screen topic for more information.

Table 7. Password Screen Icons Icon

Description Password Lock Icon

Tire Angle Indicator Icon

A field with five blanks appears below the Password Lock Icon. See Figure 2. Rear Work Light Icon. This is an optional feature.

Front Work Light Icon. This is an optional feature.

Activity Log Submenu Icons Table 8 presents the icons that appear on the Activity Log Submenus. These icons provide status information or numeric information. Refer to Activity Log Menu for more information.

Table 8. Activity Log Submenus and Icons Icon

Load Weight In Pounds (lb) Icon

Description

Activity Log Submenus

Load Weight In Kilograms (Kg) Icon

Load Weight Readout (example)

System Time Readout (example)

Password Screen Icons

Operator Checklist Log Submenu

Password Log Submenu

The Password Screen has only one icon, which is shown in Table 7. If the truck is equipped with Operator Passwords enabled, the Password screen is the first

Icon Glossary

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Table 8. Activity Log Submenus and Icons (Continued) Icon

Description

Table 8. Activity Log Submenus and Icons (Continued) Icon

Description

Impact Events Log Submenu

Supervisor Password Type Icon

Empty Log Icon

Service Password Type Icon

Checklist Failed Icon

Soft Impact Type Icon

Checklist Passed Icon

Hard Impact Type Icon

Password Lock Icon

Calibration Submenu Icons

*****

Hidden or "no password" Field Log Entry Icon Clock Icon for occurrence date

Table 9 presents the icons that appear on the Calibration Submenus. See Calibration Menu for more information.

Table 9. Calibration Submenus and Icons Icon

Description

Load Weight Display Submenu

Hourglass Icon for system time

Operator Password Type Icon

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Icon Glossary

Table 9. Calibration Submenus and Icons (Continued) Icon

Description

Table 9. Calibration Submenus and Icons (Continued) Icon

Description

"Position Empty Forks To Load Weight Height" Prompt Icon

Return to Set Tilt (RTST) Set Point Prompt Icon

"Enter Known Load Weight" Prompt Icon

This icon points to the * key and is used for RTST calibration in this submenu.

"Position Load Weight To Height" Prompt Icon

Valve Threshold Submenu

"Known Load Weight Value (lb)" Prompt Icon

"Known Load Weight Value (Kg)" Prompt Icon

This icon points to the * key (the Enter soft key) and is used for load weight calibration in this submenu. Return to Set Tilt Stop Point Submenu

Valve Threshold Function 1 "A" Direction Prompt Icon

Valve Threshold Function 1 "B" Direction Prompt Icon

Valve Threshold Function 2 "A" Direction Prompt Icon

Valve Threshold Function 2 "B" Direction Prompt Icon

Icon Glossary

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Table 9. Calibration Submenus and Icons (Continued) Icon

Description

Table 9. Calibration Submenus and Icons (Continued) Icon

Description

Valve Threshold Function 3 "A" Direction Prompt Icon

Center Steering Wheel Prompt Icon

Valve Threshold Function 3 "B" Direction Prompt Icon

This icon points to the * key and is used for steering wheel center point calibration in this submenu.

Valve Threshold Function 4 "A" Direction Prompt Icon

Steer Axle Position Submenu

Valve Threshold Function 4 "B" Direction Prompt Icon

This icon points to the * key and is used for valve calibration in this submenu. Steering Wheel Knob Center Point Submenu

Steering Wheel Full Left Prompt Icon

Steering Wheel Full Right Prompt Icon

This icon points to the * key and is used for steer axle position calibration in this submenu.

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Icon Glossary

Table 9. Calibration Submenus and Icons (Continued)

Table 10. Display Submenus and Icons Icon

Icon

Description

Set Date and Time Format Submenu

Manual Hydraulics Submenu

Clock Icon for setting time Main Manual Hydraulic End Point Calibration Prompt Icon Calendar Icon for setting date This icon points to the * key and is used for manual hydraulic end point calibration in this submenu.

24-Hour Clock Icon

Display Submenu Icons Table 10 presents the icons that appear on the Display Submenus. Refer to Display Menu for more information.

12-Hour Clock Icon

DD/MM/YY (Europe) Date Format Icon

MM/DD/YY (USA) Date Format Icon

Icon Glossary

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Table 10. Display Submenus and Icons (Continued) Icon

Description YY/MM/DD (ISO 8601) Date Format Icon

Set Daylight Savings Submenu

Table 10. Display Submenus and Icons (Continued) Icon

Description First Sunday Icon

Last Sunday Icon

First Friday Icon

Last Friday Icon

Daylight Savings Adjustment Enable Icon

NOTE: Not all icons for setting daylight savings time are shown. The four icons above serve as examples of the 14 variations. Set Time and Date Submenu

Daylight Savings Start Month Indicator Icon

Daylight Savings Start Day Indicator Icon

Daylight Savings End Month Indicator Icon

Daylight Savings End Day Indicator Icon

Clock Icon for setting time

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Icon Glossary

Table 10. Display Submenus and Icons (Continued) Icon

Description Calendar Icon for setting date

Table 11. Status Submenus and Icons Icon

Description

Vehicle System Manager (VSM) Version Submenu

Set Units Submenu

Hardware Version Indicator Icon

Set Units Icon

Imperial Units Indicator Icon

Software Version Indicator Icon

Display Version menu

Metric Units Indicator Icon

Status Submenu Icons Table 11 presents the icons that appear on the Status Submenus. See Status Menu for more information. Hardware Version Indicator Icon

Icon Glossary

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Table 11. Status Submenus and Icons (Continued) Icon

Description Software Version Indicator Icon

Truck Serial Number Submenu

Table 11. Status Submenus and Icons (Continued) Icon

Description Traction Hour Meter Icon

Pump Hour Meter Icon

Secure Hour Meter Indicator Icon

E-Hyd Controller Version Submenu

Truck Serial Number Symbol Icon

Hour Meters Submenu

Hardware Version Indicator Icon

Software Version Indicator Icon

Truck Hour Meter Icon

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Icon Glossary

Table 11. Status Submenus and Icons (Continued) Icon

Description

Pump Motor Controller Version Submenu

Table 11. Status Submenus and Icons (Continued) Icon

Description Hardware Version Indicator Icon

Software Version Indicator Icon

Traction Controller 2 Version Submenu

Hardware Version Indicator Icon

Software Version Indicator Icon

Traction Controller 1 Version Submenu

Hardware Version Indicator Icon

Software Version Indicator Icon

Icon Glossary

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Table 11. Status Submenus and Icons (Continued) Icon

Description

Table 11. Status Submenus and Icons (Continued) Icon

Description Hardware Version Indicator Icon

Light Controller Version Submenu

Software Version Indicator Icon

Truck Setup Submenu Icons Table 12 presents the icons that appear on the Truck Setup Submenus. See Truck Setup Menu for more information Hardware Version Indicator Icon

Table 12. Truck Setup Submenu Icons Icon

Description

Add/Remove Password Submenu Software Version Indicator Icon

Impact Sensor Version Submenu

Password Icon

Null Symbol Icon

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Icon Glossary

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Operator Password Type Icon

Automatic Deceleration Rate Indicator Icon

Supervisor Password Type Icon

Deceleration Type Indicator Icon

Service Password Type Icon

Pedal Up Setting Icon. This setting lets the lift truck coast until the pedal is fully released.

Trash Can Icon

Proportional Setting Icon. With this setting, the lift truck decelerates in proportion to how far the pedal is released in relation to the current traction speed.

Hare (increase performance) Icon

Supervisor Icon

Motor Braking Submenu Battery Setup Submenu

Regenerative Braking Indicator Icon

Icon Glossary

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Table 12. Truck Setup Submenu Icons (Continued) Icon

Description Operating Voltage Icon

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Acceleration Rates Submenu Visible to Service Technicians only.

Battery Capacity Icon

Full Cell Voltage Icon

Empty Cell Voltage Icon Low Speed Acceleration Rate Setting Icon BDI Adjustment Submenu High Speed Acceleration Rate Setting Icon

Performance Type Indicator Icon

Standard Performance Rate Icon

Parasitic Current Icon Extended Shift Performance Rate Icon

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Icon Glossary

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Hour Meter Initialization Submenu Visible to Service Technicians only.

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Impact Monitor Shutdown Submenu

Truck Hour Meter Icon

Impact Shutdown Delay Icon

Traction Hour Meter Icon

Impact Shutdown Type Icon

Impact Detection Icon Pump Hour Meter Icon

ON Icon

OFF Icon

Disable Traction Icon

Icon Glossary

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Table 12. Truck Setup Submenu Icons (Continued) Icon

Description Disable All Icon

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description Check Hydraulics Icon

Operator Checklist Submenu Check Mast Icon

Check for Leaks Icon

Check Operator Restraint Icon

NOTE: The icons displayed when using this submenu correspond to the submenu icons for the various functions. Up to 30 checklist items can be enabled for the Operator Checklist.

Check Pedal Movement Icon

Check Park Brake Icon Check Service Brake Icon

Check Fuses Icon

Check Horn Icon

Check Hoses Icon

Press the * key (Enter Key) below this icon to indicate proper operation of the current checklist item. Press the # key below this icon to indicate improper operation of the current checklist item (to indicate a problem with it).

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Icon Glossary

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Minimum Pump Standby Submenu

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description Interval Month Setting Icon

Interval Hourmeter Setting Icon

Derated Traction Speed Icon

Traction Speed Limit Submenu

Minimum Standby Pump Flow Rate Icon

Scheduled Maintenance Reminder Submenu

Forward MPH Icon

Reverse MPH Icon

Scheduled Maintenance Reminder, enabled (ON) Forward km/h Icon

Scheduled Maintenance Reminder, disabled (OFF)

Icon Glossary

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Table 12. Truck Setup Submenu Icons (Continued) Icon

Description Reverse km/h Icon

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Auto Power-Off Time Delay Submenu

Return to Set Tilt (RTST) Submenu

Auto Power-Off Time Delay Indicator Icon

Return To Set Tilt Delay Icon

Impact Monitor Settings Submenu

Tilt Forward Only Icon

Tilt Both Ways Icon

Infinity Symbol Icon Soft Impact Force Icon

Soft Impact Time Icon

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Icon Glossary

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description Hard Impact Force Icon

Hard Impact Time Icon

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description Motion Alarm Icon

Lower Adjustments Submenu Visible to service technicians only.

Motion Alarm Submenu

Motion Alarm Indicator Icon

Motion Alarm Indicator Disabled Icon. The X over the icon means the motion alarm is deactivated (turned off).

Ramp Up Time Indicator Icon. Ramp rate can be from 0 to 2 seconds in 0.1 second increments. Ramp Down Time Indicator Icon. Ramp rate can be from 0 to 2 seconds in 0.1 second increments. Lower Max Speed Indicator Icon

Icon Glossary

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Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Lift Adjustments Submenu Visible to service technicians only.

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Tilt Forward Adjustments Submenu Visible to service technicians only.

Ramp Up Time Indicator Icon. Ramp rate can be from 0 to 2 seconds in 0.1 second increments.

Ramp Down Time Indicator Icon. Ramp rate can be from 0 to 2 seconds in 0.1 second increments.

Lift Max Speed Indicator Icon

Tilt Forward Max Speed Indicator Icon

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Icon Glossary

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Tilt Back Adjustments Submenu Visible to service technicians only.

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Aux 1A Adjustments Submenu Visible to service technicians only.

Ramp Up Time Indicator Icon. Ramp rate can be from 0 to 2 seconds in 0.1 second increments.

Ramp Down Time Indicator Icon. Ramp rate can be from 0 to 2 seconds in 0.1 second increments.

Tilt Back Max Speed Indicator Icon

Aux 1A Max Speed Indicator Icon

Icon Glossary

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Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Aux 1B Adjustments Submenu Visible to service technicians only.

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Aux 2A Adjustments Submenu Visible to service technicians only.

Ramp Up Time Indicator Icon. Ramp rate can be from 0 to 2 seconds in 0.1 second increments.

Ramp Down Time Indicator Icon. Ramp rate can be from 0 to 2 seconds in 0.1 second increments.

Aux 1B Max Speed Indicator Icon

Aux 2A Max Speed Indicator Icon

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Icon Glossary

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Aux 2B Adjustments Submenu Visible to service technicians only.

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Optional Hydraulics Functions Submenu

Slip Sheet Control Icon

Dual Function Control Icon

Rear Lights Submenu Visible to Service Technicians only. The operator can use this menu to turn on or turn off brake, tail, and backup lamps.

Icon Glossary

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Table 12. Truck Setup Submenu Icons (Continued) Icon

Description Brake Lamp Indicator Icon

Diagnostics Submenu Icons Table 13 presents the icons that appear on the Diagnostics Submenus. See Diagnostics Menu for more information.

Table 13. Diagnostic Submenu Icons Icon

Brake Lamp Status Icon, enabled (ON)

Description

Fault Code Log Submenu

Brake Lamp Status Icon, disabled (OFF)

Restore Defaults Submenu

Up Arrow soft key

Down Arrow soft key

Hour Meter Icon

Restore Defaults Icon Trash Can Icon

This icon points to the * key and is used for restoring defaults in this submenu.

Traction 1 Icon

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Icon Glossary

Table 13. Diagnostic Submenu Icons (Continued) Icon

Description Traction 2 Icon

Hour Meter / Time Stamp of first occurrence

Table 13. Diagnostic Submenu Icons (Continued) Icon

Description View Previous Device Fault Log Icon

Speedometer Submenu

Hour Meter / Time Stamp of last occurrence

Hydraulic Pump Icon

Light Controller Icon

MPH Icon. Indicates reading is in miles per hour.

E-Hydraulic Valves Icon

km/h Icon. Indicates reading is in kilometers per hour.

Impact Icon

Accelerator Pedal Position (APP) Icon

Display Icon

APP Sensor Voltage 1 Indicator Icon

View Next Device Fault Log Icon

APP Sensor Voltage 2 Indicator Icon

Icon Glossary

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Table 13. Diagnostic Submenu Icons (Continued) Icon

Description

Table 13. Diagnostic Submenu Icons (Continued) Icon

Forklift Truck Enabled Icon

Description Direction Indicator Icon. Filled down arrow means reverse direction is selected.

Forklift Truck Disabled Icon indicates that traction and hydraulics are disabled.

Direction Indicator Icon. Unfilled up arrow means forward direction is not selected. Direction Indicator Icon. Unfilled N indicates truck is not in neutral.

Direction Select Submenu

Direction Indicator Icon. Unfilled down arrow means reverse direction is not selected. Park Brake On Icon.

Traction Motor 1 Status Submenu Forklift Truck Enabled Icon

Forklift Truck Disabled Icon indicates that traction and hydraulics are disabled.

Direction Indicator Icon. Filled up arrow means forward direction is selected. Direction Indicator Icon. Filled N indicates truck is in neutral.

∞C

Temperature in degrees Celsius

∞F

Temperature in degrees Fahrenheit

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Icon Glossary

Table 13. Diagnostic Submenu Icons (Continued) Icon

Description Forklift Truck Enabled Icon

Table 13. Diagnostic Submenu Icons (Continued) Icon

Description

Traction Motor 2 Status Submenu

Forklift Truck Disabled Icon

RPM Indicator Icon

Motor Temperature Indicator Icon

The icons on the Traction Motor 2 Status submenu are the same as on the Traction Motor 1 Status submenu. Occupancy Sensor Submenu

Motor Controller Temperature Indicator Icon

Motor Controller Voltage Indicator Icon

Motor RMS Current Indicator Icon. RMS = Root Mean Squared

Forklift Truck Enabled Icon

Forklift Truck Disabled Icon

Icon Glossary

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Table 13. Diagnostic Submenu Icons (Continued) Icon

Description

Table 13. Diagnostic Submenu Icons (Continued) Icon

Occupancy Sensed, Seat Icon. The current voltage reading from the seat occupancy sensor is displayed to the right of this icon. This icon is in the lower right corner of the screen. If seat belt monitoring is in effect and no occupancy is detected, the seat belt icon has an X overlay icon over it.

Description Brake Fluid Sensor Icon. Measures brake fluid voltage.

Brake Pressure Icon. Brake pressure sensor reports current brake voltage which is displayed in Volts. Pump Status Submenu

Brake System Sensors Submenu

∞C

Temperature in degrees Celsius

∞F

Temperature in degrees Fahrenheit

Forklift Truck Enabled Icon

Forklift Truck Disabled Icon

Park Brake Indicator Icon

RPM Indicator Icon

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Icon Glossary

Table 13. Diagnostic Submenu Icons (Continued) Icon

Description Motor Temperature Indicator Icon

Motor Controller Temperature Indicator Icon

Motor Controller Voltage Indicator Icon

Motor RMS Current Indicator Icon. (RMS = Root Mean Square)

Table 13. Diagnostic Submenu Icons (Continued) Icon

Description Forklift Truck Disabled Icon

Hydraulic Function 1 Input Indicator Icon

Hydraulic Function 2 Input Indicator Icon

Hydraulic Function 3 Input Indicator Icon

Hydraulic Control Inputs Submenu Hydraulic Function 4 Input Indicator Icon

Button Pressed Icon for Functions 1-5. This icon shows the status of the function. (This icon is not displayed on trucks not equipped with Hydraulic functions.)

Forklift Truck Enabled Icon

Button Released Icon for Functions 1-5. This icon shows the status of the function. (This icon is not displayed on trucks not equipped with Hydraulic functions.)

Icon Glossary

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Table 13. Diagnostic Submenu Icons (Continued) Icon

Description

E-Hydraulic Valves Submenu

Table 13. Diagnostic Submenu Icons (Continued) Icon

Description Hydraulic Function 4 Output Indicator Icon

Engaged Icon for Functions 1-5. This icon means the auxiliary solenoid is being driven. Disengaged Icon for Functions 1-5. This icon means the auxiliary solenoid is not being driven. Forklift Truck Icon

Hydraulic Sensors Submenu

Forklift Truck Disabled Icon

Hydraulic Function Icon

Hydraulic Function 1 Output Indicator Icon

Hydraulic Function 2 Output Indicator Icon

Hydraulic Function 3 Output Indicator Icon

Forklift Truck Enabled Icon

Forklift Truck Disabled Icon

Hydraulic Temperature Indicator Icon

2200 YRM 1336

Icon Glossary

Table 13. Diagnostic Submenu Icons (Continued) Icon

Description

Table 13. Diagnostic Submenu Icons (Continued) Icon

Description

Tilt Sensor Indicator Icon

Battery Voltage Indicator Icon

Height Sensor Indicator Icon

5 V Supply Voltage Indicator Icon

Load Weight Sensor Indicator Icon

12 V Supply Voltage Indicator Icon

System Voltages Submenu

Steering Position Sensors Submenu

Forklift Truck Enabled Icon

Forklift Truck Disabled Icon

Operating Screen

2200 YRM 1336

Table 13. Diagnostic Submenu Icons (Continued) Icon

Description Steering Wheel Position Sensor Icon

Axle Position Sensor Icon. (Visible only on trucks equipped with the dual traction controllers or the Steer Synchronization feature.)

Operating Screen INTRODUCTION The Operating Screen, shown in Figure 9, is located on the Display Panel along with the numeric keys and control keys. At key-on, the Password Screen is the first screen displayed unless Operator Passwords are disabled. After a valid password is entered, the Operating Screen appears by default. The Operating Screen uses small graphic images, called icons, to provide continuous feedback to the lift truck operator. This feedback includes performance settings, status and warning messages, and essential truck operating information. The

Operating Screen is active at all times during normal lift truck operation. NOTE: Icons for the Front and Rear Work Lights are shown. These are optional features. The icons, indicators, and numbers on the Operating Screen are explained in the topics that follow.

Figure 9. Operating Screen

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PERFORMANCE MODE CONTROLS The Performance Mode controls are shown in Figure 10.

Operating Screen • MODE 3 - Top speed is the same as Mode 4. Acceleration is 80 percent of Mode 4. • MODE 2 - Top speed is 80 percent of Mode 4. Acceleration is 70 percent of Mode 4. • MODE 1 - Top speed is 60 percent of Mode 4. Acceleration is 60 percent of Mode 4. Pressing the "Hare" soft key, 4, increases the current mode and pressing the "Tortoise" soft key, 1, decreases the current mode, assuming performance mode change is available to the current operator. The performance mode can be changed only when both the hydraulic and direction controls are in Neutral and the truck is stopped. If a performance mode change is attempted at a time when either of these conditions is not met, the newly selected mode will flash and the change will not occur until the necessary conditions are met.

STATUS AND WARNING ICONS When the truck is powered On, the system continuously monitors a number of parameters and displays up to six icons to provide status information and warnings to the operator, as shown in Figure 11. Also see the Operating Screen Icons topic. 1. PERFORMANCE MODE INDICATOR INCREASE 2. PERFORMANCE MODE SOFT KEY - INCREASE 3. PERFORMANCE MODE SOFT KEY - DECREASE 4. PERFORMANCE MODE INDICATOR DECREASE 5. CURRENT PERFORMANCE MODE

Figure 10. Performance Mode Controls The current performance mode is shown on the Operating Screen. There are four available performance modes, numbered 1, 2, 3, and 4. Performance mode 4 provides the maximum performance. If passwords are enabled, the last active performance mode on the truck is displayed on the screen when the truck is powered On, unless the current operator has been assigned a lower available performance mode. The maximum performance mode allowed for each operator is set by the Supervisor or Service Technician during the Add/Remove Password section of Truck Setup. See the Password Screen topic for more information. Depending on the maximum performance mode allowed, it may be possible for the operator to use the Performance Mode soft keys on the Display Panel to change the current performance mode. • MODE 4 - This is the highest performance mode. Other modes are a lower percentage of Mode 4.

1. 2. 3. 4. 5. 6.

SERVICE DUE MOTOR TEMPERATURE HIGH BRAKE FLUID LOW WARNING SEAT BELT WARNING DIRECTION / PARK BRAKE INDICATORS TIRE ANGLE

Figure 11. Status and Warning Icons

Operating Screen NOTE: Icons for Front and Rear Lights are shown. These are optional features. Depending on conditions, the following icons can appear in this area (see the Operating Screen Icons topic): • Wrench Icon • Temperature High Icon • Brake Fluid Low Icon • Hydraulic Fluid Level Icon • Hydraulic Filter Icon • Fasten Seat Belt Icon

2200 YRM 1336 The BDI is located in the top center of the Operating Screen, as shown in Figure 12. The BDI is displayed as a five-segment horizontal bar and it has a battery icon on its left side.

When the wrench icon is continuously On, it means that scheduled maintenance is due. When it is flashing, it indicates that an active fault has been detected by the system. The wrench icon appears in the bottom location of the status/warning icon area when it is displayed. It has the lowest priority of the three icons, wrench, hydraulic filter, or hydraulic fluid level, that can be displayed in this location. The hydraulic filter icon shows in the same location, in place of the wrench icon, if a hydraulic filter restriction is detected. It has the second highest priority of the three icons that can be displayed in this location. The hydraulic fluid level icon shows in the same location, in place of the wrench icon or the hydraulic filter icon, if a low level is detected in the hydraulic fluid reservoir. It has the highest priority of the three icons that can be displayed in this location. The motor temperature high icon is displayed if a high motor temperature is detected, meaning that the temperature of one of the motors or motor controllers has gone above the defined threshold temperature. The brake fluid low icon is displayed if a low level is detected in the brake fluid reservoir. The fasten seat belt icon is displayed for the first ten seconds after the truck is powered On, or for ten seconds after the seat is reoccupied after the operator leaves the seat for ten seconds or more. This warning is based on seat occupancy, not the seat belt connection itself. If the operator selects a screen other than the Operating Screen before the ten seconds are up, the fasten seat belt icon will no longer be displayed.

BATTERY DISCHARGE INDICATOR NOTE: Because the Battery Discharge Indicator (BDI) algorithm determines the Battery State Of Charge (BSOC) based on information gathered during operation it may take several seconds for the BDI to show the correct BSOC for the battery.

1. BATTERY DISCHARGE INDICATOR

Figure 12. Battery Discharge Indicator The system continuously monitors the truck’s current BSOC, and this is indicated on the BDI by the number of filled bar segments. Table 14 shows the battery’s state of charge in percentages, compared to the number of filled segments.

Table 14. BSOC in Relation to BDI BSOC Charge Remaining (%)

Number of Filled Segments

76% or more

Five (5)

50% to 75%

Four (4)

35% to 50%

Three (3)

25% to 35%

Two (2)

21% to 25%

One (1) segment, plus flashing plus low battery alarm

0 to 20%

Zero (0) segments, plus flashing plus a second low battery alarm

The BDI is always visible when the Operating Screen is active. All five of the BDI segments are filled (illuminated) when the BSOC is at 75% or higher. As the BSOC goes down, the segments on the right change to just outlines until the BSOC reaches 25%, which is indicated when only the leftmost segment, next to the battery icon, is filled.

2200 YRM 1336 If the battery charge drops below 25%, the "low battery alarm" sounds and the BDI begins flashing. The "low battery alarm" also sounds if the lift truck is turned On when the BSOC is below 25%. If the BSOC drops to 20%, the leftmost segment changes to an outline and a second "low battery alarm" sounds. The lift truck will be subjected to operating and performance limitations if the BSOC drops below 20%.

DIRECTION AND PARKING BRAKE INDICATORS These indicators are displayed in the center of the Operating Screen, as shown in Figure 11. • An up-arrow indicates the truck will move forward if the accelerator is pressed. • A down-arrow indicates the truck will move backward (reverse) if the accelerator is pressed. • A solid "N" indicates the truck will not move if the accelerator is pressed, though it can still roll if the service brake is released. • The parking brake icon is a "P" with a circle around it to represent a wheel and arcs around the circle that represent brakes. When this icon is displayed, it indicates the truck parking brake is applied and the truck will not move if the accelerator is pressed.

HAZARD FLASHERS AND LIGHTING CONTROLS If the lift truck is equipped with CAN controlled hazard flashers and lighting controls, the icons that indicate the status of the lift truck’s hazard flashers and lights are displayed on the Operating Screen. The soft keys the operator can use to control these lights are located near the Operating Screen. • The Front Work Light Icon, on the lower right of the screen, is always visible. The operator can turn the front lights On and Off by pressing the 2 soft key. • The Rear Work Light Icon, on the upper right of the screen, is always visible. The operator can turn the rear lights On and Off by pressing the 3 soft key. • The Hazard Flashers Icon, a triangle on the lower left of the screen, is always visible if the lift truck

Operating Screen is equipped with hazard flashers. The operator can press the # soft key to toggle the truck’s hazard flashers Off and On.

TIRE ANGLE INDICATOR The Tire Angle indicator is displayed in the lower center of the Operating Screen, as shown in Figure 11. The purpose of this indicator is to show the operator the current steer angle (the direction of the tires that steer the truck). This informs the operator which way the truck will move if the accelerator pedal is pressed, given the current tire angle. The Tire Angle indicator shows the steering angle to the nearest 22.5° from full left, to full right.

SYSTEM TIME The System Time for the lift truck, shown as 12:34 in Figure 11, appears in the lower right corner of the Operating Screen. System time can be reset by a Supervisor or Service Technician using the procedures described in Setup Display. If the Clock Hour Format is set to a 12-hour clock, the time numbers will be followed by an "A" (AM) or a "P" (PM) as appropriate. Otherwise, the system time uses a 24-hour clock.

LOAD WEIGHT INDICATOR The Load Weight indicator for the lift truck, shown as 99999 beside the Load Weight Icon in Figure 11, appears at the midpoint of the right side of the Operating Screen. If the lift truck supports the Load Weight feature, the Operating Screen will display the load weight during any mast hydraulic command and for five seconds afterwards. The Load Weight Icon indicates whether Lb (pound) or Kg (kilogram) units are being used. Use the procedures described in the Set Units Menu topic in the Display Menu section to set the load units for this lift truck. Use the procedures in the Load Weight Display topic in the Calibration Menu section to calibrate the load weight for this lift truck.

System Off/Alert Screens

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System Off/Alert Screens INTRODUCTION

Pump Hour Meter Icon

Several screens appear only briefly on the Operating Screen. These include the System Off Screen and Alert Screens. The purpose of the System Off Screen is to supply brief status information as the system is powered off. Alert Screens appear momentarily to attract attention. The topics that follow provide more information about these types of screens.

Secure Hour Meter Indicator Icon

SYSTEM OFF SCREEN When the lift truck power is first turned off, the System Off Screen is displayed for five seconds. The system will also display this screen for five seconds if the Scroll Forward Key (— ) is pressed while the truck is powered off. Figure 13 shows the System Off Screen.

• The Truck Hour Meter shows the total time the operator has been in the seat with the key or keyless switch in the ON position. • The Pump Hour Meter shows the total time the hydraulic pump has been running. • The Traction Hour Meter shows the total time on traction motor while the truck has been moving. • The Secure Hour Meter shows the total time the operator has been in the seat with the key or keyless switch in the ON position and can not be reset. • The time shown on the meters is displayed in hours, but the system stores the values to the nearest 0.1 hour. These meters can be examined more closely or reset by a Service Technician using the procedures described in the Status Menu section.

ALERT SCREENS

1. TRUCK HOUR METER 2. PUMP HOUR METER

Figure 13. System Off Screen The System Off Screen displays the 2 of the 4 possible hour meters. By default the Truck Hour Meter is in the upper right corner of the Operating Screen and the Hydraulic Pump Hour Meter is in the lower right. Optionally the System Off screen can show any one of the following 4 hour meters. Truck Hour Meter Icon

Traction Hour Meter Icon

There are two types of alert screens, Fault Screens (failure indication screens) and Interlock Notification Screens. Both types of alert screens are temporary in nature because the system immediately restores the original screen after a key press or other action removes the problem. When the system detects an active failure, the display changes to a Fault Screen which flashes a fault code, the wrench icon, and other icons to indicate the problem, similar to the example shown in Figure 14. As it is displayed, the alert screen flashes to draw the user’s attention. Pressing either the Scroll Back Key ( —) or Scroll Forward Key (— ) after the alert screen appears causes the system to return to the last screen displayed.

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Password Screen to apply the accelerator pedal, the system will switch from the Operating Screen to an alert screen showing the seatbelt icon, as shown in Figure 15. In this example, if the operator releases the accelerator pedal, the system will change the screen back to the Operating Screen. Alternatively, the operator can press either the Scroll Back Key or the Scroll Forward Key to go to a top-level menu but the accelerator pedal input will still be unavailable because the interlock condition has not been met.

1. EXAMPLE FAULT CODE 2. WRENCH ICON 3. ICONS OF DISABLED/PERFORMANCE LIMITED FUNCTIONS

Figure 14. Example Fault Screen The Interlock Notification Screen appears whenever the operator tries to apply an input that is not available because one or more interlock conditions have not been met. For example, if the operator is not seated and tries

Figure 15. Example Interlock Alert Screen

Password Screen INTRODUCTION The Password Screen is a main menu (top-level menu) that is visible at Service Technician, Supervisor, and Operator password access levels. When the key switch or keyless switch is turned on, the Password Screen is the first screen displayed (unless Operator Passwords are deactivated). To access this menu at another time, cycle through the main title screens by pressing the Scroll Back Key ( —) or Scroll Forward Key (— ) until the Password Screen is displayed, as shown in Figure 16. Next, press the Enter Key (*) to enter the Password Screen. The Password Screen also appears when an operator first starts to use a lift truck, and it also appears when a defined time limit is exceeded under certain conditions. There are no submenus below the Password Screen, but there are submenus under two other top-level menus that involve passwords: • The Add/Remove Password submenu under the Truck Setup menu

• The Password Log submenu under the Activity Log menu Explanations of the Password Screen and the Add/Remove Password submenu (accessed through the Truck Setup menu) follow.

PASSWORD SCREEN NOTE: Operator passwords are used only on trucks equipped with software enable option. As already stated, the Password Screen is the first screen to appear when the key switch or keyless switch is turned on (unless Operator Passwords are deactivated). The Password Screen is visible at all password access levels. Figure 16 shows the initial Password Screen that is displayed after power On. A line of five blanks below the Password Icon serves as the password entry field.

Password Screen

2200 YRM 1336 is displayed for up to five seconds or until the user starts to enter another password, as shown in Figure 17.

Figure 16. Initial Password Screen NOTE: A valid password must be a five digit number composed of only the numbers 0, 1, 2, 3, 4, 5, 6, 7, 8,and 9 such as 37524 or 22954. If invalid keys (i.e., #, or *) are pressed they will be ignored. If more than five valid numbers are pressed for the password, only the last five are accepted.

Service Technician Password Setup Service Technician-level password access is required to add, delete, or edit Service Level Passwords and to do the first installation of a Supervisor-level password. Anyone with Service Technician-level access can add, delete, or edit Operator or Supervisor passwords. NOTE: A Service Technician-level password is required to input an initial Supervisor password for the lift truck. Once an initial Supervisor password is installed, that Supervisor-level password access can be used to add, delete, or edit additional Supervisor passwords as well as Operator passwords. Perform the following steps to set up a password: 1. Using keys 0-9, enter a valid password. 2. Press the Enter Key to input the password to the system. Once you press the Enter Key, the system uses the five most recently entered valid numbers to compare with the currently stored password list. 3. If the password entered does not match any currently stored password, an invalid password screen

Figure 17. Invalid Password Screen 4. Once the system accepts the entered password, the operator is granted access to the menus associated with that password (i.e., menus displayed at Operator-level, Supervisor-level, or Service Technician-level access). NOTE: In certain circumstances a default operator password of 11111 will be in the currently stored password list. NOTE: If there are no Service Technician-level passwords in the currently stored password list, the factory default Service Technician-level password, 55555, can be used to gain access to the system. Use the factory default Service Technician-level password, 55555, when installing the lift truck at the customer location to set up customer passwords. When initial installation is complete, choose a new Service Technician-level password. However, once a new Service Technician-level password has been assigned, 55555 is no longer a usable password and it cannot be assigned as a password through the screen menu or by using the PC Service Tool. (If all Service Technician-level passwords are deleted, the system again accepts the 55555 default password.) If there is only one Service Technician password and it is lost, the password can be reset using the PC Service Tool.

2200 YRM 1336

Password Screen

ADDING/REMOVING/CHANGING PASSWORDS The Add/Remove Password submenu is accessible through the Truck Setup Menu and it is visible at Service Technician and Supervisor password access levels. This menu allows a Service Technician or a Supervisor to add, remove, or change passwords whose level is

equal to or lower than their own password level. This means a Service Technician can modify the passwords assigned to Operators, Supervisors, and other Service Technicians, while a Supervisor can modify passwords assigned to Operators or other Supervisors. Up to 250 passwords can be assigned for use. Table 15 shows the process for adding a new password.

Table 15. Add Password

ó Scroll Keys

Truck Setup Top-level menu ↑ Up Arrow/ Down Arrow Soft Key ↓

Truck Setup Add/Remove Password Submenu

Press Enter Key (*)

The initial Password screen will display

Enter new password using keys 0 through 9

Press Enter Key (*)

First Press the Up Arrow or Down Arrow Soft Key to select password access level

Operator, Supervisor, or Service Technician password access level

Then Press "Hare" (4) soft key to cycle through performance modes

Available performance modes are minimum (1) to maximum (4, the default)

Press the Enter Key) to add this password

Password Screen Figure 18 shows the Change/Remove password screen. The Up Arrow/Down Arrow soft keys (i.e., 2 and 3) cycle between the privilege level(s) associated with this password. You can use the Hare soft key (#) to cycle through the available performance modes for this password. Press the Trash Can soft key (4) to remove this password from the current passwords.

2200 YRM 1336

Legend for Figure 18 1. ICON FOR TYPE OF PASSWORD ENTERED (OPERATOR/SUPERVISOR/SERVICE TECHNICIAN) 2. UP ARROW SOFT KEY ICON 3. DOWN ARROW SOFT KEY ICON 4. "TRASH CAN" SOFT KEY ICON 5. CURRENT PERFORMANCE MODE 6. "HARE" SOFT KEY ICON 7. CURRENT PASSWORD ICON AND FIELD In order to remove an individual password or modify the privileges associated with it, you need to know the password number. In addition, you must have a privilege level equal to or greater than the privilege level of the password being modified. This means a Service Technician can modify all passwords, but a Supervisor can only modify the passwords of Operators and other Supervisors. Table 16 shows the process for changing or removing an existing password for the lift truck.

PASSWORD LOG

Figure 18. Change/Remove Password Screen

The Password Log submenu is accessible through the Activity Log Title menu. See the next section, Activity Log Menu, for more information. This menu allows a Service Technician or a Supervisor to view the last 250 valid passwords entered into the system and the password access level (i.e., Operator, Supervisor, or Service Technician) associated with each password.

2200 YRM 1336

Password Screen

Table 16. Change or Remove Password

ó Scroll Keys

Truck Setup main menu (Top-level menu) ↑ Up Arrow/ Down Arrow Soft Key ↓

Truck Setup Add/Remove Password submenu

Press Enter Key (*)

The initial Password screen will display

Enter known password

Press Enter Key (*)

The Modify Password screen displays

To change a password: Press the Up Arrow or Down Arrow Soft Key to select password access level

Operator, Supervisor, or Service Technician Icon displays

Press "Hare" (4) soft key to cycle through performance modes

Available performance modes are minimum (1) to maximum (4, the default)

Press Trash Can (#) soft key to remove this password from the list

Press the * key to return to the initial Password screen

Press the Enter Key to update this password

To remove a password: Press either Scroll Key ( ó ó ) to exit

Activity Log Menu

2200 YRM 1336

Activity Log Menu INTRODUCTION The Activity Log Menu is a main menu (top-level menu) that is visible at Service Technician and Supervisor password access levels. To access this menu, cycle through the main menu title screens by pressing the Scroll Back Key ( —) or Scroll Forward Key (— ) until the Activity Log Title Screen is displayed, as shown in Figure 19.

The following sections describe the Activity Log submenus.

Press the Enter Key (*) to enter the Activity Log Menu. Three submenus are available under this menu as shown in Figure 20. The first of the three submenus provided under the Activity Log menu, the Operator Checklist Log, appears on the Operating Screen. See Figure 21. You can enter the Operator Checklist Log submenu by pressing the Enter Key. To access the Password Log menu or the Impact Events Log menu, press the Scroll Back Key or Scroll Forward Key and then press the Enter Key.

1. OPERATOR CHECKLIST LOG

Figure 19. Activity Log Title Screen

2. PASSWORD LOG

3. IMPACT EVENTS LOG

Figure 20. Activity Log Submenus

OPERATOR CHECKLIST LOG

Figure 21 shows the title screen for this menu.

This submenu is visible at Service Technician and Supervisor password access levels. This second-level menu allows a Service Technician or a Supervisor to view the 60 most recent checklist events, where an event is defined as: • Each failed checklist item, or • A completely successful pass through the full checklist.

Pressing the Scroll Back Key or Scroll Forward Key while anywhere in this submenu returns the Activity Log main menu title screen to the Operating Screen.

2200 YRM 1336

Figure 21. Operator Checklist Log Menu Figure 22 shows an example Operator Checklist Log screen and indicates the available controls.

Activity Log Menu

1. 2. 3. 4. 5. 6. 7. 8. 9.

PASSWORD VALUE AT LOG OCCURRENCE TYPE OF ENTRY (PASS/FAIL) UP ARROW SOFT KEY ICON CURRENT LOG ENTRY (OR "EMPTY" SYMBOL) DOWN ARROW SOFT KEY ICON CHECKLIST ITEM THAT FAILED TRASH CAN SOFT KEY (USED TO EMPTY LOG) TRACTION HOURS AT LOG OCCURRENCE SYSTEM DATE AT LOG OCCURRENCE

Figure 23. Failed Checklist Log Entry If there are no log entries or the final log entry has been scrolled past, an empty log screen is displayed, as shown in Figure 24.

1. 2. 3. 4. 5. 6. 7. 8. 9.

PASSWORD VALUE AT LOG OCCURRENCE TYPE OF ENTRY (PASS/FAIL) UP ARROW SOFT KEY ICON CURRENT LOG ENTRY (OR "EMPTY" SYMBOL) DOWN ARROW SOFT KEY ICON CHECKLIST ITEM THAT PASSED TRASH CAN SOFT KEY (USED TO EMPTY LOG) TRACTION HOURS AT LOG OCCURRENCE SYSTEM DATE AT LOG OCCURRENCE

Figure 22. Operator Checklist Log Screen Figure 23 shows a failed Checklist Log Entry.

1. 2. 3. 4.

EMPTY SYMBOL SYSTEM TIME ICON SYSTEM DATE ICON PASSWORD ICON

Figure 24. Empty Log Screen

Activity Log Menu

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The process for viewing and removing the operator checklist logs from the system is shown in Table 17. When a person with Supervisor password-level access views the log, any recorded events under Service Tech-

nician-level access will show ***** instead of the actual password number. Also, if there was no password logged in at the time of an event, the password will show as *****.

Table 17. Access Operator Checklist Log Screens

ó Scroll Keys

Activity Log main menu title screen ↑ Up Arrow/ Down Arrow Soft Key ↓

Activity Log Operator Checklist Log submenu

Press Enter Key (*)

The most recent Operator Checklist Log entry will display

Press the Up Arrow or Down Arrow soft key to scroll through the log entries

To remove a log entry: Press the Trash Can (#) soft key to remove this password log entry

An empty log screen replaces this log screen

Press either Scroll Key ( ó or ó ) to exit

PASSWORD LOG The Password Log Submenu is visible at Service Technician and Supervisor password access levels. A Service Technician or a Supervisor can use it to view the last 250 valid passwords entered into the system and the password access level (i.e., Operator, Supervisor, or Service Technician) associated with each password. Figure 25 shows the title screen for this menu.

Figure 25. Password Log Menu

2200 YRM 1336 Pressing the Scroll Back Key or Scroll Forward Key while anywhere in this submenu will return the Activity Log main menu title screen to the Operating Screen. Figure 26 shows an example Password Log screen and indicates the available controls.

Activity Log Menu

Legend for Figure 26 1. PASSWORD VALUE AT LOG OCCURRENCE 2. OPERATOR/SUPERVISOR/SERVICE TECHNICIAN ICON 3. UP ARROW SOFT KEY ICON 4. CURRENT LOG ENTRY (OR "EMPTY" SYMBOL) 5. DOWN ARROW SOFT KEY ICON 6. "TRASH CAN" SOFT KEY ICON 7. TRACTION HOURS AT LOG OCCURRENCE 8. SYSTEM DATE AT LOG OCCURRENCE The process for viewing and removing password logs from the system is shown in Table 18. A person viewing the password log cannot see the passwords of other operators or Supervisors who have access privileges higher than their own. This means that a Supervisor viewing the Password Log cannot see a Service Technician’s password. When viewing the log entry of a person with a higher access level, the password is displayed as *****.

Figure 26. Password Log Screen

After removing a log entry, an "Empty" symbol replaces the former log entry number until the next entry has been scrolled into view. If there are no remaining log entries, an "Empty" log screen is displayed, as shown in Figure 24.

Activity Log Menu

2200 YRM 1336

Table 18. Access Password Log Screens

ó Scroll Keys

Activity Log main menu title screen ↑ Up Arrow/ Down Arrow Soft Key ↓

Activity Log Password Log submenu

Press Enter Key (*)

The most recent Password Log entry will display

Press the Up Arrow or Down Arrow soft key to scroll through the log entries

To remove all log entries: Press Trash Can (#) Key to remove all password log entries

This log screen is replaced by the Empty log screen

Press either Scroll Key ( ó or ó ) to exit

IMPACT EVENTS LOG This submenu is visible at Service Technician and Supervisor password access levels. This menu allows a Service Technician or a Supervisor to view the 20 most recent impact events, where an event is defined as: • Soft impact (0.2 to 2.5 g in tenths of g force), or • Hard impact (0.5 to 3.0 g in tenths of g force) as defined during the Truck Setup process Figure 27 shows the title screen for this menu.

Figure 27. Impact Events Log Menu

2200 YRM 1336 Pressing the Scroll Back Key or Scroll Forward Key while anywhere in this submenu returns the Activity Log main menu title screen to the Operating Screen. Figure 28 shows an example Impact Events Log screen and indicates the available controls.

Activity Log Menu

Legend for Figure 28 1. 2. 3. 4. 5. 6. 7. 8.

PASSWORD VALUE AT LOG OCCURRENCE TYPE OF IMPACT (SOFT/HARD) ICON UP ARROW SOFT KEY ICON CURRENT LOG ENTRY (OR "EMPTY" SYMBOL) DOWN ARROW SOFT KEY ICON "TRASH CAN" SOFT KEY ICON TRACTION HOURS AT LOG OCCURRENCE SYSTEM DATE AT LOG OCCURRENCE

If there are no log entries or the final log entry has been scrolled past, the system displays an "Empty" log screen, as Figure 24 shows. The process for viewing and removing the Impact Events Log is shown in Table 19. When a person with Supervisor password-level access views the log, any recorded events under Service Technician-level access are shown as ***** instead of the actual password number. Also, if there was no password logged in at the time of an event, the password appears as *****.

Figure 28. Impact Events Log Screen

Calibration Menu

2200 YRM 1336

Table 19. Access Impact Events Log Screens

ó Scroll Keys

Activity Log Main menu ↑ Up Arrow/ Down Arrow Soft Key ↓

Activity Log Impact Events Log Submenu

Press Enter Key (*)

The most recent Impact Events Log entry will display

Press the Up Arrow or Down Arrow soft key to scroll through the log entries

To remove all log entries: Press Trash Can (#) Key to remove all log entries

This log screen is replaced by the Empty log screen

Press either Scroll Key ( ó or ó ) to exit

Calibration Menu INTRODUCTION The Calibration Menu is a main menu (top-level menu) that is visible at Service Technician, Supervisor, and Operator password access levels. The Calibration Submenus and Icons topic shows the icons displayed on calibration screens. To access this menu, cycle through the main menu title screens by pressing the Scroll Back Key ( —) or Scroll Forward Key (— ) until the Calibration Title Screen is displayed, as shown in Figure 29. Press the Enter Key (*) to enter the Calibration Menu and the system will display the first submenu in the Calibration Menu, the Load Weight Display submenu, which is shown in Figure 30. Press the Enter Key again if you want to enter this submenu. If you want a different submenu, use the Scroll Back Key or Scroll Forward Key to move to another submenu and press the Enter Key.

Figure 29. Calibration Title Screen

2200 YRM 1336

Calibration Menu in the load weight icon. Use a load weight that is between 1,000 lbs (450 kg) and 16,000 lbs (7,260 kg). NOTE: Do not exceed the truck’s rated capacity. 5. Press the Enter Key. 6. When prompted, position the load by adjusting the tilt and height of the mast and forks to the load weight height. 7. Press the Enter Key. The system stores the new setting and returns to the Calibration Menu.

RETURN TO SET TILT STOP POINT CALIBRATION Figure 30. Load Weight Display Submenu The Calibration Menu presents these submenus: • Load Weight Display • Return to Set Tilt Stop Point • E-Hydraulic Valves • Steering Wheel Knob Center Point • Steer Axle Position • Manual Hydraulics

NOTE: This calibration must be done by a service technician or supervisor and is only available on trucks that have the Return to Set Tilt feature. Figure 31 shows the screen display during a Return to Set Tilt Stop Point calibration.

The following sections describe the Calibration submenus.

LOAD WEIGHT CALIBRATION NOTE: This measurement is not for trade. This menu item, shown in Figure 30, allows a Service Technician, Supervisor, or Operator to calibrate Load Weight. To calibrate Load Weight, select this submenu from the Calibration Menu and follow the prompts on the display. NOTE: When the user is logged in under an operator level password or default password, only the tare weight default zero point calibration is available. To calibrate the Load Weight Display: 1. Starting from the Calibration Menu, scroll to the Load Weight Display screen and press the Enter Key. 2. When prompted, position the empty forks at the load weight height, which is site dependent. 3. Press the Enter Key. 4. When prompted, use the numeric keys to enter the known load weight in lb or kg units, as indicated

Figure 31. Return to Set Tilt Stop Point Sequence To calibrate the Return to Set Tilt Stop Point: 1. Starting from the Calibration Menu, scroll to the Return to Set Tilt Stop Point screen and press the Enter Key. 2. When prompted, position the mast at the desired tilt angle. 3. Press the Enter Key. The system records the new setting and returns to the Calibration Menu.

Calibration Menu

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E-HYDRAULIC AND MANUAL VALVE THRESHOLD CALIBRATION NOTE: This calibration must be done by a service technician or supervisor.

Figure 32 shows how the E-Hydraulic Valve calibration sequence starts with the 1A function, followed by the 1B function, and so on. The screen display changes from one function to the next as the user calibrates these control valves.

Figure 32. E-Hydraulic Valves To calibrate the E-Hydraulic and manual valves: 1. Start the truck and let it run for a few minutes to warm up to normal operating temperature. 2. Perform an air bleed operation by exercising all functions until they operate smoothly. 3. Starting from the Calibration Menu, scroll to the E-Hydraulic Valves screen and press the Enter Key. 4. With no load on the forks, raise them, if they are not already raised. 5. When prompted, move the lever toward the mast, the A direction, until the forks begin to creep. Creep means moving the forks as slowly as possible. Press the Enter Key and the system records the valve reading. 6. When prompted, move the lever toward the rear of the truck, the B direction, until the forks begin to creep and press the Enter Key. The system records the valve reading. Steps 5 and 6 provide the hydraulic input for function 1.

STEERING WHEEL KNOB CENTER POINT CALIBRATION The steering wheel knob center point is the position to which the system adjusts the steering wheel while the lift truck is being driven straight ahead. NOTE: This calibration must be done by a service technician or supervisor and is only available on trucks equipped with the Synchronized Steering function. Figure 33 shows the screen display during a Steering Wheel Knob Center Point calibration.

NOTE: If a valve reading is not within the acceptable range, an abort message appears. Press any key to continue. 7. Continue the process for functions 2, 3, and 4 as prompted by the system. The system records the valve readings for each function, and when this calibration process is completed, returns to the Calibration Menu.

Figure 33. Steering Wheel Knob Center Point

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Calibration Menu

To calibrate the Steering Wheel Knob Center Point:

STEER AXLE POSITION CALIBRATION

1. Starting from the Calibration Menu, scroll to the Steering Wheel Knob Center Point screen and press the Enter Key. 2. When prompted, position the steering wheel in the position that will drive the lift truck straight ahead. 3. Press the Enter Key. The system records the steering wheel position as the new center point and returns to the Calibration Menu.

NOTE: This calibration must be done by a service technician or supervisor and is only available on trucks equipped with the Synchronized Steering function or dual traction motors. Figure 34 shows the screens that appear while calibrating the steer axle position.

Figure 34. Calibrating Steer Axle Position To calibrate the Steer Axle Position: 1. Starting from the Calibration Menu, scroll to the Steer Axle Position screen and press the Enter Key. 2. When prompted, turn the steering wheel counterclockwise until the axle hits the stop. 3. Press the Enter Key. 4. When prompted, turn the steering wheel clockwise until the axle hits the stop. 5. Press the Enter Key. If the settings are acceptable, the system records the steer positions and returns to the Calibration Menu. If the settings are outside of the acceptable range, an X appears over the calibration icon. Press the Enter Key and the system will prompt the user to repeat steps 2 – 5.

Figure 35. Manual Hydraulic End Point Calibration

MANUAL HYDRAULICS CALIBRATION NOTE: This calibration must be done by a service technician or supervisor and is only available on trucks equipped with manual hydraulics. Figure 35 shows the screen menu the system displays during this calibration.

To calibrate the Manual Hydraulic end point: 1. With no load on the forks, raise them, if they are not already raised. 2. Starting from the Calibration Menu, scroll to the Manual Hydraulic End Point Calibration screen and press the Enter Key.

Display Menu

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3. When prompted, move all hydraulic levers to both of their extreme locations; that is, move each lever as far as it will go in both directions.

4. Press the Enter Key. The system records the extreme locations and returns to the Calibration Menu.

Display Menu INTRODUCTION

SET DATE AND TIME FORMAT MENU

The Display Menu is a main menu (top-level menu) that is visible at Service Technician and Supervisor password access levels. To access this menu, cycle through the main menu title screens by pressing the Scroll Back Key ( —) or Scroll Forward Key (— ) until the Display Title Screen is displayed, as shown in Figure 36.

A Supervisor or a Service Technician can use this menu to define the system date and time format. Figure 37 shows the title screen for this menu.

Figure 37. Set Date and Time Format Menu

Figure 36. Display Title Screen

To enter this submenu, press the Enter Key. Figure 38 shows the Set Date and Time Format screen that will appear.

Press the Enter Key (*) to enter the Display Menu and the system will display the Set Date and Time Format screen as shown in Figure 37. Press the Enter Key again to enter this submenu. For a different submenu, use the Scroll Back Key or Scroll Forward Key to move to the desired submenu and press the Enter Key. To return to the Display Menu, press the Scroll Back Key or Scroll Forward Key. Press the Scroll Back Key or Scroll Forward Key a second time to return to the main menu. The Display Menu offers these submenus (see the Display Submenus and Icons topic): • Set Date and Time Format Menu • Set Daylight Saving Time Menu • Set Time and Date Menu • Set Units Menu The sections that follow describe these submenus.

1. 2. 3. 4. 5. 6.

CLOCK ICON CLOCK HOUR FORMAT UP ARROW SOFT KEY ICON CURRENT DATE FORMAT DOWN ARROW SOFT KEY ICON CALENDAR ICON

Figure 38. Set Date and Time Format Screen

2200 YRM 1336

Display Menu

The Clock Hour Format can be set to either a 12-hour clock or a 24-hour clock. To set the Clock Hour Format, press the 2 Up Arrow soft key. The system will place a box around the current Clock Hour Format. Press the Enter Key and then use the 2 Up Arrow soft key or 3 Down Arrow soft key to select either the 12-hour or the 24-hour clock format. When you have the desired format displayed, press the Enter Key and the system will begin using the selected clock hour format for all menus in the system.

There are three options for the Current Date Format: • USA, MM/DD/YY • Europe, DD/MM/YY • ISO 8601, YY/MM/DD

To set the Current Date Format, use the 3 Down Arrow soft key to change the focus to the Current Date Format Icon.

Table 20 shows the process for selecting and changing the date and time formats for the system.

Use the 2 or 3 soft key to cycle through the Current Date Format options. When you have the desired format displayed, press the Enter Key and the system will begin using that date format as the current date format setting for all menus in the system.

Table 20. Accessing the Set Date and Time Format Screen

Use the Scroll Keys ( ó or ó ) Display the main menu Use the Up Arrow ↑ or Down Arrow↓ Key

Display the Set Date and Time Format Menu submenu

Press Enter Key (*)

The Set Date and Time Format screen will display

Use the 2 Up Arrow soft key to select the Set Time Format Icon and display the 12-hour or 24-hour clock icon

Use the 3 Down Arrow soft key to select the Set Date Format Icon and display the three date formats

Press Enter Key to update the time and date format for all menus in the system

Press either Scroll Key ( ó or ó ) to exit

Display Menu

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SET DAYLIGHT SAVING TIME MENU A Service Technician or a Supervisor can use this submenu to enable or disable the use of daylight saving time on trucks and set it up to make automatic time changes. When this feature is enabled (set to On), the system time clock increases by one hour at 2:00 am on the selected Start Date and decreases by one hour at the same time on the selected End Date. Figure 39 shows the title screen for this menu.

Legend for Figure 40 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

DAYLIGHT SAVINGS ENABLE ENABLE INDICATOR (THE ON SETTING IS UP) DAYLIGHT SAVINGS START MONTH SETTING START DAY INDICATOR DAYLIGHT SAVINGS END DAY SETTING END DAY INDICATOR DAYLIGHT SAVINGS END DAY INDICATOR DAYLIGHT SAVINGS END MONTH INDICATOR DAYLIGHT SAVINGS START DAY INDICATOR DAYLIGHT SAVINGS START MONTH INDICATOR

Procedure for Setting Up Automatic Daylight Savings Time NOTE: To exit from the Daylight Savings submenu at any time without making any changes, press the Scroll Back Key or Scroll Forward Key. The system returns to the Display menu. 1. Navigate to the Daylight Savings submenu. 2. Press the 2 Up Arrow soft key to set daylight saving time to On and press the Enter Key (*). 3. Set the month daylight saving time will begin.

Figure 39. Set Daylight Saving Time Menu To enable daylight saving time, press the Enter Key at the menu shown in Figure 39.

a. Press the 3 Down Arrow soft key to activate the Start Month indicator and press the Enter Key. b. Use the 2 or 3 soft key to cycle through the numbers, 1-12, of the months to the desired start month and press the Enter Key.

The system will display the screen shown in Figure 40. 4. Set the day daylight saving time will begin. a. Press the 3 Down Arrow soft key to activate the Start Date indicator and press the Enter Key. b. Use the 2 or 3 soft key to cycle through the dates by numbers, by first days of the week, and by last days of the week to the desired start day. This can be a date, such as the 13th of the month, or a day of the week, such as Sunday. When you get to the desired date, press the Enter Key. 5. Set the month daylight saving time will end. a. Press the 3 Down Arrow soft key to activate the End Month Indicator and press the Enter Key.

Figure 40. Set Daylight Saving Time Screen

b. Use the 2 or 3 soft key to cycle through the numbers, 1-12, of the months to the desired end month and press the Enter Key.

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Display Menu of the week to the desired end day and press the Enter Key.

6. Set the day daylight saving time will end. a. Press the 3 Down Arrow soft key to activate the End Day indicator and press the Enter Key. b. Use the 2 or 3 soft key to cycle through the numbers, first days of the week, and last days

7. Exit from the Daylight Savings submenu and return to the Display menu by pressing the Scroll Back Key or Scroll Forward Key.

Table 21. Set Daylight Saving Time Menu

Main Menu Setup Display

Press the Enter Key (*)

Setup Display Set Daylight Saving

Press Enter Key

Set Daylight Saving Daylight Save On/Off

Press Enter Key

↑ SCROLL ↓ Setup Display Back One Level

Daylight Save On/Off Daylight Save On

Select On or Off and press Enter Key

↑ SCROLL ↓ Daylight Save On/Off Daylight Save Off

↑ SCROLL ↓

Set Daylight Saving Daylight Save Start

Press Enter Key

Daylight Save Start Month 12

Select Daylight Saving Start Month from available selections and press Enter Key

Daylight Save Start Day 31

↑ SCROLL ↓

Daylight Save Start Month 01

Daylight Save Start Day 01

Select the Day of the Month from available selections and press Enter Key

↑ SCROLL ↓ Daylight Save Start Day Last

Press Enter Key

Daylight Save Start Last Su

Select the Day of the Week from available selections and press Enter Key

↑ SCROLL ↓ Daylight Save Start Last Sa ↑ SCROLL ↓

↑ SCROLL ↓ Daylight Save Start Day first

Press Enter Key

Daylight Save Start first Su

Select the Day of the Week from available selections and press Enter Key

↑ SCROLL ↓ Daylight Save Start first Sa

Display Menu

2200 YRM 1336

Table 21. Set Daylight Saving Time Menu (Continued)

Set Daylight Saving Daylight Save End ↑ SCROLL ↓ Set Daylight Saving Back One Level

Press Enter Key

Daylight Save End Month 12

Select Daylight Saving End Month from available selections and press Enter Key

↑ SCROLL ↓

Daylight Save End Month 01

Daylight Save End Day 31

Select the Day of the Month from available selections and press Enter Key

↑ SCROLL ↓

Daylight Save End Day 01

↑ SCROLL ↓ Daylight Save End Day Last

Press Enter Key

Daylight Save End Last Su

Select the Day of the Week from available selections and press Enter Key

↑ SCROLL ↓ Daylight Save End Last Sa

↑ SCROLL ↓

Daylight Save End Day first

Press Enter Key

Daylight Save End first Su

Select the Day of the Week from available selections and press Enter Key

↑ SCROLL ↓ Daylight Save End first Sa

SET TIME AND DATE MENU A Service Technician or a Supervisor can use this menu to set the time and date on the on-board clock. Figure 41 shows the title screen for this menu.

Figure 41. Set Date and Time Menu

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Procedure for Setting Time and Date NOTE: To exit from a menu at any time without making any changes, press the Scroll Back Key or Scroll Forward Key.

Display Menu is DD/MM/YY, for example, then the left segment displayed is the day of the month. (Current Date Format can be changed in the Set Date and Time Format submenu.)

1. At the Display Menu, scroll to the Set Time and Date Format submenu, unless already there, and press the Enter Key (*) to enter this submenu.

a. Use the number keys to enter the correct value and press the Enter Key. If the current value for the left segment of the date is correct, simply press the Enter Key.

2. Press the 2 or 3 soft key to select the time icon, then press the Enter Key.

b. Repeat step a. for the middle and right segments of the date.

The system will display a flashing line under the hour portion of the time. To change the hour:

The system will put the new system date into effect immediately.

a. Use the number keys to enter the correct hour and press the Enter Key. If the hour does not need to be changed, just press the Enter Key. If the number you entered is a valid hour setting, the system accepts it and moves the flashing line to the next segment, the minutes portion of the time. b. Use the number keys to enter the minutes and press the Enter Key. If the minutes are correct, simply press the Enter Key. If the number you entered is a valid minutes setting, the system accepts it and moves the flashing line to the A (for AM) or P (for PM) designator.

SET UNITS MENU A Service Technician or a Supervisor can use this menu to set the type of units the system will use to either Imperial or Metric. Figure 42 shows the Set Units submenu. To set the type of units the system will use, either Imperial or Metric, enter the Set Units Menu. Use the 2 Up Arrow or 3 Down Arrow soft key to select Imperial or Metric. When the corresponding icon for the type of units desired is displayed on the screen, press the Enter Key and the system will begin using the units selected immediately.

Figure 42. Set Units Menu

Status Menu

2200 YRM 1336

Status Menu INTRODUCTION The Status Menu is a main menu (top-level menu) that is visible at Service Technician and Supervisor password access levels. To access this menu, cycle through the main menu title screens by pressing the Scroll Back Key ( —) or Scroll Forward Key (— ) until the Status Title Screen is displayed, as shown in Figure 43.

The Status Menu provides these submenus: • VSM Versions • Display Versions • Truck Serial Number • Hour Meters • E-Hydraulic Controller Versions • Pump Motor Controller Versions • Traction Motor Controller 1 Versions • Traction Motor Controller 2 Versions • Light Controller Versions • Impact Sensor Versions The topics that follow describe the Status submenus. NOTE: These menu selections are only available to logged in Service Technicians and Supervisors.

VSM VERSIONS NOTE: The manufacturer’s hardware and software versions may not match the hardware and software versions shown on the device’s exterior label

Figure 43. Status Title Screen Press the Enter Key (*) to enter the Status Menu and the system will display the Vehicle System Manager (VSM) Version submenu as shown in Figure 44. Press the Enter Key again to enter this submenu. For a different submenu, use the Scroll Back Key or Scroll Forward Key to move to the desired submenu and press the Enter Key.

This submenu makes it possible to view the manufacturer’s internal hardware and software versions of the VSM Controller. Figure 46 shows how the version information is displayed on the screen. The top line lists the manufacturer’s hardware version; the second line lists the manufacturer’s software version.

Figure 45. Versions Screen

Figure 44. Status Menu

2200 YRM 1336

Status Menu

DISPLAY VERSIONS NOTE: The manufacturer’s hardware and software versions may not match the hardware and software versions shown on the device’s exterior label Use this submenu to view the hardware and software versions of the Display. The screen for Display Versions is identical to the screen used for VSM Versions. Figure 46 shows how the information is presented on the screen. The top line lists the hardware version; the second line lists the software version.

TRUCK SERIAL NUMBER Use this submenu to view the serial number assigned to the truck. The truck serial number always has 11 characters, plus a 3 digit version number. The serial number can include letters with the numbers. Figure 46 shows how the serial number is displayed on the screen.

Figure 47. Hour Meters Screen

E-HYDRAULIC CONTROLLER VERSIONS NOTE: The manufacturer’s hardware and software versions may not match the hardware and software versions shown on the device’s exterior label. Use this submenu to view the manufacturer’s internal hardware and software versions of the E-Hydraulic Input Controller. NOTE: This item is visible only on trucks equipped with E-Hydraulics. The manufacturer’s hardware and manufacturer’s software version information is presented on the screen as shown in Figure 45.

PUMP MOTOR CONTROLLER VERSIONS Figure 46. Truck Serial Number

HOUR METERS Use this submenu to view hour meter readings. These include a truck hour meter, traction hour meter, pump hour meter (displayed only if the Master Controller is controlling the hydraulic pump), and a secure hour meter. Secure hour meters cannot be reset. Figure 47 shows an example of the way hour meters and readings are presented on the screen.

NOTE: The manufacturer’s hardware and software versions may not match the hardware and software versions shown on the device’s exterior label. Use this submenu to view the manufacturer’s internal hardware and software versions of the Pump Motor Controller. The manufacturer’s hardware and manufacturer’s software version information is presented on the screen as shown in Figure 45.

Truck Setup Menu

2200 YRM 1336

TRACTION MOTOR CONTROLLER 1 VERSIONS NOTE: The manufacturer’s hardware and software versions may not match the hardware and software versions shown on the device’s exterior label. Use this submenu to view the manufacturer’s internal hardware and software versions of Traction Motor Controller 1. NOTE: If the truck is equipped with two traction motors, this submenu displays the versions for the right side traction motor only. The manufacturer’s hardware and manufacturer’s software version information is presented on the screen as shown in Figure 45.

TRACTION MOTOR CONTROLLER 2 VERSIONS NOTE: The manufacturer’s hardware and software versions may not match the hardware and software versions shown on the device’s exterior label. Use this submenu to view the manufacturer’s internal hardware and software versions of Traction Motor Controller 2. Traction Motor Controller 2 controls the left side traction motor.

The manufacturer’s hardware and manufacturer’s software version information is presented on the screen as shown in Figure 45.

LIGHT CONTROLLER VERSIONS NOTE: The manufacturer’s hardware and software versions may not match the hardware and software versions shown on the device’s exterior label. Use this submenu to view the manufacturer’s internal hardware and software versions of the Light Controller. The manufacturer’s hardware and manufacturer’s software version information is presented on the screen as shown in Figure 45.

IMPACT SENSOR VERSIONS NOTE: The manufacturer’s hardware and software versions may not match the hardware and software versions shown on the device’s exterior label. Use this submenu to view the manufacturer’s internal hardware and software versions of the Impact Sensor. NOTE: If the truck is not equipped with an Impact Sensor, this submenu is not displayed. The manufacturer’s hardware and manufacturer’s software version information is presented on the screen as shown in Figure 45.

NOTE: The Status Menu displays this item only if the CDF configuration indicates dual traction motors are present.

Truck Setup Menu INTRODUCTION The Truck Setup Menu is a main menu (top-level menu) that is visible at Service Technician and Supervisor password access levels.

Scroll Back Key or Scroll Forward Key to move to the desired submenu and press the Enter Key.

NOTE: This menu is available only when the truck is not moving and the E-Hydraulics controller is in the neutral position. To access this menu, cycle through the main menu title screens by pressing the Scroll Back Key ( —) or Scroll Forward Key (— ) until the Truck Setup Title Screen is displayed, as shown in Figure 48. Press the Enter Key (*) to enter the Truck Setup Menu. The system will display the Add/Remove Password submenu shown in Figure 49. Press the Enter Key again to enter this submenu. For a different submenu, use the 76

Figure 48. Truck Setup Title Screen

2200 YRM 1336

Truck Setup Menu The following sections describe the Truck Setup submenus.

ADD/REMOVE PASSWORD NOTE: This submenu is available to logged in Service Technicians and Supervisors. This submenu, shown in Figure 49, allows Service Technicians and Supervisors to add or remove passwords. See the Adding/Removing/Changing Passwords topic in the Password Screen section for more information.

MOTOR BRAKING Figure 49. Add/Remove Password Submenu The Truck Setup Menu presents these submenus: • Add/Remove Password • Motor Braking • Battery Setup • BDI Adjustment Settings • Acceleration Rates • Hour Meter Initialization • Impact Monitor Shutdown • Operator Checklist • Minimum Pump Standby Flow Rate • Scheduled Maintenance Reminder • Traction Speed Limit • Return to Set Tilt • Auto Power-Off Time Delay • Impact Monitor Settings • Motion Alarm • Lift Hydraulic Function Maximum Speed and Ramp Times • Lower Hydraulic Function Maximum Speed and Ramp Times • Tilt Forward Hydraulic Function Maximum Speed and Ramp Times • Tilt Backward Hydraulic Function Maximum Speed and Ramp Times • Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times • Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times • Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times • Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times • Optional Hydraulic Functions • Rear Lights Control • Restore Default Settings

NOTE: This submenu is available to logged in Service Technicians and Supervisors. There are three motor braking settings, Regenerative Braking Rate, Auto Deceleration Rate, and Auto Deceleration Type. See Figure 50. Regenerative Braking setting controls how much motor braking is applied when the direction is changed from Forward to Reverse or Reverse to Forward. This type of deceleration is proportional to the accelerator pedal position. The further the accelerator is depressed the greater the deceleration. Auto Deceleration setting controls how much motor braking is applied when transitioning from higher accelerator pedal position to a lower acceleration pedal position. There are two types of Auto Deceleration, Pedal Up and Proportional. A fully released pedal produces maximum deceleration for both Pedal Up or Proportional deceleration.

Figure 50. Motor Braking Setup

Truck Setup Menu

2200 YRM 1336

Changing the Motor Braking Settings To change the Set Regenerative Braking Rate or Set Auto Deceleration Rate setting, use the 2 and 3 soft keys to select the current value of the setting you want to adjust. When there is a box around the value you want to change, press the Enter Key. Next, use the number keys to enter the desired value, then press the Enter Key to save the new setting. The Regenerative Braking Rate setting is the value at the top of the screen. This value can be from 0 to 100% in increments of 1%. A 100% setting provides maximum regenerative braking while a 0% setting in effect deactivates regenerative braking. The Auto Deceleration Rate setting is the second setting down from the top. The setting value can be in the 0 to 100% in increments of 1%. A 100% setting provides maximum auto deceleration while a 0% setting in effect deactivates it. Auto Deceleration rate is always a percentage of the current Regenerative Braking Rate. Thus, if Regeneration brake = 0% then Auto Deceleration = 0%. The Auto Deceleration Type is the third setting down from the top. To change the type, use the 2 and 3 soft keys to select the current type and press the Enter Key. Next, use the 2 or 3 soft key to choose either Pedal Up or Proportional deceleration and press the Enter Key to save the new setting. Pedal Up deceleration allows the truck to coast until the pedal is fully released. Proportional deceleration causes the truck to decelerate in proportion to how far the pedal is released in relation to the current traction speed.

BATTERY SETUP NOTE: This submenu is available to logged in Service Technicians only. There are four battery settings, Battery Voltage, Battery Amp Hour settings, Cell Voltage levels, and Empty Cell Voltage. Use this menu to change the truck system’s voltage and ampere settings or to adjust the battery’s cell voltage levels. Figure 51 shows how the Battery Setup information is displayed on the screen. Press the 2 and 3 soft keys to select the setting value you want to change. When there is a box around the value, press the Enter Key.

Figure 51. Battery Setup The available values for the Battery Voltage Setting are 24, 36, 48, 72, and 80 V. To change the Battery Voltage use the soft keys to move the selection box to the Battery Voltage symbol and press the Enter Key. Enter 24, 36, 48, 72 or 80 with the number keys and press the Enter Key to save it. The available values for the Battery Amp Hour Capacity range from 200 to 3000 Amp Hour (AHr) in 10 Amperes per Hour increments. To change the Battery Amp Hour Capacity use the soft keys to move the selection box to the Battery AHr symbol and press the Enter Key. Enter three or four digits as required. The last digit will be rounded to the nearest 10. Press the Enter Key to save it. The available values for the Full Cell Voltage (Charged) range from 1.00 to 3.00 V in 0.01 Volt increments. To change use the soft keys to move the selection box to the Full Cell Voltage symbol and press the Enter Key. Enter three digits within the allowable range and press the Enter Key to save the change. The available values for the Empty Cell Voltage (Discharged) range from 1.00 to 3.00 V in 0.01 Volt increments. To change the capacity use the soft keys to move the selection box to the Empty Cell Voltage symbol and press the Enter Key. Enter three digits within the allowable range and press the Enter Key to save the change.

2200 YRM 1336

Truck Setup Menu

NOTE: If adjustments are required determine the correct settings as follows:

the Battery Setup settings are not at the factory defaults reset them before proceeding.

Determine Amp Hour Capacity from the battery data plate. If multiple capacity batteries are available for the truck use an average of the high and low capacities.

There are four problems that may require a cell voltage setting change. • The display does not read 5 bars with a fresh charged battery. See Step 1 below. • The display stays at 5 bars as the battery discharges. See Step 2 below. • The display reads 0 bars at too high a battery specific gravity or voltage. See Step 3 below. • The display reads 0 bars at too low a battery specific gravity or voltage. See Step 4 below.

Determine “Full Cell Voltage” and “Empty Cell Voltage”. Due to parasitic loads, cable and contactor resistances, and variations in the battery temperature the open circuit voltages when measured with a volt meter will not exactly match the voltages shown on the display. The following instructions assume the Battery Setup settings are set to the factory defaults. See Table 22. If

Table 22. Battery Setup Factory Defaults Model

Battery Full

Battery Empty

ERC22-35VG (ERC045-070VG) (A968)

2.12 Volts

1.98 Volts

ERP22-35VL (ERP045-070VL) (A976)

2.10 Volts

2.00 Volts

ERC16-20VA (ERC030-040VA) (A969)

2.12 Volts

1.98 Volts

ERP15-20VT (ERP030-040VT) (G807)

2.12 Volts

1.96 Volts

ERP16-20VF (ERP30-40VF) (A955)

2.12 Volts

1.96 Volts

1. If the display does not read 5 bars with a fresh charged battery the full cell voltage needs to be lowered. For the BDI to read correctly the truck must be operated for 10 minutes doing light driving. If the display still does not read 5 bars after light driving lower the full cell voltage 0.01V (a change of 0.01V will make a significant change) Use the left arrow key to return to the Operating Screen and drive the truck momentarily and check to see if the BDI is now at 5 bars. If not lower the full cell voltage another 0.01V, return to the Operating Screen, drive momentarily and check as above. Repeat as necessary. 2. If the display stays at 5 bars as the battery discharges the full cell voltage need to be increased. Run truck until battery is at 75% of the usable charge as measured per the battery manufacturer’s instructions (discharged 20% if 80% is usable). If BDI indicator is still at 5 bars increase the full cell voltage. As above a step of 0.01cell voltage will make a significant change. Use the left arrow key to return to the Operating Screen

and check to see if there are now 4 bars showing. Repeat as necessary. NOTE: The battery must be charged to at leased 50% of its capacity to reset lift lockout 3. If the display reads 0 bars at too high a battery specific gravity or voltage operate the truck checking the battery per the battery manufactures recommendations until the battery is discharged to the manufacturer’s recommendation. Decrease the empty cell voltage in steps of 0.01 volts. Use the left arrow key to return to the Operating Screen and check to see if there are now 1 or more bars showing. Repeat if necessary. 4. If the display reads 1 or more bars and the battery is discharged when measured as per the battery manufacturer’s recommendation. Increase the empty cell voltage in steps of 0.01 volts. Use the left arrow key to return to the Operating Screen and check to see 0 bars are displayed. Repeat if necessary.

Truck Setup Menu

BDI ADJUSTMENT SETTING NOTE: This submenu is available to logged in Service Technicians only.

2200 YRM 1336 Figure 53 shows how the Acceleration rates and type are presented on the screen.

Figure 52 shows how the Battery Discharge Indicator (BDI) adjustment setting is displayed on the screen. The Parasitic Current Icon and the present value are located in the middle of the screen.

Figure 53. Acceleration Setup

Figure 52. BDI Adjustment Setting The BDI Adjustment Setting menu provides a way to adjust the Parasitic Current so it is well suited to current truck conditions. If extra hardware or equipment that draws significant power, such as heater vests, have been installed on the truck since it went into service, a BDI adjustment should be made to compensate for the additional power draw. The factory setting accounts for the DC-DC converter and other normal loads. Increase this setting as required if additional items have been added to the truck. When items are added that have an intermittent duty cycle average the current based on the duty cycle. To adjust the Parasitic Current, use the number keys to enter the new value and press the Enter Key to save it. Acceptable values for Parasitic Current range from 0 to 200 Amp, in 1 Ampere increments.

ACCELERATION RATES NOTE: This submenu is available to logged in Service Technicians only. Use this menu to set Acceleration Rate 1 or Acceleration Rate 2 or to select either Standard or Extended Shift mode.

The icon at the top left of the screen is for Acceleration Rate 1 and the icon below it is for Acceleration Rate 2. • Acceleration Rate 1 is used to limit the acceleration of the traction system at low speeds. A setting of 100% is the maximum available acceleration, below this the vehicle acceleration will be reduced. • Rate 2 is used to limit the acceleration of the traction system at high speeds. At higher motor speeds the maximum acceleration of the vehicle is limited by the traction motor(s), thus the default setting is the maximum available acceleration. • Standard Performance Mode has a greater acceleration and higher speeds on grades as compared to Extended Shift Mode but at the cost of increased power consumption and shorter battery shift lift. To change an acceleration rate setting, use the 2 and 3 soft keys to select the value for Acceleration Rate 1 or Acceleration Rate 2. When there is a box around the current value, press the Enter Key. Next, use the number keys to enter the new value desired. Acceptable values range from 5 to 100%. A 100% setting produces maximum acceleration at slow speeds. After entering the new value, press the Enter Key to save it. The third icon down from the top is for Acceleration Type. An X over the setting icon in Figure 53 means the truck is currently set to operate in Standard shift mode, not Extended Shift mode. To change the acceleration type, use the 2 and 3 soft keys to move to the current value for the acceleration type. Press the Enter Key to select it, then use the 2 or 3 soft key to select either Standard or Extended Shift mode and press the Enter Key to save your selection.

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Truck Setup Menu

HOUR METER INITIALIZATION NOTE: The key must be cycled in order for the Hour Meter Initialization to take affect. NOTE: This submenu is available to logged in Service Technicians only. Use this menu to view and change the Traction Hour, Pump Hour, and Truck Hour settings. Figure 54 shows how the settings are displayed on the screen.

Figure 55. Setup Screen for Impact Settings The second icon down from the top is the Impact Monitor Shutdown Delay Icon. To set the Shutdown Delay, use the 2 and 3 soft keys to select the current value for this setting. When there is a box around the value, press the Enter Key, then use the number keys on the Display Panel to enter a value from 0 to 30 seconds and press the Enter Key to save the new setting.

Figure 54. Hour Meter Setup The top icon is for Traction Hour, the second icon down is for Pump Hour, and the third icon down is for Truck Hour. To adjust the Traction Hour, Pump Hour, or Truck Hour setting, use the 2 and 3 soft keys to select the current value of the setting you want to change. When there is a box around the value for the traction hour meter, pump hour meter, or truck hour meter, press the Enter Key, then use the number keys to enter a new value up to 99999 and press the Enter Key to save it.

IMPACT MONITOR SHUTDOWN NOTE: This submenu is available to logged in Service Technicians and Supervisors. This menu makes it possible to adjust the way the system reacts after an impact is detected. These settings are laid out on the screen as shown in Figure 55. The top left icon is the Impact Detection Icon. To set impact detection to On or Off, use the 2 and 3 soft keys to select the current value for this setting. When there is a box around the On or Off Icon, use the 2 or 3 soft key to display the desired setting and press the Enter Key to save it.

The third icon down from the top is the Impact Monitor Shutdown Type Icon. To set the Disable Type to All or Traction, use the 2 and 3 soft keys to select the current value for this setting. When there is a box around the All Icon or the Traction Icon, use the 2 or 3 soft key to display the desired setting and press the Enter Key to save it.

OPERATOR CHECKLIST NOTE: This submenu is available to logged in Service Technicians and Supervisors. A Service Technician or Supervisor can use this menu to program the checklist items that will be displayed to users. The lift truck system can be set up to display all, some, or none of the 30 items in the Operator Checklist when the key switch or keyless switch is turned on. Each checklist item is represented by a separate icon. During setup, the 30 icons are displayed, one at a time, in the middle of the screen. If an X appears over the icon when it is displayed, the checklist item represented by the icon is inactive (deactivated) and the checklist item will not appear during the Operator Checklist sequence. If there is no X over the icon, the checklist item is active (enabled).

Truck Setup Menu Figure 56 shows the Activate/Deactivate Checklist Item Screen with an icon that represents a checklist item.

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MINIMUM PUMP STANDBY FLOW RATE NOTE: This submenu is available to logged in Service Technicians and Supervisors. This menu can be used to adjust the minimum standby pump flow rate. Values stored in the truck’s CDF determine the range of allowable values for this setting. This means a setting of 1% the value is the lowest available setting for the minimum standby pump flow rate and it is equal to the lowest defined value in the CDF. A 100% value is the highest available setting for the minimum standby pump flow rate. The example presented in Figure 57 shows the icon for minimum pump standby flow rate and a current value of 56, which means the value is 56% of the maximum allowed. NOTE: A setting of 0% turns the standby flow off which may result in decreased steering performance.

Figure 56. Activate/Deactivate Checklist Item Screen The icon in Figure 56 does not have an X over it, so the checklist item this icon represents is enabled (activated). The X icon in the lower left area of the screen, right above the # soft key indicates the currently displayed checklist item will be deactivated if the # key is pressed. If the checklist item was deactivated, pressing the Enter Key (*) above the Check Mark Icon in the lower right area of the screen would enable it. Any checklist item can be activated or deactivated by a Service Technician or Supervisor as follows: Use the 2 and 3 soft keys (the up and down arrow keys) to move through the icons to the one that represents the checklist item you want to enable or disable. If the currently displayed icon has an X over it, press the Enter Key. The system will enable the checklist function the icon represents and redraw the icon with no X over it and the checklist function will now be programmed to appear during the Operator Checklist sequence. If the currently displayed icon does not have an X over it, press the # soft key to disable the checklist function the icon represents. The system will redraw the icon with an X over it and this checklist function will be skipped (it will not appear) during the Operator Checklist sequence. NOTE: If all items on the checklist are deactivated, the Operator Checklist feature is deactivated and the system does not present the Operator Checklist to the operator.

To change the setting for the minimum standby pump flow rate, use the number keys to enter the new rate desired, then press the Enter Key to save the new setting. The value of this setting can range from 0% to 100% in steps of 1%.

Figure 57. Minimum Pump Standby Flow Rate Screen

2200 YRM 1336 Using this menu item the user shall be able to adjust the scheduled maintenance reminder settings. The items available to the user are: • Maintenance Reminders ON/OFF • Maintenance Interval in Months • Maintenance Interval in Truck Hours • Derated Traction Speed Percentage after the scheduled time has expired.

Truck Setup Menu The service technician must reset the scheduled time for the next maintenance time interval to allow normal operation again.

The maintenance intervals are user settable countdown timers. Once the user has set the interval it begins counting down. Each time the user enters the menu the current count until the interval will expire will be displayed. Setting the Maintenance Reminders Status to OFF deactivates the feature. Setting an Interval to 0 deactivates that Interval. With the Maintenance Reminder Status set to ON and Setting one or both of the reminder intervals to nonzero numbers activates the maintenance reminders feature.

Figure 58. Scheduled Maintenance Reminder

Once a previously active interval counts down to zero, the maintenance reminder becomes active. To deactivate the maintenance reminder the user must either set the status to OFF or enter a new service interval. The scheduled maintenance month interval is based on the system date. The value ranges from 0 to 99 in increments of 1 month. The scheduled maintenance hour interval is based on the trucks hour meter. The value ranges from 0 to 9999 in increments of 1 hour. The derated traction speed percentage setting is a percentage of the current maximum speed limit. A setting of 100% has no reduction in top speed while 0% disables the traction system. This value can be from 0% to 100% in increments of 1%.

Figure 59. System Off Screen

When scheduled maintenance reminder interval has expired, a reminder is activated. If a reminder is active the system will display the maintenance reminder alert screen for 5 seconds at key ON. If the maintenance reminder is not reset or deactivated within 20 hours after the maintenance interval has expired, lift truck operation will be slowed to the derated traction speed setting on the next key cycle. The truck will operate with a reduced traction speed until the maintenance reminder interval is set or the feature is turned OFF.

Figure 60. Maintenance Reminder Alert Screen

Truck Setup Menu

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TRACTION SPEED LIMIT NOTE: This submenu is available to logged in Service Technicians and Supervisors. The example shown in Figure 61 shows the MPH Icon and a current Traction Speed Limit setting of 12. The type of speed units, MPH or km/h is set in a submenu of the Display main menu.

Figure 62. RTST Setup Screen

Figure 61. Traction Speed Limit Example To change the traction speed limit setting, use the number keys to enter the new value desired, then press the Enter Key to save it. Acceptable values for the traction speed limit range from 1 to 99 km/h when metric units are in use, and 1 to 99 MPH when Imperial units are in use. NOTE: The maximum traction speed will always be limited by the maximum traction motor speed as set by the CDF, regardless of the traction speed limit setting.

RETURN TO SET TILT NOTE: This submenu is available to logged in Service Technicians and Supervisors. It is visible only on trucks equipped with the RTST feature. This menu provides a way to adjust the Return to Set Tilt (RTST) delay time and to program this feature to work only in the forward direction or in both directions. Figure 62 shows the RTST Setup Screen with the delay direction set to Forward.

The icon at the top left of the screen is for the delay time. When a box is around the current value, press the Enter Key. Then use the 2 or 3 soft key to step through the available values for the delay time, 0, 0.1, 0.2, 0.4, 0.6, 0.8, 1.0, 2.0, 3.0 seconds or Continuous and press the Enter Key to save the new value. When the delay time is set to 0, this feature is deactivated. When set to Continuous, the delay time is infinite (limitless). The lift truck icon in Figure 62 indicates the mast assembly is programmed to return to the set tilt angle only when it is moving forward, which is the Forward option. To set up the mast assembly so that it returns to the set tilt whether it is moving forward or backward, use the 2 or 3 soft key to set the RTSH direction to Both.

AUTO POWER-OFF TIME DELAY NOTE: This submenu is available to logged in Service Technicians and Supervisors. This menu can be used to shut the lift truck OFF if the operator has left the seat for a set number of minutes. This menu can be used to adjust the setting for the amount of time before the truck enters the Power Off mode. Figure 63 shows an Auto Power-Off Delay Setup Screen that has a 20m delay setting value, which is a 20 minute delay. To change the Auto Power-Off Time Delay setting, select the current value. When a box is around it, press the Enter Key, then use the number keys to enter a value from 0 to 30 minutes and press the Enter Key to save the new setting.

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Truck Setup Menu An example of a soft impact is a truck rolling over and crushing a wooden pallet. In this case the impact force is much less than experienced with a hard impact but it lasts for a significantly longer time period.

Figure 63. Auto Power-Off Time Delay Setup Screen

IMPACT MONITOR SETTINGS NOTE: This submenu is available to logged in Service Technicians and Supervisors. It is visible only on trucks equipped with the Impact Monitoring feature. This menu provides a way to adjust the settings the impact monitor uses when it detects impacts. Figure 64 shows the Impact Monitor Settings Screen.

The Soft Impact Force, the setting at the top of the screen, can be set to a value in the range 0.2 to 2.5 g., in tenths of gravitational force. The Soft Impact Time, the second setting down from the top, can be adjusted to require the impact monitor to see an impact force greater than the Soft Impact Force for 1 to 12 samples before a soft impact event will be reported. The Hard Impact Force, the third setting down, can be set to a value in the range 0.5 to 3.0 g., in tenths of gravitational force. The Hard Impact Time, the forth setting down from the top, can be adjusted to require the impact monitor to see an impact force greater than the Hard Impact Force for 1 or 2 samples before a hard impact event will be reported. The Hard Impact Force, the third setting down, can be set to a value in the range 0.5 to 3.0 g., in tenths of gravitational force.

Initial Adjustment of Soft and Hard Impact Settings NOTE: When adjusting the impact sensor settings, be sure to:

The impact monitor can detect both hard and soft impacts.

Adjust the truck to the lowest Soft Impact Force setting, the Soft Impact Time set to 6, and the highest Hard Impact Force Setting. Drive the truck at the fastest operational speed for the environment. Apply the brakes to bring the truck to an abrupt stop. Determine if an impact event has occurred.

An example of a hard impact is a truck colliding with a steel column in a warehouse which causes the truck to stop suddenly. In this case the impact force is very strong but it occurs during a short time period.

Increase either the Soft Impact Force setting until the vehicle can be abruptly stopped with the service brake without reporting an impact event. Read and record the value, from the dash display, that was triggered a Soft

Figure 64. Impact Monitor Settings Screen

Impact Detection

Truck Setup Menu

2200 YRM 1336

Impact when abruptly stopping the truck. Change the Soft Impact Force threshold to the next highest setting. To adjust the hard threshold, take the soft threshold value and add 0.3 g. Set the Hard Impact Time to 2. Monitor truck during all normal operations. If impacts are recorded during normal operations, go to (Readjustment of Soft and Hard Impact Settings).

Readjustment of Soft and Hard Impact Settings. If the majority of impacts recorded during the initial adjustment period are soft impacts, change the settings as follows: • Increase the Soft Impact Time by 1 for large scale adjustments. • Increase the Soft Impact Force by 0.1g for smaller adjustments. • Increase the Hard Impact Force to the current Soft Impact + 0.3g. If the majority of impacts recorded during the initial adjustment period are hard impacts, change the settings as follows: • Increase the Hard Impact Time by 1 sample for large adjustments. • Increase the Hard Impact Force by 0.1g for smaller adjustments. After making the necessary adjustments, have the operator again operate the lift truck under normal conditions to ensure that the adjustments are correct.

MOTION ALARM

Figure 65. Motion Alarm Setup Screen

LIFT HYDRAULIC FUNCTION MAXIMUM SPEED AND RAMP TIMES Flow rate adjustment of the lift function is available on all trucks. Ramp up and ramp down rate adjustments of the hoist function are available only on trucks equipped with E-Hydraulics. Use this menu to enable or disable the valve whether the truck has E-Hydraulics or manual hydraulics. Valid maximum flow rate settings can be from 0% to 100%. A value of 0% deactivates the hydraulic function and associated diagnostics. Figure 66 shows the Lift/Lower Max Speed Setup Screen.

NOTE: This submenu is available to logged in Service Technicians and Supervisors and visible on all trucks. Use this menu to enable or disable the Motion Alarm feature. Figure 65 shows the Motion Alarm Setup Screen with the alarm option set to On. Use the 2 and 3 soft keys to toggle the setting between On and Off. An X over the fork lift truck icon indicates the Motion Alarm feature is set to Off. If this feature is Off and you want to enable it, press the 2 or 3 soft key to have the system display the icon without an X over it, then press the Enter Key to store the setting.

1. 2. 3. 4. 5. 6.

LIFT RAMP UP TIME SETTING LIFT RAMP DOWN TIME SETTING LIFT MAXIMUM SPEED CURRENT SETTING LIFT MAXIMUM SPEED INDICATOR LIFT RAMP DOWN TIME INDICATOR LIFT RAMP UP TIME INDICATOR

Figure 66. Lift/Lower Max Speed Setup Screen

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Truck Setup Menu

To change the ramp up time setting, use the 2 and 3 soft keys to select the value beside the top left icon, the hoist function’s ramp up time. When there is a box around this value, press the Enter Key, then use the 2 or 3 soft key to step through the valid settings for ramp up time, which can be from 0 to 2 seconds in 0.1 second increments. When you have the desired value displayed, press the Enter Key.

TILT BACKWARD HYDRAULIC FUNCTION MAXIMUM SPEED AND RAMP TIMES

To change the ramp down time setting, follow the same procedure except in this case, select the value beside the second icon down.

Set the maximum hydraulic flow supplied for the tilt backward function to a value from 0% to 100%. A value of 0% deactivates this function.

To adjust the maximum hydraulic flow supplied for the lift function (1B), select the value beside the lower left icon and press the Enter Key. Then use the number keys to enter the desired value for the maximum hydraulic flow, which can be 0% to 100%. A value of 0% deactivates this function.

Set the ramp time settings to a value of 0 to 2 seconds.

LOWER HYDRAULIC FUNCTION MAXIMUM SPEED AND RAMP TIMES To change the ramp up or down time setting or to adjust the maximum flow supplied for the Lower function (the hydraulic function 1A settings), follow the procedure given in Lift Hydraulic Function Maximum Speed and Ramp Times. Set the maximum hydraulic flow to a value from 0% to 100%. A value of 0% deactivates this function. Set the ramp time settings for the hoist function to a value of 0 to 2 seconds in 0.1 second increments. The setup screen for this submenu is similar to Figure 66.

TILT FORWARD HYDRAULIC FUNCTION MAXIMUM SPEED AND RAMP TIMES To change the ramp up or down time setting or to adjust the maximum flow supplied for the tilt forward (the hydraulic function 2A settings), follow the procedure given in Lift Hydraulic Function Maximum Speed and Ramp Times. Set the maximum hydraulic flow supplied for the tilt forward function to a value from 0% to 100%. A value of 0% deactivates this function. Set the ramp time settings to a value of 0 to 2 seconds. The setup screen for this submenu is similar to Figure 66.

To change the ramp up or down time setting or to adjust the maximum flow supplied for the tilt backward (the hydraulic function 2B settings), follow the procedure given in Lift Hydraulic Function Maximum Speed and Ramp Times.

The setup screen for this submenu is similar to Figure 66.

AUXILIARY 1A HYDRAULIC FUNCTION MAXIMUM SPEED AND RAMP TIMES To change the ramp up or down time setting or to adjust the maximum flow supplied for hydraulic function 3A, follow the procedure given in Lift Hydraulic Function Maximum Speed and Ramp Times Set the maximum hydraulic flow to a value from 0% to 100%. A value of 0% deactivates this function. Set the ramp time settings to a value of 0 to 2 seconds. The setup screen for this submenu is similar to Figure 66.

AUXILIARY 1B HYDRAULIC FUNCTION MAXIMUM SPEED AND RAMP TIMES To change the ramp up or down time setting or to adjust the maximum flow supplied for hydraulic function 3B, follow the procedure given in Lift Hydraulic Function Maximum Speed and Ramp Times. Set the maximum hydraulic flow to a value from 0% to 100%. A value of 0% deactivates this function. Set the ramp time settings to a value of 0 to 2 seconds. The setup screen for this submenu is similar to Figure 66.

AUXILIARY 2A HYDRAULIC FUNCTION MAXIMUM SPEED AND RAMP TIMES To change the ramp up or down time setting or to adjust the maximum flow supplied for hydraulic function 4A, follow the procedure given in Lift Hydraulic Function Maximum Speed and Ramp Times.

Truck Setup Menu Set the maximum hydraulic lift to a value from 0% to 100%. A value of 0% deactivates this function.

2200 YRM 1336 Press the 2 or 3 soft key to set control of this function to Enabled or Disabled.

Set the ramp time settings to a value of 0 to 2 seconds. The setup screen for this submenu is similar to Figure 66.

AUXILIARY 2B HYDRAULIC FUNCTION MAXIMUM SPEED AND RAMP TIMES To change the ramp up or down time setting or to adjust the maximum flow supplied for hydraulic function 4B, follow the procedure given in Lift Hydraulic Function Maximum Speed and Ramp Times. Set the maximum hydraulic lift to a value from 0% to 100%. A value of 0% deactivates this function. Set the ramp time settings for the hoist to a value of 0 to 2 seconds. The setup screen for this submenu is similar to Figure 66.

OPTIONAL HYDRAULIC FUNCTIONS NOTE: This submenu is displayed only to logged in Service Technicians or Supervisors. This menu allows a Service Technician or Supervisor to enable or disable dual hydraulic function control. This feature allows control of two hydraulic functions from a single valve. Figure 67 shows the Hydraulic Accessories Setup Screen.

Figure 67. Hydraulic Accessories Setup Screen

REAR LIGHTS CONTROL NOTE: This submenu is available to logged in Service Technicians only. This menu permits a Service Technician to enable or disable the outputs that control brake, tail, and backup lamps. Figure 68 shows the Rear Lights Control Setup Screen. Press the 2 or 3 soft key to set the outputs that control the rear lights to Enabled or Disabled.

Slip Sheet: When the optional slip sheet function is enabled the truck will enter a freewheeling state when the truck is below a set travel speed, the pedals are released, and the associated hydraulic function is engaged (standard interlocks still apply). If equipped with an automatic park brake the brake shall be released. Auxiliary Hydraulics: This feature enables/disables control of a diverter solenoid allowing control of 2 hydraulic functions from a single valve. In some applications, customers may wish to add an additional function to the hydraulic system without changing the valve assembly. In such a case, it is desirable to redirect flow from the Aux 1, Aux 2 or Aux 3 valves to a different function using an external direction select valve. This solenoid valve diverts the A and B flow to a different function while the main valve controls flow and direction.

Figure 68. Rear Lights Control Setup Screen

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Diagnostics Menu

RESTORE DEFAULT SETTINGS NOTE: This submenu is available on all trucks to logged in Service Technicians and Supervisors. This menu allows a Service Technician or Supervisor to change all adjustable truck settings back to their factory default settings. Calibrations are NOT reset when this function is used. Figure 69 shows the Restore Defaults Screen. While in this menu, press the Enter Key to restore all truck settings, except hour meters and system time, to their factory default settings. The system then returns to the Truck Setup Menu.

Figure 69. Restore Defaults Screen

Diagnostics Menu INTRODUCTION The Diagnostics Menu is a main menu (top-level menu) that is visible only at the Service Technician password access level. To enter this menu, cycle through the main menu title screens by pressing the Scroll Back Key ( —) or Scroll Forward Key (— ) until the Diagnostics Title Screen is displayed, as shown in Figure 70.

Figure 71. Fault Code Log Submenu

Figure 70. Diagnostics Title Screen Press the Enter Key (*) to enter the Diagnostics Menu. The system will then display the first submenu in this menu, the Fault Code Log submenu, which is shown in Figure 71. Press the Enter Key again to enter this submenu. For a different submenu, use the Scroll Back Key or Scroll Forward Key to move to the desired submenu and press the Enter Key.

The Diagnostics Menu offers these submenus (see the Diagnostic Submenu Icons topic in the Icon Glossary): • Fault Code Log • Speedometer • Direction Switch • Traction Motor 1 Status • Traction Motor 2 Status • Occupancy Sensor • Brake System Sensors • Pump Status • Hydraulic Control Inputs • E-Hydraulic Valves • Hydraulic Sensors • System Voltages • Steering Position Sensors

Diagnostics Menu

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The following topics describe the Diagnostics submenus.

Figure 72 shows how the devices appear on the display. The Master Controller’s fault log displays first.

FAULT CODE LOG

Press the 2 Up Arrow soft key to view a previous log or press the 3 Down Arrow soft key to view the next log.

Use this submenu to view the 20 most recent fault codes for any of these devices: Master Controller, Traction Controller 1 or 2, Pump Controller, Light Controller, E-Hydraulics, Impact, or Display.

To clear the fault log for the device being viewed, press the 4 soft key near the Trash Can Icon.

NOTE: Pressing the Scroll Back Key or Scroll Forward Key returns the user to the Diagnostics Menu list.

Figure 72. Fault Log Menu Order

Fault Log Details Each log entry presents the fault code, the number of occurrences, the truck hour at the time of the first occurrence, the system time at the first occurrence, and the system time at the last occurrence. The system shows either the system time of the occurrences or the hour meter reading of the occurrences as shown in Figure 73. Press the 1 soft key next to the hour glass or clock Icon in the upper left corner of the display to switch between display of system times or hour meter readings.

Figure 73. Fault Log Example

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Legend for Figure 73 1. FAULT CODE 2. OCCURRENCE COUNT 3. HOUR METER/TITLE STAMP OF LAST OCCURRENCE 4. SOFT KEY - VIEW PREVIOUS LOG FAULT ENTRY 5. FAULT LOG ENTRY NUMBER 6. SOFT KEY - VIEW NEXT LOG FAULT ENTRY 7. SOFT KEY - VIEW FAULT LOG OF NEXT ENTRY 8. DEVICE INDICATOR 9. SOFT KEY - VIEW FAULT LOG OF PREVIOUS ENTRY 10. TRASH CAN SOFT KEY - CLEARS FAULT LOG 11. HOUR METER/TIME STAMP OF FIRST OCCURRENCE 12. SOFT KEY - CHANGES BETWEEN SYSTEM TIMES AND HOUR METERS

Diagnostics Menu

DIRECTION SWITCH Use this submenu to view the current status of the direction switch. A solid (filled) up arrow indicates the currently selected direction is forward as shown in Figure 74.

SPEEDOMETER Use this submenu to view the current wheel based travel speed, which is shown in MPH or km/h. A positive value indicates a forward travel speed; a negative value indicates a reverse travel speed.

Figure 74. Direction Switch Example If both directions are indicated on the display, it means the user has pressed both the forward and reverse switches on a Monotrol pedal. When a null icon (circle with diagonal line across it) appears over the forklift truck icon in the top right corner of the screen, it means traction and hydraulics are deactivated.

TRACTION MOTOR 1 STATUS Figure 75 shows the Traction Motor 1 Status screen. The value to the right of the icon at the top of the screen is the traction pump motor’s current RPM.

The type of speed units, MPH or km/h is set in a submenu of the Display main menu. The accelerator pedal percentage indicator displays the current calculated accelerator pedal percent, where less than 2% is considered a fully released accelerator pedal and 100% is considered fully applied accelerator pedal. Accelerator pedal voltage 1 is used to calculate the position of the accelerator pedal. Accelerator pedal voltage 2 is used for diagnostic purposes.

The second value down from the top is the temperature of the pump motor. Temperatures are shown in degrees Fahrenheit or Celsius, depending on the units assigned in the Set Units item on the Maintenance Menu. The third value down is the temperature of the controller. The fourth value down is the motor controller voltage (or the battery voltage read by the controller). The fifth value down is the RMS (Root Mean Squared) AC current from the motor to the controller in Amperes. When there is a null icon over the forklift truck icon in the top right corner of the screen, it indicates traction and hydraulics are deactivated.

Diagnostics Menu

2200 YRM 1336 If seat belt monitoring is engaged, the seat belt status is also shown by the icon in the lower right corner of the screen. If the occupancy sensor detects the presence of an operator, the seat belt icon is shown; if the seat is not occupied, an X is displayed over the seat belt icon. When there is a null icon over the forklift truck icon in the top right corner of the screen, it indicates traction and hydraulics are deactivated.

BRAKE SYSTEM SENSORS Figure 77 illustrates the Brake System Sensors screen, which presents the current voltages of the park brake, the brake fluid sensor, and the brake pressure system. 1. 2. 3. 4. 5. 6.

PUMP MOTOR RPM PUMP MOTOR TEMPERATURE CONTROLLER TEMPERATURE MOTOR CONTROLLER VOLTAGE MOTOR RMS CURRENT FORKLIFT TRUCK ICON

Figure 75. Motor Status Example

TRACTION MOTOR 2 STATUS This screen is the identical to the Traction Motor 1 Status screen. It is displayed only if the truck has dual traction motors.

OCCUPANCY SENSOR Figure 76 shows the Occupancy Sensor screen.

Figure 77. Brake Diagnostics Screen The value to the right of the park brake icon is the current voltage reading from the park brake’s position sensor. The second value down is the current voltage reading from the brake fluid sensor. The third value down is the current voltage reading from the brake pressure sensor. When there is a null icon over the forklift truck icon in the top right corner of the screen, it indicates traction and hydraulics are deactivated.

PUMP STATUS Figure 76. Occupancy Sensor Screen The value to the right of the seat indicator icon is the current voltage of the occupancy sensor.

Figure 78 shows the Pump Status screen, which shows the pump motor’s RPM, the temperature of the motor and temperature of the controller, the battery voltage read by the controller, and the AC current reading.

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Diagnostics Menu

Figure 79. Hydraulic Control Inputs Diagnostics 1. 2. 3. 4. 5. 6.

TRACTION PUMP MOTOR CURRENT RPM PUMP MOTOR CURRENT TEMPERATURE CONTROLLER CURRENT TEMPERATURE MOTOR CONTROLLER VOLTAGE MOTOR RMS CURRENT FORK LIFT TRUCK ICON

Figure 78. Pump Motor Status Screen The value to the right of the icon at the top of the screen is the traction pump motor’s current RPM. The second value down from the top is the current temperature of the pump motor. Temperatures are shown in degrees Fahrenheit or Celsius, depending on the units assigned in the Set Units item on the Maintenance Menu. The third value down is the current temperature of the controller. The fourth value down is the motor controller voltage. The fifth value down is the RMS (Root Mean Squared) AC current from the motor to the controller in Amperes.

Use the 1 and 4 soft keys to select the hydraulic function control you want to view. Digital switch input, or Button Status, is shown as pressed or released for each displayed lever input. If the Hydraulics controller reports the switch is not available, the switch state is displayed in the released position. Controller motions to the rear of the truck (B direction) are shown as negative values. When there is a null icon over the forklift truck icon in the top right corner of the screen, it indicates traction and hydraulics are deactivated.

E-HYDRAULIC VALVES This screen is a submenu that displays the electrical current output information from the hydraulic controls known as Hydraulic Functions 1-4. It provides current feedback from each of the equipped E-Hydraulic valves (also called Electro-Hydraulic valves). Data shown includes amperes (A) and the present state of the Auxiliary Function Solenoid; that is, whether it is Engaged or Not Engaged. This menu displays only on trucks equipped with E-Hydraulics, which provides hydraulic functions 1-4. See Figure 79.

When there is a null icon over the forklift truck icon in the top right corner of the screen, it indicates traction and hydraulics are deactivated.

HYDRAULIC CONTROL INPUTS This screen, shown in Figure 79, displays input position information from the hydraulic function controls, including lever positions for lift/lower, forward/backward, Auxiliary 1 input, Auxiliary 2 input, and any digital switches as indicated by the controllers. Auxiliary inputs are displayed only on trucks equipped with hydraulic function controls 3-4.

1. HYDRAULIC FUNCTION 1 2. AUXILIARY FUNCTION SOLENOID

Figure 80. E-Hydraulic Valves Menu

Diagnostics Menu The value on the right hand side of the Hydraulic Function 1 Icon at the top of the screen shows the Hydraulic Function 1 amperes of the valve assembly for lift/lower. The second value down from the top of the screen shows the Hydraulic Function 2 amperes for the valve assembly for tilt forward/back. The third, fourth, and fifth values down are for the Auxiliary 1 and 2 inputs. Since these inputs are optional, they are displayed only if the truck is equipped with them. The third value down shows the Hydraulic Function 3 (Auxiliary 1 input) amperes and the fourth value down shows the Hydraulic Function 4 (Auxiliary 2 input) amperes. When the ampere value is a positive number, it is a value in the A direction (the A direction means motion toward the front or the right of the truck). If the value is a negative number, the value shown is in the B direction (motion toward the rear or the left of the truck).

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HYDRAULIC SENSORS Figure 81 displays the current temperature of the hydraulic tank and the current voltages of the mast tilt sensor, the mast height sensor, and the hydraulic pressure sensor that detects load weight. The current temperature of the hydraulic tank is the value at the top of the screen. The second value down from the top of the screen is the current voltage of the mast tilt sensor. The third value down is the current voltage of the mast height sensor. The fourth value down is the hydraulic pressure sensor that detects load weight. When the forklift truck icon in the top right corner of the screen has a null icon over it, it indicates traction and hydraulics are deactivated.

If the forklift truck is equipped with this function, the state of the auxiliary function solenoid is displayed. This icon at the top of the screen indicates whether the valve assembly is released or pressed. If the auxiliary function solenoid is being driven, the engaged icon is displayed and the icon has an up arrow. If this solenoid is not being driven, the disengaged icon is shown and the icon has a down arrow. The forklift truck icon in the top right corner of the screen shows whether truck operations are enabled or disabled. If a null icon overlays the forklift truck icon, traction and hydraulics are deactivated. To enable traction and hydraulics, press the 2 soft key.

Figure 81. Mast Diagnostics Screen

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Diagnostics Menu

SYSTEM VOLTAGES

STEERING POSITION SENSORS

Figure 82 shows the System Voltage Diagnostics screen.

Figure 83 shows the Steering Sensor screen.

The value to the right of the top icon is the current system operating voltage of the 5 V supply. The value to the right of the second icon down from the top of the screen is the current system operating voltage of the 12 V supply.

This submenu displays the current voltage output from the steering wheel and axle position sensors. The status of the axle position displays only on trucks equipped with either dual traction motors or the Steer Synchronization feature.

The value to the right of the third icon down is the battery voltage.

Figure 83. Steering Sensor Screen

Figure 82. Voltage Diagnostics Screen

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 1336

1/11 (7/10)(6/10)(3/10)(2/10)(9/09)(2/09)(9/08) Printed in U.S.A.

Maintenance

USER INTERFACE SUPERVISOR ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]; ERC22-35VG (ERC045-070VG) [A968]; ERC16-20VA (ERC030-040VA) [A969]; ERP22-35VL (ERP045-070VL) [A976]

PART NO. 524319497

2200 YRM 1335

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

User Interface

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Description ...................................................................................................................................................... Display Panel Menu Access ............................................................................................................................ Menu Flowchart................................................................................................................................................... Supervisor Menu Flowchart ............................................................................................................................ Menu Navigation.................................................................................................................................................. Main Menu Structure .................................................................................................................................. Screens and Title Screens.......................................................................................................................... Submenus................................................................................................................................................... Returning to the Main Menu ....................................................................................................................... Icons and Settings ...................................................................................................................................... Soft Keys..................................................................................................................................................... Entering Numbers....................................................................................................................................... Icon Glossary ...................................................................................................................................................... Introduction ..................................................................................................................................................... Soft Key Icons ................................................................................................................................................. Overlay Icons .................................................................................................................................................. Icons on System Off Screen and Alert Screens.............................................................................................. Main Menu Title Screens ................................................................................................................................ Submenu Icons Grouped by Menu.................................................................................................................. Operating Screen Icons .............................................................................................................................. Password Screen Icons .............................................................................................................................. Activity Log Submenu Icons........................................................................................................................ Calibration Submenu Icons......................................................................................................................... Display Submenu Icons .............................................................................................................................. Status Submenu Icons................................................................................................................................ Truck Setup Submenu Icons ....................................................................................................................... Operating Screen ................................................................................................................................................ Introduction ..................................................................................................................................................... Performance Mode Controls ........................................................................................................................... Status and Warning Icons ............................................................................................................................... Battery Discharge Indicator............................................................................................................................. Direction and Parking Brake Indicators ........................................................................................................... Hazard Flashers and Lighting Controls........................................................................................................... Tire Angle Indicator ......................................................................................................................................... System Time ................................................................................................................................................... Load Weight Indicator ..................................................................................................................................... System Off/Alert Screens .................................................................................................................................... Introduction ..................................................................................................................................................... System Off Screen .......................................................................................................................................... Alert Screens .................................................................................................................................................. Password Screen................................................................................................................................................. Introduction ..................................................................................................................................................... Password Screen ............................................................................................................................................ Service Technician Password Setup ........................................................................................................... Adding/Removing/Changing Passwords ......................................................................................................... Password Log.................................................................................................................................................. Activity Log Menu ................................................................................................................................................ Introduction ..................................................................................................................................................... Operator Checklist Log ................................................................................................................................... Password Log..................................................................................................................................................

1 1 1 2 2 8 8 9 9 10 10 10 11 11 11 11 13 13 16 18 18 19 19 20 23 25 28 34 34 35 35 36 37 37 37 37 37 38 38 38 38 39 39 39 40 41 42 44 44 44 47

Table of Contents

User Interface

TABLE OF CONTENTS (Continued) Impact Events Log .......................................................................................................................................... Calibration Menu ................................................................................................................................................. Introduction ..................................................................................................................................................... Load Weight Calibration .................................................................................................................................. Return to Set Tilt Stop Point Calibration.......................................................................................................... E-Hydraulic and Manual Valve Threshold Calibration ..................................................................................... Steering Wheel Knob Center Point Calibration ............................................................................................... Steer Axle Position Calibration........................................................................................................................ Manual Hydraulics Calibration......................................................................................................................... Display Menu....................................................................................................................................................... Introduction ..................................................................................................................................................... Set Date and Time Format Menu.................................................................................................................... Set Daylight Saving Time Menu ...................................................................................................................... Procedure for Setting Up Automatic Daylight Savings Time ....................................................................... Set Time and Date Menu ................................................................................................................................ Procedure for Setting Time and Date ......................................................................................................... Set Units Menu................................................................................................................................................ Status Menu ........................................................................................................................................................ Introduction ..................................................................................................................................................... VSM Versions.................................................................................................................................................. Display Versions.............................................................................................................................................. Truck Serial Number........................................................................................................................................ Hour Meters .................................................................................................................................................... E-Hydraulic Controller Versions ...................................................................................................................... Pump Motor Controller Versions ..................................................................................................................... Traction Motor Controller 1 Versions ............................................................................................................... Traction Motor Controller 2 Versions ............................................................................................................... Light Controller Versions ................................................................................................................................. Impact Sensor Versions .................................................................................................................................. Truck Setup Menu................................................................................................................................................ Introduction ..................................................................................................................................................... Add/Remove Password ................................................................................................................................... Restore Default Settings ................................................................................................................................. Motion Alarm ................................................................................................................................................... Impact Monitor Settings .................................................................................................................................. Impact Detection ......................................................................................................................................... Setting Adjustments .................................................................................................................................... Initial Adjustment of Soft and Hard Impact Settings ................................................................................... Readjustment of Soft and Hard Impact Settings......................................................................................... Auto Power-Off Time Delay ............................................................................................................................. Return to Set Tilt ............................................................................................................................................. Traction Speed Limit........................................................................................................................................ Scheduled Maintenance Reminder ................................................................................................................. Minimum Pump Standby Flow Rate ................................................................................................................ Operator Checklist .......................................................................................................................................... Impact Monitor Shutdown ............................................................................................................................... Motor Braking.................................................................................................................................................. Changing the Motor Braking Settings .........................................................................................................

48 50 50 51 51 52 52 53 53 54 54 54 55 56 58 58 59 59 59 60 60 60 61 61 61 61 61 61 62 62 62 63 63 63 63 64 64 64 64 65 65 65 66 67 67 68 69 69

User Interface

Table of Contents

TABLE OF CONTENTS (Continued) This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]; ERC22-35VG (ERC045-070VG) [A968]; ERC16-20VA (ERC030-040VA) [A969]; ERP22-35VL (ERP045-070VL) [A976]

iii

2200 YRM 1335

General

General DESCRIPTION This topic describes the functions of the display panel that are available to the Supervisor. With a proper service technician password, a Service Technician can access menu items that are not visible at Operator or Supervisor password-level access.

DISPLAY PANEL MENU ACCESS Turning the keyless start switch or key switch to the On position activates the Display Panel. Figure 1 shows the layout of the Display Panel including the location of the keyless start switch or key switch. The operator password screen appears at startup as shown in Figure 2 if Operator Passwords are enabled. Use the number keys on the Display Panel to enter your five-digit Supervisor password. For more information, see the Password Screen topic. If a non-service technician password has already been entered at the initial password screen, you can navigate to the Password Screen by pressing the Enter Key (*) to go to the Main Menu, then press either the Scroll Back Key ( —) or the Scroll Forward Key (— ) to access the Password Screen. Refer to the Main Menu Structure topic for orientation on the Main Menu title screens (the main level menus).

1. 2. 3. 4. 5. 6. 7. 8.

2 AND 3 KEYS SCROLL FORWARD KEY (RIGHT ARROW) 5, 6, 7, 8, 9, AND 0 KEYS KEYLESS START SWITCH OR KEY SWITCH SCROLL BACK KEY (LEFT ARROW) 1 AND 4 KEYS POUND KEY (# KEY) ENTER KEY (* STAR KEY)

Figure 1. Lift Truck Display Panel

Figure 2. Password Screen

Menu Flowchart

2200 YRM 1335

Menu Flowchart SUPERVISOR MENU FLOWCHART NOTE: Depending upon how the lift truck is equipped, some of the functions described in this section may not be included in the on-board menu structure for a particular lift truck. NOTE: The icons displayed on the Operating Screen vary from any one time to another, depending on the current operation of the lift truck and other factors. The Battery Discharge Indicator, system time, and direction indicator are always displayed.

2200 YRM 1335

Menu Flowchart

Figure 3. Supervisor Flowchart (Sheet 1 of 4)

Menu Flowchart

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Figure 3. Supervisor Flowchart (Sheet 2 of 4)

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Menu Flowchart

Figure 3. Supervisor Flowchart (Sheet 3 of 4)

Menu Flowchart

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Figure 3. Supervisor Flowchart (Sheet 4 of 4)

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Menu Flowchart

Table 1. Supervisor Menu Flowchart A

Operating Screen

Password Entry

Activity Log

Calibration

Operator Checklist

3 4

Diagnostics

Truck Setup

Truck Status

Display Adjustment

Load Weight

Add/Remove Password

VSM Version

Set Date and Time Format

Impact Events

Manual Hydraulics

Restore Default

Impact Sensor Version

Set Units

Password

Steering Axle Position

Light Controller Version

Set Time and Date

Steering Wheel Knob Center Point

Traction Motor Controller 2 Version

Set Daylight Saving Time

Valve Threshold

Traction Motor Controller 1 Version

SHEET 1

Pump Motor Controller Version

Return to Set Tilt Stop

E-Hydraulic Controller Version

Hour Meters

10 11

Truck Serial Number Display Version

SHEET 2

12 13 14

Motion Alarm

Impact Monitor Settings

Auto Power-Off Time Delay

17 18 19

Return to Set Tilt Traction Speed Limit

SHEET 3

Scheduled Maintenance Required

Minimum Pump Standby

Operator Checklist

Interlock Menu Screen

Cycle the Key

Traction Switch

Secure Battery

Hydraulic Switch

Release Park Brake

Temperature Too High

Operator out of Seat

Lift Limit Exceeded

Release Accelerator

Charge Battery

Release Hydraulic Input

Impact DetectedEnter Service/ Supervisor Password

SHEET 4

Impact Monitor Shutdown

Motor Braking

Menu Navigation

2200 YRM 1335

Menu Navigation This topic explains how to use the keys on the Display Panel, shown in Figure 4, to navigate from one menu to another and change settings.

Operator Passwords are deactivated (in this case, the Activity Log Title Screen appears). After entering your password successfully, the system displays the Operating Screen on the orange 1.5 x 2.5 inch LCD screen of the Display Panel as shown in Figure 4. When a title screen or a menu screen is displayed on the LCD screen, the screen is still referred to as the “screen” in a generic way, but the actual Operating Screen is shown in Figure 4. See the Operating Screen section for details. When the Operating Screen is displayed, pressing the Scroll Forward Key (— ) causes the system to display the Password Screen. If you press the Scroll Forward Key a second time, the system displays the Activity Log Title Screen, shown in Figure 5, on the LCD screen.

1. LCD SCREEN

2. DISPLAY PANEL

Figure 4. Display Panel With Operating Screen Displayed Keys used for menu navigation include: • The 1, 2, 3, 4, and # keys. • The Enter Key (*) which is also called the star key because of its * label. • The Scroll Back Key ( —) and the Scroll Forward Key ( — ). These keys are explained in detail in the General section of this document.

Main Menu Structure

The Password Screen, discussed in the Adding/Removing/Changing Passwords topic in the Password Screen section, is the first screen displayed when the key switch or keyless switch is turned to the On position unless

Use the Scroll Back Key or the Scroll Forward Key to move from one title screen to another. Press the Enter Key to enter one of these main menus.

Figure 5. Activity Log Title Screen

The main menus (top-level menus) appear on the screen in the order shown in Figure 6.

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1. OPERATING SCREEN 2. PASSWORD SCREEN 3. ACTIVITY LOG TITLE SCREEN

Menu Navigation

4. CALIBRATION TITLE SCREEN 5. DIAGNOSTICS TITLE SCREEN 6. TRUCK SETUP TITLE SCREEN

7. STATUS TITLE SCREEN 8. DISPLAY TITLE SCREEN

Figure 6. Main Menu Structure

Screens and Title Screens

Submenus

The main menu has eight menus, or screens, which are shown in Figure 6. By pressing the Scroll Forward Key to advance through all of them.

Submenus are the “branches” of a main menu. The Activity Log Menu has only three submenus, while the Truck Setup Menu has 13 submenus. Each submenu is represented by a title screen. When the title screen of the submenu you want is displayed on the screen, press the Enter Key to enter that submenu. For example, if you enter the Operator Checklist Log submenu, shown in Figure 7, the system displays the menu shown in Figure 8.

If you press the Scroll Forward Key after reaching the Display Title Screen, the system returns (loops back) to the Operating Screen. Press the Scroll Forward Key to scroll through the screens again. Alternatively, use the Scroll Back Key to scroll through the screens in the reverse direction. The Password Screen and Operating Screen do not have submenus below them. The other title screens are all main menus which have submenus under them. Submenus can also be called second-level menus. Figure 5 is an example of a main menu screen. Supervisors have access to the Activity Log, Calibration, Display, Truck Setup, and Status Title Screens. Service Technicians have access to all title screens; Operators use only the Password Screen, Operating Screen, and Calibration Title Screen.

When viewing a submenu title screen, you can return to the main menu at any time by pressing the Scroll Back Key or the Scroll Forward Key. Menu navigation is possible through the use of soft keys, which are explained in the Soft Keys topic. For example, if you scroll to the Activity Log Title Screen and have it displayed on the screen as shown in Figure 5, press the Enter Key (*) to enter the Activity Log menu. The system will display the first submenu in the Activity Log menu, which is shown in Figure 7. Press the Enter Key again and the system will display the Operator Checklist Log, shown in Figure 8. The Activity Log Icon in the upper left corner of this submenu indicates you are in the Activity Log main menu.

Menu Navigation

2200 YRM 1335 icon represents: 1) a setting that can be changed, or 2) a status value that can be viewed, such as a truck’s serial number, or 3) an action that can be taken, such as clearing the fault log. Only a logged in user who has the proper privileges can change a setting, view a status value, or take an action.

Figure 7. Operator Checklist Log Title Screen

Soft Keys

Figure 8. Operator Checklist Log Menu

Returning to the Main Menu To return to the main menu from a submenu, press the Scroll Forward Key ( — ). This returns you to the title screen of the submenu (second-level menu) you are using. If you press the Scroll Forward Key a second time, the system returns you to the main menu. You can return to the main menu, or back out of a submenu, by pressing the Scroll Back Key. Press the Enter Key to save any changes you make in submenu before exiting from the submenu. If you return to the main menu before saving a change, the system does not store the change.

Icons and Settings An icon is a simple graphic that represents an object, such as a clock, or a setting such as battery voltage. Each submenu has at least one icon on it, and each

2200 YRM 1335

Icon Glossary

The following example shows how to use the soft keys. How to Change the Battery Voltage Setting 1. Starting from the main menu, use the Scroll Back Key ( —) or Scroll Forward Key (— ) to navigate to the Truck Setup Title Screen and press the Enter Key (*). 2. Use the 2 or 3 arrow soft keys to step through the menus to the Battery Setup submenu (the title screen of this submenu has a battery icon on it) and press the Enter Key. 3. Press the 2 or 3 arrow soft key to "move to" the value located to the right of the top icon an the system will place a "selection box" around the value. This number indicates the current battery voltage, such as 36. 4. With the selection box around the battery voltage value, press the Enter Key. 5. Use the 2 and 3 arrow soft keys to move up or down though the available values (36, 48, 72, and 80) until 48 is displayed, then press the Enter Key. The system stores the 48 Volt value and begins using it as the new battery voltage setting.

NOTE: While changing a setting, all other sub-items (setting items) disappear.

Icon Glossary

2200 YRM 1335

Table 2. Soft Key Icons Icon

Description Hare performance mode "increase" icon. Press the 1 soft key (or the # soft key in some cases) to increase performance. Tortoise Performance Mode “decrease” icon. Press the 3 soft key to decrease performance. Trash Can icon. Used to delete all entries in a log. Press the 4 soft key (or the # soft key in some cases) to empty a log. Up Arrow soft key. Press 2 to scroll up in most screens. Also used to view next log entry in log screen. Down Arrow soft key. Press 3 to scroll down in most screens. Also used to view next log entry in log screen. View Next Device Log icon. Press the # key for previous. View Previous Device Log icon. Press the * key for next.

This icon points to the * key (the soft Enter Key) and is used to accept a value, command a calibration action, or restore defaults, depending on the context when the * key is pressed.

Table 2. Soft Key Icons (Continued) Icon

Description Enable Current Item icon. When the * key is pressed, the current item displayed will appear during the Operator Checklist sequence. Deactivate Soft Key icon. Indicates function is deactivated. Press the * key to deactivate. “Enable” Traction and Hydraulics for Forklift icon. Press the 2 key to enable.

“Disable” Traction and Hydraulics for Forklift icon. Press the 4 key to disable.

Hazard flashers icon. Press the # key to toggle the hazard flashers on and off. Select system time for Fault Log event. Press the 1 key to select system time (this soft key toggles between system times and hour meters). Front truck lights icon. Only available with CAN light controller. Press the 4 key to turn truck lights on. Rear truck lights icon. Only available with CAN light controller. Press the 2 key to turn truck lights off.

2200 YRM 1335

Icon Glossary

OVERLAY ICONS

Table 4. Alert Screen Icons

Icon

Description Alert

Table 3. Overlay Icons Icon

Description Null symbol icon. When this icon overlays another icon it indicates that a setting value is invalid or out-of-range. X icon. This icon indicates that a feature has been deactivated (disabled).

Example of a Fault Screen Traction icon

ICONS ON SYSTEM OFF SCREEN AND ALERT SCREENS The System Off Screen and the various Alert Screens appear only briefly. These screens also show interlocks such as Operator Not in Seat. Refer to System Off/ Alert Screens for more information on these screens. The icons used in alert screens identify either status or warning conditions. Table 4 shows the icons that can appear on these screens.

Forklift Truck icon

Service Required icon

Hydraulics icon

Icon Glossary

2200 YRM 1335

Table 4. Alert Screen Icons (Continued) Icon

Description Alert

Table 4. Alert Screen Icons (Continued) Icon

Description Alert

Alert Screens

Operator Out of Seat Cycle the Key

Release Pedal Secure Battery

Release Hydraulic Input Release Park Brake

2200 YRM 1335

Icon Glossary

Table 4. Alert Screen Icons (Continued) Icon

Description

Table 4. Alert Screen Icons (Continued) Icon

Description

Alert

Traction Switch

Lift Limit

Hydraulic Switch

Charge Battery

Temperature Too High

Icon Glossary

2200 YRM 1335

Table 4. Alert Screen Icons (Continued) Icon

Description Alert

Table 5. Main Menu Title Screens Operating Screen

Truck Locked — Impact Detected — See Supervisor to Unlock

NOTE: Icons for Front and Rear Lights are shown. These are optional features. Password Screen

Fault Detected

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Icon Glossary

Table 5. Main Menu Title Screens (Continued)

Activity Log Title Screen

Status Title Screen

Calibration Title Screen

Display Title Screen

Truck Setup Title Screen

Diagnostics Title Screen

Icon Glossary

2200 YRM 1335

SUBMENU ICONS GROUPED BY MENU This topic presents the icons used in submenus in groups, with one table for each title screen of the main menu.

Operating Screen Icons

Table 6. Operating Screen Icons (Continued) Icon

Description Motor Temperature High Warning icon

Table 6 shows the icons that appear on the Operating Screen. Normally the icons convey status or operating information such as battery charge level, tire angle, front and rear work light soft keys, and system time. Sometimes icons are displayed to provide critical information, such as warnings. Refer to the Operating Screen topic for more information.

Hydraulic Fluid Level Low Warning icon. (Displayed only on trucks that have the Hydraulic Filter Monitoring option.)

NOTE: The icons displayed on the Operating Screen vary from any one time to another, depending on the current operation of the lift truck and other factors. The Battery Discharge Indicator, system time, and direction indicator are always displayed.

Hydraulic Filter Warning (restriction) icon. (Displayed only on trucks that have the Hydraulic Filter Monitoring option.)

Table 6. Operating Screen Icons Icon

Description Hare performance mode icon. Press the 1 or # soft key to increase performance. (The soft key to use depends on the currently displayed menu.) Tortoise performance mode icon. Press the 3 soft key to decrease performance.

Service Due Soon Warning icon

Hazard Flashers icon. See Table 2 for more information.

Forward Direction Indicator icon

Battery Discharge Indicator (BDI) icon

Neutral Indicator icon

Seat Belt Warning icon

Reverse Direction Indicator icon

Brake Fluid Low Warning icon

Park Brake On icon

2200 YRM 1335

Icon Glossary

Table 6. Operating Screen Icons (Continued) Icon

Description

Table 7. Password Screen Icons Icon

Password Lock icon

Tire Angle Indicator icon

Rear Work Light icon. This is an optional feature.

Description

A field with five blanks appears below the Password Lock icon. See Figure 2.

Activity Log Submenu Icons Front Work Light icon. This is an optional feature.

Table 8 presents the icons that appear on the Activity Log Submenus. These icons provide status information or numeric information. Refer to Activity Log Menu for more information.

Table 8. Activity Log Submenus and Icons Load Weight In Pounds (Lb) icon

Icon

Description

Activity Log Submenus

Load Weight In Kilograms (Kg) icon

Load Weight Readout (example)

System Time Readout (example)

Password Screen Icons The Password Screen has only one icon, which is shown in Table 7. If the truck is equipped with Operator Passwords enabled, the Password screen is the first screen to appear when you turn on the key switch or turn the keyless switch to the On position. See the Passwords Screen topic for more information.

Operator Checklist Log Submenu

Password Log Submenu

Impact Events Log Submenu

Icon Glossary

2200 YRM 1335

Table 8. Activity Log Submenus and Icons (Continued) Icon

Description

Table 8. Activity Log Submenus and Icons (Continued) Icon

Description

Empty Log icon

Service Password Type icon

Checklist Failed icon

Soft Impact Type icon

Checklist Passed icon

Hard Impact Type icon

Password Lock icon

Calibration Submenu Icons

*****

Hidden or "no password" field log entry icon Clock icon for occurrence date

Table 9 presents the icons that appear on the Calibration Submenus. See Calibration Menu for more information.

Table 9. Calibration Submenus and Icons Icon

Description

Load Weight Display Submenu

Hourglass icon for system time

Operator Password Type icon

Supervisor Password Type icon "Position Empty Forks To Load Weight Height" Prompt icon

2200 YRM 1335

Icon Glossary

Table 9. Calibration Submenus and Icons (Continued) Icon

Description "Enter Known Load Weight" Prompt icon

"Position Load Weight To Height" Prompt icon

Table 9. Calibration Submenus and Icons (Continued) Icon

Description This icon points to the * key and is used for RTST calibration in this submenu.

Valve Threshold Submenu

"Known Load Weight Value (Lb)" Prompt icon

"Known Load Weight Value (Kg)" Prompt icon

This icon points to the * key (the Enter soft key) and is used for load weight calibration in this submenu. Return to Set Tilt Stop Point Submenu

Valve Threshold Function 1 "A" Direction Prompt icon

Valve Threshold Function 1 "B" Direction Prompt icon

Valve Threshold Function 2 "A" Direction Prompt icon

Valve Threshold Function 2 "B" Direction Prompt icon

Return to Set Tilt (RTST) Set Point Prompt icon

Valve Threshold Function 3 "A" Direction Prompt icon

Icon Glossary

2200 YRM 1335

Table 9. Calibration Submenus and Icons (Continued) Icon

Description Valve Threshold Function 3 "B" Direction Prompt icon

Valve Threshold Function 4"A" Direction Prompt icon

Table 9. Calibration Submenus and Icons (Continued) Icon

Description This icon points to the * key and is used for steering wheel center point calibration in this submenu.

Steer Axle Position Submenu

Valve Threshold Function 4 "B" Direction Prompt icon

This icon points to the * key and is used for valve calibration in this submenu. Steering Wheel Knob Center Point Submenu

Steering Wheel Full Left Prompt icon

Steering Wheel Full Right Prompt icon

This icon points to the * key and is used for steer axle position in this submenu. Center Steering Wheel Prompt icon

2200 YRM 1335

Icon Glossary

Table 9. Calibration Submenus and Icons (Continued)

Table 10. Display Submenus and Icons Icon

Icon

Description

Set Date and Time Format Submenu

Manual Hydraulics Submenu

Clock icon for setting time Manual Hydraulic End Point Calibration Prompt icon Calendar icon for setting date This icon points to the * key and is used for manual hydraulic end point calibration in this submenu.

24-Hour Clock icon

Display Submenu Icons Table 10 presents the icons that appear on the Display Submenus. Refer to Display Menu for more information.

12-Hour Clock icon

DD/MM/YY (Europe) Date Format icon

MM/DD/YY (USA) Date Format icon

Icon Glossary

2200 YRM 1335

Table 10. Display Submenus and Icons (Continued) Icon

Description YY/MM/DD (ISO 8601) Date Format icon

Set Daylight Savings Submenu

Table 10. Display Submenus and Icons (Continued) Icon

Description First Sunday icon

Last Sunday icon

First Friday icon

Last Friday icon

Daylight Savings Adjustment Enable icon

NOTE: Not all icons for setting daylight savings time are shown. The four icons above serve as examples of the 14 variations. Set Time and Date Submenu

Daylight Savings Start Month Indicator icon

Daylight Savings Start Day Indicator icon

Daylight Savings End Month Indicator icon

Daylight Savings End Day Indicator icon

Clock icon for setting time

2200 YRM 1335

Icon Glossary

Table 10. Display Submenus and Icons (Continued) Icon

Description Calendar icon for setting date

Table 11. Status Submenus and Icons Icon

Description

Vehicle System Manager (VSM) Version Submenu

Set Units Submenu

Hardware Version Indicator icon

Set Units icon

Imperial Units Indicator icon

Software Version Indicator icon

Display Version Menu

Metric Units Indicator icon

Status Submenu Icons Table 11 presents the icons that appear on the Status Submenus. See Status Menu for more information. Hardware Version Indicator icon

Icon Glossary

2200 YRM 1335

Table 11. Status Submenus and Icons (Continued) Icon

Description Software Version Indicator icon

Truck Serial Number Submenu

Table 11. Status Submenus and Icons (Continued) Icon

Description Traction Hour Meter icon

Pump Hour Meter icon

Secure Hour Meter Indicator icon

E-Hyd Controller Version Submenu

Truck Serial Number Symbol icon

Hour Meters Submenu

Hardware Version Indicator icon

Software Version Indicator icon

Truck Hour Meter icon

2200 YRM 1335

Icon Glossary

Table 11. Status Submenus and Icons (Continued) Icon

Description

Pump Motor Controller Version Submenu

Table 11. Status Submenus and Icons (Continued) Icon

Description Hardware Version Indicator icon

Software Version Indicator icon

Traction Controller 2 Version Submenu

Hardware Version Indicator icon

Software Version Indicator icon

Traction Controller 1 Version Submenu

Hardware Version Indicator icon

Software Version Indicator icon

Icon Glossary

2200 YRM 1335

Table 11. Status Submenus and Icons (Continued) Icon

Description

Table 11. Status Submenus and Icons (Continued) Icon

Description Hardware Version Indicator icon

Light Controller Version Submenu

Software Version Indicator icon

Truck Setup Submenu Icons Table 12 presents the icons that appear on the Truck Setup Submenus. See Truck Setup Menu for more information. Hardware Version Indicator icon

Table 12. Truck Setup Submenu Icons Icon

Description

Add/Remove Password Submenu Software Version Indicator icon

Impact Sensor Version Submenu

Password icon

Null Symbol icon

2200 YRM 1335

Icon Glossary

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description Supervisor Password Type icon

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Motion Alarm Submenu

Trash Can icon

Hare (increase performance) icon

Restore Defaults Submenu

Motion Alarm Indicator icon

Motion Alarm Indicator Disabled icon. The X over the icon means the motion alarm is deactivated (turned off). Motion Alarm Clock icon

Restore Defaults icon

Impact Monitor Settings Submenu

This icon points to the * key and is used for restoring defaults in this submenu.

Icon Glossary

2200 YRM 1335

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Return to Set Tilt (RTST) Submenu Soft Impact Force icon

Soft Impact Time icon

Hard Impact Force icon

Hard Impact Time icon

Auto Power-Off Time Delay Submenu

Return To Set Tilt Delay icon

Return To Set Tilt Truck icon

Tilt Both Ways icon

Infinity Symbol icon

Auto Power-off Time Delay Indicator icon

2200 YRM 1335

Icon Glossary

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Traction Speed Limit Submenu

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Scheduled Maintenance Reminder Submenu

Forward MPH icon

Scheduled Maintenance Reminder, enabled (ON)

Reverse MPH icon

Scheduled Maintenance Reminder, disabled (OFF)

Forward km/h icon

Interval Month Setting icon

Interval Hourmeter Setting icon Reverse km/h icon Derated Traction Speed icon

Icon Glossary

2200 YRM 1335

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Minimum Pump Standby Submenu

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description Check Fuses icon

Check Horn icon

Check Hoses icon

Minimum Standby Pump Flow Rate icon

Operator Checklist Submenu

Check Hydraulics icon

Check Mast icon

Check for Leaks icon

Check Operator Restraint icon

Note: The icons displayed when using this submenu correspond to the submenu icons for the various functions. Up to 30 checklist items can be enabled for the Operator Checklist. Check Park Brake icon

Check Pedal Movement icon

Check Service Brake icon

2200 YRM 1335

Icon Glossary

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Press the * key (Enter Key) below this icon to indicate proper operation of the current checklist item.

OFF icon

Press the * key below this icon to indicate improper operation of the current checklist item (to indicate a problem with it).

Disable Traction icon

Disable All icon

Impact Monitor Shutdown Submenu

Motor Braking Submenu

Impact Shutdown Delay icon Regenerative Braking Indicator icon Impact Shutdown Type icon Automatic Deceleration Rate Indicator icon Impact Detection icon

Deceleration Type Indicator icon ON icon

Operating Screen

2200 YRM 1335

Table 12. Truck Setup Submenu Icons (Continued) Icon

Description

Table 12. Truck Setup Submenu Icons (Continued) Icon

Pedal Up Setting icon. This setting lets the lift truck coast until the pedal is fully released.

Description Proportional Setting icon. With this setting, the lift truck decelerates in proportion to how far the pedal is released in relation to the current traction speed. Supervisor icon

uses small graphic images, called icons, to provide continuous feedback to the lift truck operator. This feedback includes performance settings, status and warning messages, and essential truck operating information. The Operating Screen is active at all times during normal lift truck operation. NOTE: Icons for the Front and Rear Work Lights are shown. These are optional features. The icons, indicators, and numbers on the Operating Screen are explained in the topics that follow.

Figure 9. Operating Screen

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PERFORMANCE MODE CONTROLS The Performance Mode controls are shown in Figure 10.

1. 2. 3. 4. 5. 6.

SERVICE DUE MOTOR TEMPERATURE HIGH BRAKE FLUID LOW WARNING SEAT BELT WARNING DIRECTION / PARK BRAKE INDICATORS TIRE ANGLE

Figure 11. Status and Warning Icons

Operating Screen NOTE: Icons for front and rear lights are shown. These are optional features. Depending on conditions, the following icons can appear in this area (see the Table 6 topic): • Wrench Icon • Temperature High Icon • Brake Fluid Low Icon • Hydraulic Fluid Level Icon • Hydraulic Filter Icon • Fasten Seat Belt Icon

2200 YRM 1335 The BDI is located in the top center of the Operating Screen, as shown in Figure 12. The BDI is displayed as a five-segment horizontal bar and it has a battery icon on its left side.

When the wrench icon is continuously On, it means that scheduled maintenance is due. When it is flashing, it indicates that an active fault has been detected by the system. The wrench icon appears in the bottom location of the status/warning icon area when it is displayed. It has the lowest priority of the three icons, wrench, hydraulic filter, or hydraulic fluid level, that can be displayed in this location. The hydraulic filter icon shows in the same location, in place of the wrench icon, if a hydraulic filter restriction is detected. It has the second highest priority of the three icons that can be displayed in this location. The hydraulic fluid level icon shows in the same location, in place of the wrench icon or the hydraulic filter icon, if a low level is detected in the hydraulic fluid reservoir. It has the highest priority of the three icons that can be displayed in this location. The motor temperature high icon is displayed if a high motor temperature is detected, meaning that the motor temperature of one of the motors or motor controllers has gone above the defined threshold temperature. The brake fluid low icon is displayed if a low level is detected in the brake fluid reservoir. The fasten seat belt icon is displayed for the first ten seconds after the truck is powered On, or for ten seconds after the seat is reoccupied after the operator leaves the seat for ten seconds or more. This warning is based on seat occupancy, not the seat belt connection itself. If the operator selects a screen other than the Operating Screen before the ten seconds are up, the fasten seat belt icon will no longer be displayed.

1. BATTERY DISCHARGE INDICATOR

Figure 12. Battery Discharge Indicator The system continuously monitors the truck’s current BSOC, and this is indicated on the BDI by the number of filled bar segments. Table 13 shows the battery’s state of charge in percentages, compared to the number of filled segments.

Table 13. BSOC in Relation to BDI BSOC Charge Remaining (%)

Number of Filled Segments

76% or more

Five (5)

50% to 75%

Four (4)

35% to 50%

Three (3)

25% to 35%

Two (2)

21% to 25%

One (1) segment, plus flashing plus low battery alarm

0 to 20%

Zero (0) segments, plus flashing plus a second low battery alarm

2200 YRM 1335 If the battery charge drops below 25%, the "low battery alarm" sounds and the BDI begins flashing. The "low battery alarm" also sounds if the lift truck is turned On when the BSOC is below 25%. If the BSOC drops to 20%, the leftmost segment changes to an outline and a second "low battery alarm" sounds. The lift truck will be subjected to operating and performance limitations if the BSOC drops below 20%.

DIRECTION AND PARKING BRAKE INDICATORS These indicators are displayed in the center of the Operating Screen, as shown in Figure 11. • An up-arrow indicates the truck will move forward if the accelerator is pressed. • A down-arrow indicates the truck will move backward (reverse) if the accelerator is pressed. • A solid "N" indicates the truck will not move if the accelerator is pressed, though it can still roll if the service brake is released. • The parking brake icon is a "P" with a circle around it to represent a wheel and arcs around the circle to represent brakes. When this icon is displayed, it indicates the truck parking brake is applied and the truck will not move if the accelerator is pressed.

HAZARD FLASHERS AND LIGHTING CONTROLS If the lift truck is equipped with CAN controlled hazard flashers and lighting controls, the icons that indicate the status of the lift truck’s lights and hazard flashers are displayed on the Operating Screen. The soft keys the operator can use to control these lights are located near the Operating Screen. • The Front Work Light Icon, on the lower right of the screen, is always visible. The operator can turn the front lights On and Off by pressing the 2 soft key. • The Rear Work Light Icon, on the upper right of the screen, is always visible. The operator can turn the rear lights On and Off by pressing the 3 soft key. • The Hazard Flashers Icon, a triangle on the lower left of the screen, is always visible if the lift truck

Operating Screen is equipped with hazard flashers. The operator can press the # soft key to toggle the truck’s hazard flashers Off and turn them back On by pressing the # soft key a second time.

LOAD WEIGHT INDICATOR The Load Weight indicator for the lift truck, shown as 99999 beside the Load Weight Icon in Figure 11, appears at the midpoint of the right side of the Operating Screen. If the lift truck supports the Load Weight feature, the Operating Screen will display the load weight during any mast hydraulic command and for five seconds afterwards. The Load Weight Icon indicates whether lb (pound) or kg (kilogram) units are being used. Use the procedures described in the Set Units Menu topic in the Display Menu section to set the load units for this lift truck. Use the procedures in the Load Weight Display topic in the Calibration Menu section to calibrate the load weight for this lift truck.

System Off/Alert Screens

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System Off/Alert Screens Icon

INTRODUCTION

Description Traction Hour Meter Icon

Pump Hour Meter Icon

SYSTEM OFF SCREEN

Secure Hour Meter Indicator Icon

When the lift truck power is first turned off, the System Off Screen is displayed for five seconds. The system will also display this screen for five seconds if the Scroll Forward Key (— ) is pressed while the truck is powered off. Figure 13 shows the System Off Screen.

1. TRUCK HOUR METER 2. PUMP HOUR METER

Description Truck Hour Meter Icon

ALERT SCREENS There are two types of alert screens, Fault Screens (failure indication screens) and Interlock Notification Screens. Both types of alert screens are temporary in nature because the system immediately restores the original screen after a key press or other action removes the problem. When the system detects an active failure, the display changes to a Fault Screen which flashes a fault code, the wrench icon, and other icons to indicate the problem, similar to the example shown in Figure 14. As it is displayed, the alert screen flashes to draw the user’s attention. Pressing either the Scroll Back Key ( —) or Scroll Forward Key (— ) after the alert screen appears causes the system to return to the last screen displayed.

2200 YRM 1335

Password Screen to apply the accelerator pedal, the system will switch from the Operating Screen to an alert screen showing the seat belt icon, as shown in Figure 15.

1. EXAMPLE FAULT CODE 2. WRENCH ICON 3. ICONS OF DISABLED/PERFORMANCE LIMITED FUNCTIONS

Figure 15. Example Interlock Alert Screen In this example, if the operator releases the accelerator pedal, the system will change the screen back to the Operating Screen. Alternatively, the operator can press either the Scroll Back Key or the Scroll Forward Key to go to a top-level menu but the accelerator pedal input will still be unavailable because the interlock condition has not been met.

• The Password Log submenu under the Activity Log menu Explanations of the Password Screen and the Add/Remove Password submenu (accessed through the Truck Setup menu) follow.

PASSWORD SCREEN NOTE: Operator passwords are used only on trucks equipped with a software enable option. As already stated, the Password Screen is the first screen to appear when the key switch or keyless switch is turned on (unless Operator Passwords are deactivated). The Password Screen is visible at all password access levels. Figure 16 shows the initial Password Screen that is displayed after power On. A line of five blanks below the Password Icon serves as the password entry field.

Password Screen

2200 YRM 1335 is displayed for up to five seconds or until the user starts to enter another password, as shown in Figure 17.

Figure 17. Invalid Password Screen 4. Once the system accepts the entered password, the operator is granted access to the menus associated with that password (i.e., menus displayed at Operator-level, Supervisor-level, or Service Technician-level access). NOTE: In cerain circumstances a default operator password of 11111 will be in the currently stored password list. NOTE: If there are no Service Technician-level passwords in the currently stored password list, the factory default Service Technician-level password, 55555, can be used to gain access to the system. Use the factory default Service Technician-level password, 55555, when installing the lift truck at the customer location to set up customer passwords. When initial installation is complete, choose a new Service Technician-level password. However, once a new Service Technician-level password has been assigned, 55555 is no longer a usable password and it cannot be assigned as a password through the screen menu or by using the PC Service Tool. (If all Service Technician-level passwords are deleted, the system again accepts the 55555 default password.) If there is only one Service Technician password and it is lost, the password can be reset using the PC Service Tool.

2200 YRM 1335

Password Screen

Table 14. Add Password

ó Scroll Keys

Truck Setup Top-level menu ↑ Up Arrow/ Down Arrow Soft Key ↓

Truck Setup Add/Remove Password Submenu

Press Enter Key (*)

The initial Password screen will display

Enter new password using keys 0 through 9

Press Enter Key (*)

First Press the Up Arrow or Down Arrow Soft Key to select password access level

Operator, Supervisor, or Service Technician password access level

Then Press "Hare" (4) soft key to cycle through performance modes

Available performance modes are minimum (1) to maximum (4, the default)

Press the Enter Key) to add this password

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Legend for Figure 18 1. ICON FOR TYPE OF PASSWORD ENTERED (OPERATOR/SUPERVISOR/SERVICE TECHNICIAN) 2. UP ARROW SOFT KEY ICON 3. DOWN ARROW SOFT KEY ICON 4. "TRASH CAN" SOFT KEY ICON 5. CURRENT PERFORMANCE MODE 6. "HARE" SOFT KEY ICON 7. CURRENT PASSWORD ICON AND FIELD In order to remove an individual password or modify the privileges associated with it, you need to know the password number. In addition, you must have a privilege level equal to or greater than the privilege level of the password being modified. This means a Service Technician can modify all passwords, but a Supervisor can only modify the passwords of Operators and other Supervisors. Table 15 shows the process for changing or removing an existing password for the lift truck.

PASSWORD LOG

Figure 18. Change/Remove Password Screen

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Password Screen

Table 15. Change or Remove Password

ó Scroll Keys

Truck Setup main menu (Top-level menu) ↑ Up Arrow/ Down Arrow Soft Key ↓

Truck Setup Add/Remove Password submenu

Press Enter Key (*)

The initial Password screen will display

Enter known password

Press Enter Key (*)

The Modify Password screen displays

To change a password: Press the Up Arrow or Down Arrow Soft Key to select password access level

Operator, Supervisor, or Service Technician Icon displays

Press "Hare" (4) soft key to cycle through performance modes

Available performance modes are minimum (1) to maximum (4, the default)

Press Trash Can (#) soft key to remove this password from the list

Press the * key to return to the initial Password screen

Press the Enter Key to update this password

To remove a password: Press either Scroll Key ( ó or ó ) to exit

Activity Log Menu

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The following sections describe the Activity Log submenus.

1. OPERATOR CHECKLIST LOG

Figure 19. Activity Log Title Screen

2. PASSWORD LOG

3. IMPACT EVENTS LOG

Figure 20. Activity Log Submenus

OPERATOR CHECKLIST LOG

Figure 21 shows the title screen for this menu.

Pressing the Scroll Back Key or Scroll Forward Key while anywhere in this submenu returns the Activity Log main menu title screen to the Operating Screen.

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Activity Log Menu Figure 23 shows a failed Checklist Log Entry.

Figure 21. Operator Checklist Log Menu Figure 22 shows an example Operator Checklist Log screen and indicates the available controls.

1. 2. 3. 4. 5. 6. 7. 8. 9.

Figure 23. Failed Checklist Log Entry If there are no log entries or the final log entry has been scrolled past, an empty log screen is displayed, as shown in Figure 24.

1. 2. 3. 4. 5. 6. 7. 8. 9.

Figure 22. Operator Checklist Log Screen

1. 2. 3. 4.

EMPTY SYMBOL SYSTEM TIME ICON SYSTEM DATE ICON PASSWORD ICON

Figure 24. Empty Log Screen

Activity Log Menu

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The process for viewing and removing the operator checklist logs from the system is shown in Table 16. When a person with Supervisor password-level access views the log, any recorded events under Service

Technician-level access will show ***** instead of the actual password number. Also, if there was no password logged in at the time of an event, the password will show as *****.

Table 16. Access Operator Checklist Log Screens

ó Scroll Keys

Activity Log main menu title screen ↑ Up Arrow/ Down Arrow Soft Key ↓

Activity Log Operator Checklist Log submenu

Press Enter Key (*)

The most recent Operator Checklist Log entry will display

Press the Up Arrow or Down Arrow soft key to scroll through the log entries

To remove a log entry: Press the Trash Can (#) soft key to remove this password log entry

An empty log screen replaces this log screen

Press either Scroll Key ( ó or ó ) to exit

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Activity Log Menu

1. PASSWORD VALUE AT LOG OCCURRENCE 2. OPERATOR/SUPERVISOR/SERVICE TECHNICIAN ICON 3. UP ARROW SOFT KEY ICON 4. CURRENT LOG ENTRY (OR "EMPTY" SYMBOL) 5. DOWN ARROW SOFT KEY ICON 6. "TRASH CAN" SOFT KEY ICON 7. TRACTION HOURS AT LOG OCCURRENCE 8. SYSTEM DATE AT LOG OCCURRENCE

Figure 26. Password Log Screen Figure 25. Password Log Menu Pressing the Scroll Back Key or Scroll Forward Key while anywhere in this submenu will return the Activity Log main menu title screen to the Operating Screen. Figure 26 shows an example Password Log screen and indicates the available controls. The process for viewing and removing password logs from the system is shown in Table 17.

A person viewing the password log cannot see the passwords of other operators or Supervisors who have access privileges higher than their own. This means that a Supervisor viewing the Password Log cannot see a Service Technician’s password. When viewing the log entry of a person with a higher access level, the password is displayed as *****. After removing a log entry, an "Empty" symbol replaces the former log entry number until the next entry has been scrolled into view. If there are no remaining log entries, an "Empty" log screen is displayed, as shown in Figure 24.

Activity Log Menu

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Table 17. Access Password Log Screens

ó Scroll Keys

Activity Log main menu title screen ↑ Up Arrow/ Down Arrow Soft Key ↓

Activity Log Password Log submenu

Press Enter Key (*)

The most recent Password Log entry will display

Press the Up Arrow or Down Arrow soft key to scroll through the log entries

To remove all log entries: Press Trash Can (#) Key to remove all password log entries

This log screen is replaced by the Empty log screen

Press either Scroll Key ( ó or ó ) to exit

Figure 27. Impact Events Log Menu

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Activity Log Menu

Pressing the Scroll Back Key or Scroll Forward Key while anywhere in this submenu returns the Activity Log main menu title screen to the Operating Screen. Figure 28 shows an example Impact Events Log screen and indicates the available controls. If there are no log entries or the final log entry has been scrolled past, the system displays an "Empty" log screen, as Figure 24 shows. The process for viewing and removing the system’s operator checklist logs is shown in Table 18. When a person with Supervisor password-level access views the log, any recorded events under Service Technician-level access are shown as ***** instead of the actual password number. Also, if there was no password logged in at the time of an event, the password appears as *****.

1. 2. 3. 4. 5. 6. 7. 8.

Figure 28. Impact Events Log Screen

Calibration Menu

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Table 18. Access Impact Events Log Screens

ó Scroll Keys

Activity Log Main menu ↑ Up Arrow/ Down Arrow Soft Key ↓

Activity Log Impact Events Log Submenu

Press Enter Key (*)

The most recent Impact Events Log entry will display

Press the Up Arrow or Down Arrow soft key to scroll through the log entries

To remove all log entries: Press Trash Can (#) Key to remove all entries

This log screen is replaced by the Empty log screen

Press either Scroll Key ( ó or ó ) to exit

Figure 29. Calibration Title Screen

2200 YRM 1335 Press the Enter Key (*) to enter the Calibration Menu and the system will display the first submenu in the Calibration Menu, the Load Weight Display submenu, which is shown in Figure 30. Press the Enter Key again if you want to enter this submenu. If you want a different submenu, use the Scroll Back Key or Scroll Forward Key to move to another submenu and press the Enter Key.

Calibration Menu 2. When prompted, position the empty forks at the load weight height, which is site dependent. 3. Press the Enter Key. 4. When prompted, use the numeric keys to enter the known load weight in lb or kg units, as indicated in the load weight icon. Use a load weight that is between 1,000 lbs (450 kg) and 16,000 lbs (7,260 kg). NOTE: Do not exceed the truck’s rated capacity. 5. Press the Enter Key. 6. When prompted, position the load by adjusting the tilt and height of the mast and forks to the load weight height. 7. Press the Enter Key. The system stores the new setting and returns to the Calibration Menu.

RETURN TO SET TILT STOP POINT CALIBRATION

Figure 30. Load Weight Display Submenu The Calibration Menu presents these submenus: • Load Weight Display • Return to Set Tilt Stop Point • E-Hydraulic Valves • Steering Wheel Knob Center Point • Steer Axle Position • Manual Hydraulics

NOTE: This calibration must be done by a supervisor or service technician and is only available on trucks that have the Return to Set Tilt feature. Figure 31 shows the screen display during a Return to Set Tilt Stop Point calibration.

The following sections describe the Calibration submenus.

Figure 31. Return to Set Tilt Stop Point Sequence To calibrate Return to Set Tilt Stop Point: 1. Starting from the Calibration Menu, scroll to the Return to Set Tilt Stop Point screen and press the Enter Key. 2. When prompted, position the mast at the desired tilt angle. 3. Press the Enter Key. The system records the new setting and returns to the Calibration Menu.

Calibration Menu

2200 YRM 1335

E-HYDRAULIC AND MANUAL VALVE THRESHOLD CALIBRATION NOTE: This calibration must be done by a supervisor or service technician.

STEERING WHEEL KNOB CENTER POINT CALIBRATION The steering wheel knob center point is the position to which the system adjusts the steering wheel while the lift truck is being driven straight ahead. NOTE: This calibration must be done by a supervisor or service technician and is only available on trucks equipped with the Synchronized Steering function. Figure 33 shows the screen display during a Steering Wheel Knob Center Point calibration.

Figure 33. Steering Wheel Knob Center Point

2200 YRM 1335

Calibration Menu

To calibrate the Steering Wheel Knob Center Point: 1. Starting from the Calibration Menu, scroll to the Steering Wheel Knob Center Point screen and press the Enter Key. 2. When prompted, position the steering wheel in the position that will drive the lift truck straight ahead. 3. Press the Enter Key. The system records the steering wheel position as the new center point and returns to the Calibration Menu.

STEER AXLE POSITION CALIBRATION NOTE: This calibration must be done by a supervisor or service technician and is only available on trucks equipped with the Synchronized Steering function or dual traction motors.

Figure 34 shows the screens that appear while calibrating the steer axle position. To calibrate the Steer Axle Position: 1. Starting from the Calibration Menu, scroll to the Steer Axle Position screen and press the Enter Key. 2. When prompted, turn the steering wheel counterclockwise until the axle hits the stop. 3. Press the Enter Key. 4. When prompted, turn the steering wheel clockwise until the axle hits the stop. 5. Press the Enter Key. If the settings are acceptable, the system records the steer positions and returns to the Calibration Menu. If the settings are outside of the acceptable range, an X appears over the calibration icon. Press the Enter Key and the system will prompt the user to repeat steps 2 – 5.

Figure 34. Calibrating Steer Axle Position

MANUAL HYDRAULICS CALIBRATION NOTE: This calibration must be done by a supervisor or service technician and is only available on trucks equipped with manual hydraulics. Figure 35 shows the screen menu the system displays during this calibration. To calibrate the Manual Hydraulic end point: 1. With no load on the forks, raise them, if they are not already raised. 2. Starting from the Calibration Menu, scroll to the Manual Hydraulic End Point Calibration screen and press the Enter Key. 3. When prompted, move all hydraulic levers to both of their extreme locations; that is, move each lever as far as it will go in both directions. 4. Press the Enter Key. The system records the extreme locations and returns to the Calibration Menu.

Figure 35. Manual Hydraulic End Point Calibration

Display Menu

2200 YRM 1335

Display Menu INTRODUCTION The Display Menu is a main menu (top-level menu) that is visible at Supervisor and Service Technician password access levels. To access this menu, cycle through the main level menu screens by pressing the Scroll Back Key ( —) or Scroll Forward Key (— ) until the Display Title Screen is displayed, as shown in Figure 36.

Figure 37. Set Date and Time Format Menu To enter this submenu, press the Enter Key. Figure 38 shows the Set Date and Time Format screen that will appear.

Figure 36. Display Title Screen Press the Enter Key (*) to enter the Display Menu and the system will display the Set Date and Time Format screen as shown in Figure 37. Press the Enter Key again to enter this submenu. For a different submenu, use the Scroll Back Key or Scroll Forward Key to move to the desired submenu and press the Enter Key. To return to the Display Menu, press the Scroll Back Key or Scroll Forward Key. Press the Scroll Back Key or Scroll Forward Key a second time to return to the main menu. The Display Menu offers these submenus (see the Display Submenus and Icons topic): • Set Date and Time Format Menu • Set Daylight Saving Time Menu • Set Time and Date Menu • Set Units Menu The sections that follow describe these submenus.

SET DATE AND TIME FORMAT MENU A Supervisor or a Service Technician can use this menu to define the system date and time format. Figure 37 shows the title screen for this menu.

1. 2. 3. 4. 5. 6.

CLOCK ICON CLOCK HOUR FORMAT UP ARROW SOFT KEY ICON CURRENT DATE FORMAT DOWN ARROW SOFT KEY ICON CALENDAR ICON

Figure 38. Set Date and Time Format Screen The Clock Hour Format can be set to either a 12-hour clock or a 24-hour clock. To set the Clock Hour Format, press the 2 Up Arrow soft key. The system will place a box around the current Clock Hour Format. Press the Enter Key and then use the 2 Up Arrow soft key or 3 Down Arrow soft key to select either the 12-hour or the 24-hour clock format. When you have the desired format displayed, press the Enter Key and the system will begin using the selected clock hour format for all menus in the system.

2200 YRM 1335

Display Menu

To set the Current Date Format, use the 3 Down Arrow soft key to change the focus to the Current Date Format Icon. There are three options for the Current Date Format: • USA, MM/DD/YY • Europe, DD/MM/YY • ISO 8601, YY/MM/DD

Table 19. Accessing the Set Date and Time Format Screen

Use the Scroll Keys ( ó or ó ) Display the main menu Use the Up Arrow ↑ or Down Arrow ↓ Key

Display the Set Date and Time Format Menu submenu

Press Enter Key (*)

The Set Date and Time Format screen will display

Use the 2 Up Arrow soft key to select the Set Time Format Icon and display the 12-hour or 24-hour clock icon

Use the 3 Down Arrow soft key to select the Set date Format Icon and display the three date formats

Press Enter Key to update the time and date format for all menus in the system

Press either Scroll Key ( ó or ó ) to exit

SET DAYLIGHT SAVING TIME MENU A Supervisor or a Service Technician can use this submenu to enable or disable the use of daylight saving time on trucks and set it up to make automatic time changes. When this feature is enabled (set to On), the system time clock increases by one hour at 2:00 am on the selected Start Date and decreases by one hour at the same time on the selected End Date. Figure 39 shows the title screen for this menu.

Figure 39. Set Daylight Saving Time Menu

Display Menu To enable daylight saving time, press the Enter Key at the menu shown in Figure 39. The system will display the screen shown in Figure 40.

2200 YRM 1335 3. Set the month daylight saving time will begin. a. Press the 3 Down Arrow soft key to activate the Start Month indicator and press the Enter Key. b. Use the 2 or 3 soft key to cycle through the numbers, 1-12, of the months to the desired start month and press the Enter Key. 4. Set the day daylight saving time will begin. a. Press the 3 Down Arrow soft key to activate the Start Date indicator and press the Enter Key. b. Use the 2 or 3 soft key to cycle through the dates by numbers, by first days of the week, and by last days of the week to the desired start day. This can be a date, such as the 13th of the month, or a day of the week, such as Sunday. When you get to the desired date, press the Enter Key.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Figure 40. Set Daylight Saving Time Screen

Procedure for Setting Up Automatic Daylight Savings Time NOTE: To exit from the Daylight Savings menu at any time without making any changes, press the Scroll Back Key or Scroll Forward Key. The system returns to the Display menu. 1. Navigate to the Daylight Savings submenu. 2. Press the 2 Up Arrow soft key to set daylight saving time to On and press the Enter Key (*).

5. Set the month daylight saving time will end. a. Press the 3 Down Arrow soft key to activate the End Month Indicator and press the Enter Key. b. Use the 2 or 3 soft key to cycle through the numbers, 1-12, of the months to the desired end month and press the Enter Key. 6. Set the day daylight saving time will end. a. Press the 3 Down Arrow soft key to activate the End Day indicator and press the Enter Key. b. Use the 2 or 3 soft key to cycle through the numbers, first days of the week, and last days of the week to the desired end day and press the Enter Key. 7. Exit from the Daylight Savings submenu and return to the Display menu by pressing the Scroll Back Key or Scroll Forward Key.

2200 YRM 1335

Display Menu

Table 20. Set Daylight Saving Time Menu

Main Menu Setup Display

Press the Enter Key (*)

Setup Display Set Daylight Saving

Press Enter Key

Set Daylight Saving Daylight Save On/Off

Press Enter Key

↑ SCROLL ↓ Setup Display Back One Level

Daylight Save On/Off Daylight Save On

Select On or Off and press Enter Key

↑ SCROLL ↓ Daylight Save On/Off Daylight Save Off

↑ SCROLL ↓

Set Daylight Saving Daylight Save Start

Press Enter Key

Daylight Save Start Month 12

Select Daylight Saving Start Month from available selections and press Enter Key

Daylight Save Start Day 31

↑ SCROLL ↓

Daylight Save Start Month 01

Daylight Save Start Day 01

Select the Day of the Month from available selections and press Enter Key

↑ SCROLL ↓ Daylight Save Start Day Last

Press Enter Key

Daylight Save Start Last Su

Select the Day of the Week from available selections and press Enter Key

↑ SCROLL ↓ Daylight Save Start Last Sa ↑ SCROLL ↓

↑ SCROLL ↓ Daylight Save Start Day first

Press Enter Key

Daylight Save Start first Su

Select the Day of the Week from available selections and press Enter Key

↑ SCROLL ↓ Daylight Save Start first Sa

Set Daylight Saving Daylight Save End ↑ SCROLL ↓

Press Enter Key

Daylight Save End Month 12

↑ SCROLL ↓

Select Daylight Saving End Month from available selections and press Enter Key

Daylight Save End Day 31

Select the Day of the Month from available selections and press Enter Key

↑ SCROLL ↓

Display Menu

2200 YRM 1335

Table 20. Set Daylight Saving Time Menu (Continued)

Set Daylight Saving Back One Level

Daylight Save End Month 01

Daylight Save End Day 01

↑ SCROLL ↓ Daylight Save End Day Last

Press Enter Key

Daylight Save End Last Su

Select the Day of the Week from available selections and press Enter Key

↑ SCROLL ↓ Daylight Save End Last Sa

↑ SCROLL ↓

Daylight Save End Day first

Press Enter Key

Daylight Save End first Su

Select the Day of the Week from available selections and press Enter Key

↑ SCROLL ↓ Daylight Save End first Sa

SET TIME AND DATE MENU

Procedure for Setting Time and Date

A Supervisor or a Service Technician can use this menu to set the system time and date format on the on-board clock. Figure 41 shows the title screen for this menu.

NOTE: To exit from a menu at any time without making any changes, press the Scroll Back Key or Scroll Forward Key. 1. At the Display Menu, scroll to the Set Time and Date Format submenu, unless already there, and press the Enter Key (*) to enter this submenu. 2. Press the 2 or 3 soft key to select the time icon, then press the Enter Key. The system will display a flashing line under the hour portion of the time. To change the hour: a. Use the number keys to enter the correct hour and press the Enter Key. If the hour does not need to be changed, just press the Enter Key.

Figure 41. Set Date and Time Menu

If the number you entered is a valid hour setting, the system accepts it and moves the flashing line to the next segment, the minutes portion of the time.

2200 YRM 1335

Status Menu

b. Use the number keys to enter the minutes and press the Enter Key. If the minutes are correct, simply press the Enter Key. If the number you entered is a valid minutes setting, the system accepts it and moves the flashing line to the A (for AM) or P (for PM) designator.

The system will put the new system date into effect immediately.

SET UNITS MENU A Supervisor or a Service Technician can use this menu to set the type of units the system will use to either Imperial or Metric. Figure 42 shows the Set Units submenu.

c. To change the AM/PM setting, use the 2 or 3 soft key, then press the Enter Key. If the current AM or PM setting is correct, simply press the Enter Key. The system puts the new time settings into effect immediately. 3. To set the system date, use the 2 or 3 soft key to select the date icon and press the Enter Key. The system will display a flashing line under the left segment of the date. If the Current Date Format is DD/MM/YY, for example, then the left segment displayed is the day of the month. (Current Date Format can be changed in the Set Date and Time Format submenu.) a. Use the number keys to enter the correct value and press the Enter Key. If the current value for the left segment of the date is correct, simply press the Enter Key. b. Repeat step a. for the middle and right segments of the date.

Figure 42. Set Units Menu To set the type of units the system will use, either Imperial or Metric, enter the Set Units Menu. Use the 2 Up Arrow or 3 Down Arrow soft key to select Imperial or Metric. When the corresponding icon for the type of units desired is displayed on the screen, press the Enter Key and the system will begin using the units selected immediately.

Status Menu INTRODUCTION The Status Menu is a main menu (top-level menu) that is visible at Supervisor and Service Technician password access levels. To access this menu, cycle through the main menu title screens by pressing the Scroll Back Key ( —) or Scroll Forward Key (— ) until the Status Title Screen is displayed, as shown in Figure 43.

Figure 43. Status Title Screen

Status Menu

2200 YRM 1335

Press the Enter Key (*) to enter the Status Menu and the system will display the Vehicle System Manager (VSM) Version submenu as shown in Figure 44. Press the Enter Key again to enter this submenu. For a different submenu, use the Scroll Back Key or Scroll Forward Key to move to the desired submenu and press the Enter Key.

Figure 45. Versions Screen

DISPLAY VERSIONS NOTE: The manufacturer’s hardware and software versions may not match the hardware and software versions shown on the device’s exterior label.

Figure 44. Status Menu The Status Menu provides these submenus: • VSM Versions • Display Versions • Truck Serial Number • Hour Meters • E-Hydraulic Controller Versions • Pump Motor Controller Versions • Traction Motor Controller 1 Versions • Traction Motor Controller 2 Versions • Light Controller Versions • Impact Sensor Versions

Use this submenu to view the manufacturer’s internal hardware and software versions of the Display. The screen for Display Versions is identical to the screen used for VSM Versions. Figure 45 shows how the information is presented on the screen. The top line lists the manufacturer’s hardware version; the second line lists the manufacturer’s software version.

The topics that follow describe the Status submenus. NOTE: These menu selections are only available to logged in Supervisors and Service Technicians.

VSM VERSIONS NOTE: The manufacturer’s hardware and software versions may not match the hardware and software versions shown on the device’s exterior label. This submenu makes it possible to view the manufacturer’s internal hardware and software versions of the VSM Controller. Figure 45 shows how the version information is displayed on the screen. The top line lists the manufacturer’s hardware version; the second line lists the manufacturer’s software version.

Figure 46. Truck Serial Number

2200 YRM 1335

Status Menu

TRACTION MOTOR CONTROLLER 2 VERSIONS NOTE: The manufacturer’s hardware and software versions may not match the hardware and software versions shown on the device’s exterior label.

Figure 47. Hour Meters Screen

Use this submenu to view the manufacturer’s internal hardware and software versions of Traction Motor Controller 2. Traction Motor Controller 2 controls the left side traction motor. NOTE: The Status Menu displays this item only if the CDF configuration indicates dual traction motors are present. The manufacturer’s hardware and manufacturer’s software version information is presented on the screen as shown in Figure 45.

LIGHT CONTROLLER VERSIONS

The manufacturer’s hardware and manufacturer’s software version information is presented on the screen as shown in Figure 45.

NOTE: The manufacturer’s hardware and software versions may not match the hardware and software versions shown on the device’s exterior label.

PUMP MOTOR CONTROLLER VERSIONS

Use this submenu to view the manufacturer’s internal hardware and software versions of the Light Controller. The manufacturer’s hardware and manufacturer’s software version information is presented on the screen as shown in Figure 45.

Truck Setup Menu

2200 YRM 1335

IMPACT SENSOR VERSIONS NOTE: Hardware and software versions may not match the hardware and software versions shown on the device’s exterior label. Use this submenu to view the manufacturer’s internal hardware and software versions of the Impact Sensor.

NOTE: If the truck is not equipped with an Impact Sensor, this submenu is not displayed. The manufacturer’s hardware and manufacturer’s software version information is presented on the screen as shown in Figure 45.

Truck Setup Menu INTRODUCTION The Truck Setup Menu is a main menu (top-level menu) that is visible to logged in Supervisors and Service Technicians.

Scroll Back Key or Scroll Forward Key to move to the desired submenu and press the Enter Key.

Figure 49. Add/Remove Password Submenu

Figure 48. Truck Setup Title Screen Press the Enter Key (*) to enter the Truck Setup Menu. The system will display the Add/Remove Password submenu shown in Figure 49. Press the Enter Key again to enter this submenu. For a different submenu, use the

The Truck Setup Menu presents these submenus to Supervisors: • Add/Remove Password • Restore Default Settings • Motion Alarm • Impact Monitor Settings • Auto Power-Off Time Delay • Return to Set Tilt • Traction Speed Limit • Scheduled Maintenance Reminder • Minimum Pump Standby Flow Rate • Operator Checklist • Impact Monitor Shutdown • Motor Braking

2200 YRM 1335

Truck Setup Menu

The following sections describe the Truck Setup submenus.

ADD/REMOVE PASSWORD NOTE: This menu selection is available to logged in Supervisors and Service Technicians. This submenu, shown in Figure 49, allows Supervisors and Service Technicians to add or remove passwords. See the Adding/Removing/Changing Passwords topic in the Password Screen section for more information.

RESTORE DEFAULT SETTINGS NOTE: This submenu is available on all trucks to logged in Supervisors and Service Technicians.

Figure 51. Motion Alarm Setup Screen

This menu allows a Supervisor or a Service Technician to change all adjustable truck settings back to their factory default settings. Calibrations are NOT reset when this function is used. Figure 50 shows the Restore Defaults screen.

Use the 2 and 3 soft keys to toggle the setting between On and Off. An X over the fork lift truck icon indicates the Motion Alarm feature is set to Off. If this feature is Off and you want to enable it, press the 2 or 3 soft key to have the system display the icon without an X over it, then press the Enter Key to store the setting.

Figure 50. Restore Defaults Screen While in this menu, press the Enter Key to restore all truck settings, except hour meters and system time, to their factory default settings. The system then returns to the Truck Setup Menu.

MOTION ALARM NOTE: This submenu is available to logged in Supervisors and Service Technicians on all trucks.

Figure 52. Impact Monitor Settings Screen

Use this menu to enable or disable the Motion Alarm feature. Figure 51 shows the Motion Alarm Setup Screen with the alarm option set to On.

Truck Setup Menu

Impact Detection The impact monitor can detect both hard and soft impacts. An example of a hard impact is a truck colliding with a steel column in a warehouse which causes the truck to stop suddenly. In this case the impact force is very strong but it occurs during a short time period. An example of a soft impact is a truck rolling over and crushing a wooden pallet. In this case the impact force is much less than experienced with a hard impact but it lasts for a significantly longer time period.

Setting Adjustments Use the 2 and 3 soft keys to move up or down through the current values for the four settings for Impact Force and Impact Times. When there is a box around the setting you want to change, press the Enter Key, then use the 2 or 3 soft key to step through the valid values for that setting. The Soft Impact Force, the setting at the top of the screen, can be set to a value in the range 0.2 to 2.5 g., in tenths of gravitational force. The Soft Impact Time, the second setting down from the top, can be adjusted to require the impact monitor to see an impact force greater than the Soft Impact Force for 1 to 12 samples before a soft impact event will be reported. The Hard Impact Force, the third setting down, can be set to a value in the range 0.5 to 3.0 g., in tenths of gravitational force. The Hard Impact Time, the forth setting down from the top, can be adjusted to require the impact monitor to see an impact force greater than the Hard Impact Force for 1 or 2 samples before a hard impact event will be reported. The Hard Impact Force, the third setting down, can be set to a value in the range 0.5 to 3.0 g., in tenths of gravitational force.

2200 YRM 1335

Initial Adjustment of Soft and Hard Impact Settings NOTE: When adjusting the impact sensor settings, be sure to: Adjust the truck to the lowest Soft Impact Force setting, the Soft Impact Time set to 6, and the highest Hard Impact Force Setting. Drive the truck at the fastest operational speed for the environment. Apply the brakes to bring the truck to an abrupt stop. Determine if an impact event has occurred. Increase either the Soft Impact Force setting until the vehicle can be abruptly stopped with the service brake without reporting an impact event. Read and record the value, from the dash display, that was triggered a Soft Impact when abruptly stopping the truck. Change the Soft Impact Force threshold to the next highest setting. To adjust the hard threshold, take the soft threshold value and add 0.3 g. Set the Hard Impact Time to 2. Monitor truck during all normal operations. If impacts are recorded during normal operations, go to (Readjustment of Soft and Hard Impact Settings).

2200 YRM 1335

Truck Setup Menu

AUTO POWER-OFF TIME DELAY NOTE: This submenu is available to logged in Supervisors and Service Technicians. This menu can be used to adjust the setting for the amount of time before the truck enters the Power Off mode. Figure 53 shows an Auto Power-Off Delay Setup Screen that has a 20m delay setting value, which is a 20 minute delay.

Figure 54. RTST Setup Screen The icon at the top left of the screen is for the delay time. When a box is around the current value, press the Enter Key. Then use the 2 or 3 soft key to step through the available values for the delay time, 0, 0.1, 0.2, 0.4, 0.6, 0.8, 1.0, 2.0, 3.0 seconds or Continuous and press the Enter Key to save the new value. When the delay time is set to 0, this feature is deactivated. When set to Continuous, the delay time is infinite (limitless).

Figure 53. Auto Power-Off Time Delay Setup Screen To change the Auto Power-Off Time Delay setting, select the current value. When a box is around it, press the Enter Key, then use the number keys to enter a value from 0 to 30 minutes and press the Enter Key to save the new setting.

RETURN TO SET TILT NOTE: This submenu is available to logged in Supervisors and Service Technicians. It is visible only on trucks equipped with the RTST feature. This menu provides a way to adjust the Return to Set Tilt (RTST) delay time and to program this feature to work only in the forward direction or in both directions. Figure 54 shows the RTST Setup Screen with the delay direction set to Forward.

The lift truck icon in Figure 54 indicates the mast assembly is programmed to return to the set tilt angle only when it is moving forward, which is the Forward option. To set up the mast assembly so that it returns to the set tilt whether it is moving forward or backward, use the 2 or 3 soft key to set the direction.

TRACTION SPEED LIMIT NOTE: This submenu is available to logged in Supervisors and Service Technicians. The example shown in Figure 55 shows the MPH Icon and a current Traction Speed Limit setting of 12.0.. The type of speed units, MPH or km/h, is set in a submenu of the Display main menu. To change the traction speed limit setting, use the number keys to enter the new value desired, then press the Enter Key to save it. Acceptable values for the traction speed limit range from 1 to 99 MPH when Imperial units are in use or from 1 to99 km/h when metric units are in use.

Truck Setup Menu

2200 YRM 1335 Once a previously active interval counts down to zero, the maintenance reminder becomes active. To deactivate the maintenance reminder the user must either set the status to OFF or enter a new service interval. The scheduled maintenance month interval is based on the system date. The value ranges from 0 to 99 in increments of 1 month. The scheduled maintenance hour interval is based on the trucks hour meter. The value ranges from 0 to 9999 in increments of 1 hour.

Figure 55. Traction Speed Limit Example

The derated traction speed percentage setting is a percentage of the current maximum speed limit. A setting of 100% has no reduction in top speed while 0% disables the traction system. This value can be from 0% to 100% in increments of 1%.

SCHEDULED MAINTENANCE REMINDER NOTE: This submenu is available to logged in Service Technicians and Supervisors. This menu item is only visible on trucks equipped with the Scheduled Maintenance Reminder feature. The examples shown in Figure 56, Figure 57, and Figure 58 show the icons for the scheduled maintenance reminder screen. Using this menu item the user shall be able to adjust the scheduled maintenance reminder settings. The items available to the user are: • Maintenance Reminders ON/OFF • Maintenance Interval in Months • Maintenance Interval in Truck Hours • Derated Traction Speed Percentage after the scheduled time has expired.

Figure 56. Scheduled Maintenance Reminder

2200 YRM 1335

Truck Setup Menu NOTE: A setting of 0% turns the standby flow off which may result in decreased steering performance. To change the setting for the minimum standby pump flow rate, use the number keys to enter the new rate desired, then press the Enter Key to save the new setting. The value of this setting can range from 0% to 100% in steps of 1%.

Figure 57. System Off Screen

Figure 59. Minimum Pump Standby Flow Rate Screen

OPERATOR CHECKLIST NOTE: This submenu is available to logged in Supervisors and Service Technicians.

Figure 58. Maintenance Reminder Alert Screen

MINIMUM PUMP STANDBY FLOW RATE NOTE: This submenu is available to logged in Supervisors and Service Technicians. This menu can be used to adjust the minimum standby pump flow rate. Values stored in the truck’s CDF determine the range of allowable values for this setting. This means a setting of 1% the value is the lowest available setting for the minimum standby pump flow rate and it is equal to the lowest defined value in the CDF. A 100% value is the highest available setting for the minimum standby pump flow rate. The example presented in Figure 59 shows the icon for minimum pump standby flow rate and a current value of 56, which means the value is 56% of the maximum allowed.

A Supervisor or a Service Technician can use this menu to program the checklist items that will be displayed to users. The lift truck system can be set up to display all, some, or none of the 30 items in the Operator Checklist when the key switch or keyless switch is turned on. Each checklist item is represented by a separate icon. During setup, the 30 icons are displayed, one at a time, in the middle of the screen. If an X appears over the icon when it is displayed, the checklist item represented by the icon is inactive (deactivated) and the checklist item will not appear during the Operator Checklist sequence. If there is no X over the icon, the checklist item is active (enabled). Figure 60 shows the Activate/Deactivate Checklist Item Screen with an icon that represents a checklist item.

Truck Setup Menu

2200 YRM 1335

IMPACT MONITOR SHUTDOWN NOTE: This submenu is available to logged in Supervisors and Service Technicians. This menu makes it possible to adjust the way the system reacts after an impact is detected. These settings are laid out on the screen as shown in Figure 61.

Figure 60. Activate/Deactivate Checklist Item Screen The icon in Figure 60 does not have an X over it, so the checklist item this icon represents is enabled (activated). The X Icon in the lower left area of the screen, right above the # soft key indicates the currently displayed checklist item will be deactivated if the # key is pressed. If the checklist item was deactivated, pressing the Enter Key (*) above the Check Mark Icon in the lower right area of the screen would enable it. Any checklist item can be activated or deactivated by a Supervisor or Service Technician as follows: Use the 2 and 3 soft keys (the up and down arrow keys) to move through the icons to the one that represents the checklist item you want to enable or disable. If the currently displayed icon has an X over it, press the Enter Key. The system will enable the checklist function the icon represents and redraw the icon with no X over it and the checklist function will now be programmed to appear during the Operator Checklist sequence. If the currently displayed icon does not have an X over it, press the # soft key to disable the checklist function the icon represents. The system will redraw the icon with an X over it and this checklist function will be skipped (it will not appear) during the Operator Checklist sequence. NOTE: If all items on the checklist are deactivated, the Operator Checklist feature is deactivated and the system does not present the Operator Checklist to the operator.

Figure 61. Setup Screen for Impact Settings The top left icon is the Impact Detection Icon. To set impact detection to On or Off, use the 2 and 3 soft keys to select the current value for this setting. When there is a box around the On or Off Icon, use the 2 or 3 soft key to display the desired setting and press the Enter Key to save it. The second icon down from the top is the Impact Monitor Shutdown Delay Icon. To set the Shutdown Delay, use the 2 and 3 soft keys to select the current value for this setting. When there is a box around the value, press the Enter Key, then use the number keys on the Display Panel to enter a value from 0 to 30 seconds and press the Enter Key to save the new setting. The third icon down from the top is the Impact Monitor Shutdown Type Icon. To set the Disable Type to All or Traction, use the 2 and 3 soft keys to select the current value for this setting. When there is a box around the All Icon or the Traction Icon, use the 2 or 3 soft key to display the desired setting and press the Enter Key to save it.

2200 YRM 1335

Truck Setup Menu

MOTOR BRAKING

Changing the Motor Braking Settings

NOTE: This submenu is available to logged in Service Technicians and Supervisors.

To change the Set Regenerative Braking Rate or Set Auto Deceleration Rate setting, use the 2 and 3 soft keys to select the current value of the setting you want to adjust. When there is a box around the value you want to change, press the Enter Key. Next, use the number keys to enter the desired value, then press the Enter Key to save the new setting.

There are three motor braking settings, Regenerative Braking Rate, Auto Deceleration Rate, and Auto Deceleration Type. See Figure 62. Regenerative Braking setting controls how much motor braking is applied when the direction is changed from Forward to Reverse or Reverse to Forward. This type of deceleration is proportional to the accelerator pedal position. The further the accelerator is depressed the greater the deceleration. Auto Deceleration setting controls how much motor braking is applied when transitioning from higher accelerator pedal position to a lower acceleration pedal position. There are two types of Auto Deceleration, Pedal Up and Proportional. A fully released pedal produces maximum deceleration for both Pedal Up or Proportional deceleration.

The Regenerative Braking Rate setting is the value at the top of the screen. This value can be from 0 to 100% in increments of 1%. A 100% setting provides maximum regenerative braking while a 0% setting in effect deactivates regenerative braking. The Auto Deceleration Rate setting is the second setting down from the top. The setting value can be in the 0 to 100% in increments of 1%. A 100% setting provides maximum auto deceleration while a 0% setting in effect deactivates it. Auto Deceleration rate is always a percentage of the current Regenerative Braking Rate. Thus, if Regeneration brake = 0% then Auto Deceleration = 0%. The Auto Deceleration Type is the third setting down from the top. To change the type, use the 2 and 3 soft keys to select the current type and press the Enter Key. Next, use the 2 or 3 soft key to choose either Pedal Up or Proportional deceleration and press the Enter Key to save the new setting. Pedal Up deceleration allows the truck to coast until the pedal is fully released. Proportional deceleration causes the truck to decelerate in proportion to how far the pedal is released in relation to the current traction speed. A fully released pedal produces maximum deceleration for both Pedal Up or Proportional deceleration.

Figure 62. Motor Braking Setup

Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 1335

1/11 (3/10)(2/10)(9/09)(2/09)(11/08) Printed in U.S.A.

Maintenance

WIRE HARNESS REPAIR GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]; GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809]; GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810]; GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) [C878, D878]; GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) [C879, D879]; GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818]; GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813]; ERC22-35VG (ERC045-070VG) [A968]; ERP22-35VL (ERP045-070VL) [A976]; ERP15-20VT (ERP030040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]; GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) [A909]; ESC030AC, ESC035AC, ESC040AC [B883]; GLC050LX [A967]; GLP/GDP20-25LX (GLP/GDP050LX) [A974]; ERC16-20VA (ERC030-040VA) [A969]

PART NO. 524223769

2200 YRM 1128

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Wire Harness Repair

Table of Contents

TABLE OF CONTENTS General.................................................................................................................................................................. Deutsch Crimping Tool .......................................................................................................................................... How to Strip a Wire for Use With Deutsch Crimping Tool ................................................................................. How to Crimp With the Deutsch Crimping Tool ................................................................................................. Calibration Test for the Deutsch Crimping Tool ................................................................................................. Deutsch Connectors .............................................................................................................................................. DT, DTM, and DTP Series Connectors ............................................................................................................. Connector Receptacle Replacement .......................................................................................................... Connector Plug Replacement ..................................................................................................................... Connector Receptacle Pin Replacement .................................................................................................... Connector Plug Socket Replacement ......................................................................................................... HD Series Connectors .................................................................................................................................... Connector Receptacle Replacement .......................................................................................................... Connector Plug Replacement ..................................................................................................................... Connector Receptacle Pin Replacement .................................................................................................... Connector Plug Socket Replacement ......................................................................................................... Sealing Plugs .................................................................................................................................................. Metri-Pack Connectors ........................................................................................................................................ Remove and Install.......................................................................................................................................... Micro-Pack Connectors ....................................................................................................................................... Weather-Pack Connectors................................................................................................................................... Weather-Pack Terminal Repair ....................................................................................................................... AMPSEAL Crimping Tools................................................................................................................................... AMP Hand Crimping Tool With Certi-Crimp .................................................................................................... Description.................................................................................................................................................. Stripping Wire for Use with AMP Hand Crimping Tool ................................................................................ Insulation Crimp Adjustment....................................................................................................................... Maintenance and Inspection for AMP Hand Crimping Tool ........................................................................ AMP Hand Crimping Tool ....................................................................................................................... Crimp Height Inspection ......................................................................................................................... How to use AMP Hand Crimping Tool ............................................................................................................. AMP Pro-Crimper II Tool ................................................................................................................................. Description.................................................................................................................................................. Remove and Install Die Set and Locator Assembly................................................................................ Stripping Wire for Use With AMP PRO-CRIMPER II Tool........................................................................... Contact Support Adjustment....................................................................................................................... Crimp Height Adjustment............................................................................................................................ Maintenance and Inspection Procedures ................................................................................................... PRO-CRIMPER II Tool ........................................................................................................................... Crimp Height Inspection ......................................................................................................................... How to Use AMP PRO-CRIMPER II Tool........................................................................................................ AMPSEAL Connector Assemblies....................................................................................................................... Description for Plug Connector Assembly....................................................................................................... Seal Plug .................................................................................................................................................... Contact Crimping ........................................................................................................................................ Contact Removal ........................................................................................................................................ Contact Insertion......................................................................................................................................... Description for Plug Connector and Header Assembly ................................................................................... Voltage Reading.......................................................................................................................................... Seal Plug .................................................................................................................................................... Contact Crimping ........................................................................................................................................

1 1 1 2 4 5 5 14 19 24 31 38 40 43 46 51 55 57 57 59 60 60 62 62 62 63 63 64 64 64 65 65 65 66 67 67 68 68 68 68 69 70 70 71 72 72 74 76 77 78 78

Table of Contents

Wire Harness Repair

TABLE OF CONTENTS (Continued) Contact Removal ........................................................................................................................................ Contact Insertion......................................................................................................................................... AMP Superseal 1.5 Crimping Tools..................................................................................................................... Mini Mic Receptacle and Tab Contacts ........................................................................................................... Description.................................................................................................................................................. Crimping Conditions and Measurements.................................................................................................... Insertion of Rubber Seal on Cable.............................................................................................................. Correction or Replacement of Parts ........................................................................................................... AMP Hand Application Tool............................................................................................................................. Description.................................................................................................................................................. Maintenance and Inspection ....................................................................................................................... Crimp Height Inspection ......................................................................................................................... Crimp Height Adjustment............................................................................................................................ How to Use AMP Hand Application Tool ......................................................................................................... AMP Pro-Crimper II Tool ................................................................................................................................. Description.................................................................................................................................................. Remove and Install Die Set and Locator Assembly................................................................................ Adjustments ................................................................................................................................................ Contact Support ..................................................................................................................................... Crimp Height........................................................................................................................................... Inspections and Maintenance ..................................................................................................................... Crimp Height Inspection ......................................................................................................................... Visual Inspection .................................................................................................................................... Maintenance ........................................................................................................................................... How to Use Pro-Crimper II Tool ...................................................................................................................... AMP Superseal 1.5 Connector Assemblies......................................................................................................... Description ...................................................................................................................................................... Harness Assembly ...................................................................................................................................... Positioning of Anti-Backout Device ......................................................................................................... Removal of Contacts ............................................................................................................................ Repair and Maintenance ............................................................................................................................... Panel Mount Option....................................................................................................................................... AMP Fastin-Faston Hand Tools ......................................................................................................................... Description - AMP Double Action Hand Tool................................................................................................. Maintenance and Inspection Procedures...................................................................................................... Daily Maintenance .................................................................................................................................... Periodic Tool Inspection ............................................................................................................................ Lubrication ............................................................................................................................................ Visual Inspection .................................................................................................................................. Crimp Height Inspection ........................................................................................................................... Certi-Crimp Ratchet Inspection ................................................................................................................ How to Use AMP Double Action Hand Tool .................................................................................................. Description - AMP Extraction Tool................................................................................................................. Maintenance and Inspection ......................................................................................................................... How to Use AMP Extraction Tool .................................................................................................................. AMP Fastin-Faston Receptacles and Housings ................................................................................................ Description .................................................................................................................................................... Wire Repair........................................................................................................................................................ Wire Splicing Requirements.......................................................................................................................... Deutsch Jiffy Splice....................................................................................................................................... Assemble ..................................................................................................................................................

81 83 85 85 85 85 87 88 92 92 92 92 93 93 94 94 94 95 95 96 97 97 97 97 97 98 98 98 99 101 105 105 106 106 107 107 107 107 107 108 108 109 110 110 111 112 112 118 118 119 119

Wire Harness Repair

Table of Contents

TABLE OF CONTENTS (Continued) Disassemble ............................................................................................................................................. Del-City Crimp-Solder-Shrink Splice ............................................................................................................. Twisted/Shielded Cable and Leads Repair........................................................................................................ Twisted/Shielded Cable Repair ..................................................................................................................... Twisted Leads Repair.................................................................................................................................... Special Tools .....................................................................................................................................................

121 123 124 124 126 127

This section is for the following models: GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]; GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809]; GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810]; GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) [C878, D878]; GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) [C879, D879]; GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818]; GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813]; ERC22-35VG (ERC045-070VG) [A968]; ERP22-35VL (ERP045-070VL) [A976]; ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]; GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) [A909]; ESC030AC, ESC035AC, ESC040AC [B883]; GLC050LX [A967]; GLP/GDP20-25LX (GLP/GDP050LX) [A974]; ERC16-20VA (ERC030-040VA) [A969]

iii

2200 YRM 1128

Deutsch Crimping Tool

General This section covers the repair of the wire harness connectors, pins, sockets, and splicing of wires.

Deutsch Crimping Tool HOW TO STRIP A WIRE FOR USE WITH DEUTSCH CRIMPING TOOL 1. Choose the correct AWG for the contact being used. See Table 1. 2. See Table 1 for recommended strip length for contact size. Measure strip length from end of wire as shown in Figure 1.

Figure 2. Stripped Wire

Figure 1. Strip Length Measurement 3. Strip the wire to the recommended strip length. A small piece of insulation should come off the wire after stripping. See Figure 2. 4. Check for any broken strands or for a nick in the wire. If either exists, the wires are damaged and should be cut and stripped again.

Figure 3. Strip Length Measurement Verification

5. Measure the exposed strands to verify strip length is correct. See Figure 3.

Deutsch Crimping Tool

2200 YRM 1128

Table 1. Wire Strip Length Specifications Contact Part Number

Type

Wire Gauge Range

Recommended Strip Length

580039516

20 AWG (0.5 mm 2)

3.96 to 5.54 mm (0.156 to 0.218 in.)

580039517

Socket

20 AWG (0.5 mm )

580094445

20 AWG (0.5 mm 2)

3.96 to 5.54 mm (0.156 to 0.218 in.) 4.0 to 5.5 mm (0.157 to 0.217 in.) 2

505972554

16 to 20 AWG (1.0 to 0.5 mm )

6.35 to 7.92 mm (0.250 to 0.312 in.)

505064713

Socket

16 to 20 AWG (1.0 to 0.5 mm 2)

6.35 to 7.92 mm (0.250 to 0.312 in.)

580082335

6.4 to 7.9 mm (0.252 to 0.311 in.)

16 to 20 AWG (1.0 to 0.5 mm )

580082337

Socket

16 to 20 AWG (1.0 to 0.5 mm )

6.4 to 7.9 mm (0.252 to 0.311 in.)

520038865

14 AWG (2.0 mm 2)

6.35 to 7.92 mm (0.250 to 0.312 in.)

505064747

Socket

14 AWG (2.0 mm )

580079525

Socket

14 AWG (2.0 mm 2)

6.35 to 7.92 mm (0.250 to 0.312 in.) 6.4 to 7.9 mm (0.252 to 0.311 in.) 2

150121835

12 to 14 AWG (3.0 to 2.0 mm )

5.64 to 7.21 mm (0.222 to 0.284 in.)

580050627

Socket

12 to 14 AWG (3.0 to 2.0 mm 2)

5.64 to 7.21 mm (0.222 to 0.284 in.)

HOW TO CRIMP WITH THE DEUTSCH CRIMPING TOOL

3. Loosen lock nut and turn adjusting screw until it stops. See Figure 5.

1. Strip the insulation from the wire. See How to Strip a Wire for Use With Deutsch Crimping Tool. 2. Raise the selector knob and rotate until arrow is aligned with wire gauge to be crimped. See Figure 4.

1. LOCK NUT 2. ADJUSTING SCREW

Figure 5. Adjusting Screw and Lock Nut 4. Insert the contact into the crimping tool; for pin contacts, insert short end into crimping tool; for socket contacts, insert long end into crimping tool. See Figure 6.

Figure 4. Selector Knob

5. Turn the adjusting screw clockwise until the contact is flush or slightly above flush with the indentor cover (cover around insertion point). See Figure 6. Tighten the lock nut.

2200 YRM 1128

Deutsch Crimping Tool 8. Release handles and remove crimped contact. 9. Visually check the crimped contact for the following: a. The conductor is inserted to the proper depth and is visible through the inspection hole. See Figure 8. b. There is about 0.635 to 2.54 mm (0.025 to 0.100 in.) of conductor between the contact and the insulator. c. There are no damaged wire strands.

1. INSERTION POINT 2. INDENTOR COVER

Figure 6. Insertion Point 6. Insert the wire into the contact. There should be no loose strands. All strands should be contained in the contact barrel. The contact must be centered between indicators. See Figure 7.

Figure 7. Wire Insertion 7. Close handles until handles stop.

d. There are no frayed wires or wires not entering the contact barrel. 10. If any of the conditions in Step 9 are not met, discard the contact, re-cut and strip the wire, and start the crimping process over.

1. INSPECTION HOLE 2. CRIMP 3. INSULATION GAP, 0.635 to 2.54 mm (0.025 to 0.100 in.)

Figure 8. Proper Crimp

Deutsch Crimping Tool

CALIBRATION TEST FOR THE DEUTSCH CRIMPING TOOL

2200 YRM 1128 2. Squeeze the handles of the crimp tool completely together. See Figure 11.

The G454 testing tool is needed for the following procedures. The G454 testing tool is for use with the Deutsch hand crimping tool only. See Figure 9.

Figure 11. Insertion Point

1. GO END (GREEN) 2. NO-GO END (RED)

Figure 9. G454 Testing Tool

3. Insert the Go end (green) of the G454 testing tool into the insertion point of the crimp tool while the handles are completely closed. The Go end (green) should insert easily. If it does not insert, the calibration is incorrect and the crimp tool must be replaced. See Figure 12.

NOTE: Testing for all wire sizes should be #20 wire size, selector number 4. This ensures proper calibration for all settings and further testing is not needed for the other selections. 1. Set the Deutsch hand crimp tool to #20 wire size, selector number 4. See Figure 10.

1. GO END (GREEN) 2. GO END COMPLETELY INSERTED

Figure 12. Go End Test

1. SELECTOR SET AT #20 WIRE SIZE, SELECTOR NUMBER 4

Figure 10. Selector Test Setting

2200 YRM 1128

Deutsch Connectors

4. Insert the No-Go end (red) of the G454 testing tool into the insertion point of the crimp tool while the handles are still completely closed. The No-Go end (red) should not insert. If it does insert, the calibration is incorrect and the crimp tool must be replaced. See Figure 13.

1. NO-GO END (RED) 2. NO-GO END SHOULD NOT INSERT ANY FURTHER

Figure 13. No-Go End Test

Deutsch Connectors DT, DTM, AND DTP SERIES CONNECTORS All Deutsch DT, DTM, and DTP series pin- and sockettype connectors are repaired in the same manner. For examples of the DT connectors, see Figure 14 for the different connector receptacles, Figure 15 for the different connector receptacle secondary locks, Figure 16 for the different connector plugs, and Figure 17 for the different connector plug secondary locks.

For examples of the DTM and DTP connectors, see Figure 18 for the different connector receptacles, Figure 19 for the different connector receptacle secondary locks, Figure 20 for the different connector plugs, and Figure 21 for the different connector plug secondary locks.

Deutsch Connectors

2200 YRM 1128

NOTE: ALL CONNECTOR RECEPTACLES ARE SHOWN WITH THE SECONDARY LOCK INSTALLED. A. B. C. D. E. F.

CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR

TYPE TYPE TYPE TYPE TYPE TYPE

AA AB AC AD AE AF

G. CONNECTOR TYPE AB-A (SIMILAR TO TYPE AB) H. CONNECTOR TYPE AB-B (SIMILAR TO TYPE AB) I. CONNECTOR TYPE AB-C (SIMILAR TO TYPE AB)

Figure 14. DT Connector Receptacles

2200 YRM 1128

A. B. C. D.

SECONDARY SECONDARY SECONDARY SECONDARY

Deutsch Connectors

LOCK LOCK LOCK LOCK

TYPE BA TYPE BB TYPE BC TYPE BD

E. F. G. H.

SECONDARY SECONDARY SECONDARY SECONDARY

LOCK TYPE LOCK TYPE LOCK TYPE LOCK TYPE

BE BF BG BH

Figure 15. DT Connector Receptacle Secondary Locks

Deutsch Connectors

2200 YRM 1128

NOTE: ALL CONNECTOR PLUGS ARE SHOWN WITH THE SECONDARY LOCK INSTALLED. A. B. C. D.

CONNECTOR CONNECTOR CONNECTOR CONNECTOR

TYPE TYPE TYPE TYPE

CA CB CC CD

E. F. G. H.

CONNECTOR TYPE CE CONNECTOR TYPE CF CONNECTOR TYPE CH (SIMILAR TO TYPE CB) CONNECTOR TYPE CG

Figure 16. DT Connector Plugs

2200 YRM 1128

A. B. C. D.

SECONDARY SECONDARY SECONDARY SECONDARY

Deutsch Connectors

LOCK LOCK LOCK LOCK

TYPE DA TYPE DB TYPE DC TYPE DD

E. F. G. H.

SECONDARY SECONDARY SECONDARY SECONDARY

LOCK TYPE LOCK TYPE LOCK TYPE LOCK TYPE

DE DF DG DH

Figure 17. DT Connector Plug Secondary Locks

Deutsch Connectors

2200 YRM 1128

Figure 18. DTM and DTP Connector Receptacles

2200 YRM 1128

Deutsch Connectors

Legend for Figure 18 A. DTP CONNECTOR TYPE EA B. DTM CONNECTOR TYPE EB C. DTM CONNECTOR TYPE EC

D. DTP CONNECTOR TYPE ED E. DTM CONNECTOR TYPE EE F. DTM CONNECTOR TYPE EF

A. DTP SECONDARY LOCK TYPE FA B. DTM SECONDARY LOCK TYPE FB C. DTM SECONDARY LOCK TYPE FC

D. DTP SECONDARY LOCK TYPE FD E. DTM SECONDARY LOCK TYPE FE F. DTM SECONDARY LOCK TYPE FF

Figure 19. DTM and DTP Connector Receptacle Secondary Locks

Deutsch Connectors

A. B. C. D.

2200 YRM 1128

DTM CONNECTOR TYPE GA DTM CONNECTOR TYPE GB DTM CONNECTOR TYPE GC DTP CONNECTOR TYPE GD

E. F. G. H.

DTM CONNECTOR TYPE GF DTM CONNECTOR TYPE GE DTP CONNECTOR TYPE GG DTM CONNECTOR TYPE GH

Figure 20. DTM and DTP Connector Plugs

2200 YRM 1128

A. B. C. D. E.

Deutsch Connectors

DTM SECONDARY LOCK TYPE HA DTM SECONDARY LOCK TYPE HB DTM SECONDARY LOCK TYPE HC DTP SECONDARY LOCK TYPE HD DTM SECONDARY LOCK TYPE HE

F. G. H. I.

DTM SECONDARY LOCK TYPE HF DTM SECONDARY LOCK TYPE HG DTP SECONDARY LOCK TYPE HH DTM SECONDARY LOCK TYPE HJ

Figure 21. DTM and DTP Connector Plug Secondary Locks

Deutsch Connectors

Connector Receptacle Replacement STEP 1. Release the external locking clip(s) and separate the connector plug from the connector receptacle.

STEP 2. Using a small hook end tool (Yale Part No. 150121838), or needle nose pliers, remove the secondary lock from the connector receptacle.

2200 YRM 1128

Deutsch Connectors

Step 2. (Cont)

STEP 3. Using a small, flat-blade screwdriver (Yale Part No. 150121838), release the locking finger by moving it away from the pin.

Deutsch Connectors STEP 4. Gently pull the wire backward while, at the same time, releasing the locking finger with the small, flat-blade screwdriver (Yale Part No. 150121838).

STEP 5. Tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

2200 YRM 1128

Deutsch Connectors

Step 2. (Cont)

STEP 6. Repeat STEP 3 through STEP 5 for the removal of the remaining wires. STEP 7. Insert the wires into the new connector receptacle according to the number or letter on the tag and connector receptacle. Push the wires straight into the back of the receptacle until a click is felt. Slightly tug each wire to verify the wire is properly locked in place. Remove tags.

Deutsch Connectors NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock. STEP 8. Install the secondary lock. Push the lock straight in until the lock snaps into place.

STEP 9. Push the connector plug into the connector receptacle until the external locking mechanism(s) snap(s) into place.

2200 YRM 1128

Deutsch Connectors

Step 9. (Cont)

Connector Plug Replacement STEP 1. Release the external locking clip(s) and separate the connector plug from the connector receptacle.

Deutsch Connectors STEP 2. Using a small, flat-blade screwdriver (Yale Part No. 150121838), remove the secondary lock from the connector plug.

STEP 3. Using a small, flat-blade screwdriver (Yale Part No. 150121838), release the locking finger by moving it away from the socket.

2200 YRM 1128

Deutsch Connectors

Step 3. (Cont)

STEP 4. Gently pull the wire backward while, at the same time, releasing the locking finger with the small, flat-blade screwdriver (Yale Part No. 150121838).

Deutsch Connectors STEP 5. Tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

STEP 6. Repeat STEP 3 through STEP 5 for the removal of the remaining wires. STEP 7. Insert the wires into the back of the new connector plug according to the number or letter on the tag and connector plug. Push the wires straight into the back of the plug until a click is felt. Slightly tug each wire to verify the wire is properly locked in place. Remove tags.

2200 YRM 1128

Deutsch Connectors

Step 7. (Cont)

NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock. STEP 8. Install the secondary lock. Push the lock straight in until the lock snaps into place. On 3-way secondary locks, the arrow on the lock must be oriented toward the exterior locking mechanism.

1. SEAL

Deutsch Connectors STEP 9. Push the connector plug into the connector receptacle until the external locking mechanism(s) snap(s) into place.

Connector Receptacle Pin Replacement STEP 1. Release the external locking clip(s) and separate the connector plug from the connector receptacle.

2200 YRM 1128

Deutsch Connectors

Step 1. (Cont)

STEP 2. Using a small hook end tool (Yale Part No. 150121838), or needle nose pliers, remove the secondary lock from the connector receptacle.

Deutsch Connectors STEP 3. Using a small, flat-blade screwdriver (Yale Part No. 150121838), release the locking finger by moving it away from the pin.

STEP 4. Gently pull the wire backward while, at the same time, releasing the locking finger with the small, flat-blade screwdriver (Yale Part No. 150121838).

2200 YRM 1128

Deutsch Connectors

Step 4. (Cont)

STEP 5. If more than one pin is being replaced, tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

Deutsch Connectors STEP 6. Using wire cutters, cut the wire behind the old pin and discard old pin.

STEP 7. Using wire strippers (Yale Part No. 150121841, strip the wire to the recommended length shown in Table 1.

2200 YRM 1128

Deutsch Connectors

STEP 8. Using the Deutsch Crimping Tool (Yale Part No. 150121900), crimp the new pin on the wire as shown in How to Crimp With the Deutsch Crimping Tool.

STEP 9. Insert the wire into the connector receptacle according to the number or letter on the tag and connector receptacle. Push the wire straight into the back of the receptacle until a click is felt. Slightly tug the wire to verify the wire is properly locked in place. Remove tag.

Deutsch Connectors NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock. STEP 10. Install the secondary lock. Push the lock straight in until the lock snaps into place.

STEP 11. Push the connector plug into the connector receptacle until the external locking mechanism(s) snap(s) into place.

2200 YRM 1128

Deutsch Connectors

Step 11. (Cont)

Connector Plug Socket Replacement STEP 1. Release the external locking clip(s) and separate the connector plug from the connector receptacle.

Deutsch Connectors STEP 2. Using a small, flat-blade screwdriver (Yale Part No. 150121838), remove the secondary lock from the connector plug.

STEP 3. Using a small, flat-blade screwdriver (Yale Part No. 150121838), release the locking finger by moving it away from the socket.

2200 YRM 1128

Deutsch Connectors

Step 3. (Cont)

STEP 4. Gently pull the wire backward while, at the same time, releasing the locking finger with the small, flat-blade screwdriver (Yale Part No. 150121838).

Deutsch Connectors STEP 5. If more than one socket is being removed, tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

STEP 6. Using wire cutters, cut the wire behind the old socket and discard old socket.

2200 YRM 1128

Deutsch Connectors

STEP 7. Using wire strippers Yale Part No. 150121841, strip the wire to the recommended length shown in Table 1.

STEP 8. Using the Deutsch Crimping Tool (Yale Part No. 150121900), crimp the new socket on the wire as shown in How to Crimp With the Deutsch Crimping Tool.

Deutsch Connectors

2200 YRM 1128

STEP 9. Insert the wire into the back of the new connector plug according to the number or letter on the tag and connector plug. Push the wire straight into the back of the plug until a click is felt. Slightly tug the wire to verify the wire is properly locked in place. Remove tag.

NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock. STEP 10. Install the secondary lock. Push the lock straight in until the lock snaps into place. On 3-way secondary locks, the arrow on the lock must be oriented toward the exterior locking mechanism.

1. SEAL

2200 YRM 1128

Deutsch Connectors

Step 10. (Cont)

1. SEAL STEP 11. Push the connector plug into the connector receptacle until the external locking mechanism(s) snap(s) into place.

Deutsch Connectors

2200 YRM 1128

HD SERIES CONNECTORS All Deutsch HD series pin-type connectors are repaired in the same manner.

A. TYPE A

For examples of the HD connectors, see Figure 22 for the different connector receptacles and Figure 23 for the different connector plugs.

B. TYPE B

Figure 22. HD Connector Receptacles

2200 YRM 1128

A. TYPE 1

Deutsch Connectors

B. TYPE 2

Figure 23. HD Connector Plugs

Deutsch Connectors

Connector Receptacle Replacement STEP 1. Separate the connector plug from the connector receptacle.

STEP 2. Remove the lock nut and washer retaining the receptacle to the mounting structure. Remove receptacle from mounting structure.

NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual. STEP 3. Insert a Deutsch extraction tool over the wire being removed.

2200 YRM 1128

Deutsch Connectors

Step 3. (Cont)

NOTE: Do not twist the tool or insert the tool at an angle. STEP 4. Push the tool into the connector about 25 mm (1 in.) until it bottoms on the contact flange.

NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees, and reinsert the tool into the connector. STEP 5. Hold the tool on the contact flange and pull the wire and the connection pin out of the connector.

Deutsch Connectors STEP 6. Tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

STEP 7. Repeat STEP 3 through STEP 6 for the removal of the remaining wires. STEP 8. Insert the wires into the back of the new connector receptacle according to the number or letter on the tag and connector receptacle. Push the wire straight into the back of the receptacle until a click is felt. Slightly tug each wire to verify the wire is properly locked in place. Remove tags.

2200 YRM 1128

Deutsch Connectors

STEP 9. Install receptacle into mounting structure. Install the lock nut and washer to retain the receptacle to the mounting structure.

STEP 10. Connect the connector plug to the connector receptacle.

Connector Plug Replacement STEP 1. Separate the connector plug from the connector receptacle.

Deutsch Connectors NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual. STEP 2. Insert a Deutsch extraction tool over the wire being removed.

NOTE: Do not twist the tool or insert the tool at an angle. STEP 3. Push the tool into the connector about 25 mm (1 in.) until it bottoms on the contact flange.

2200 YRM 1128

Deutsch Connectors

NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees, and reinsert the tool into the connector. STEP 4. Hold the tool on the contact flange and pull the wire and the connection socket out of the connector.

STEP 5. Tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

Deutsch Connectors STEP 6. Repeat STEP 2 through STEP 5 for the removal of the remaining wires. STEP 7. Insert the wires into the back of the new connector plug according to the number or letter on the tag and connector plug. Push the wire straight into the back of the plug until a click is felt. Slightly tug each wire to verify the wire is properly locked in place. Remove tags.

STEP 8. Connect the connector plug to the connector receptacle.

Connector Receptacle Pin Replacement STEP 1. Separate the connector plug from the connector receptacle.

2200 YRM 1128

Deutsch Connectors

STEP 2. Remove the lock nut and washer retaining the receptacle to the mounting structure. Remove receptacle from mounting structure.

NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual. STEP 3. Insert a Deutsch extraction tool over the wire being removed.

Deutsch Connectors NOTE: Do not twist the tool or insert the tool at an angle. STEP 4. Push the tool into the connector about 25 mm (1 in.) until it bottoms on the contact flange.

STEP 5. Hold the tool on the contact flange and pull the wire and the connection pin out of the connector.

STEP 6. If more than one wire is being removed, tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

2200 YRM 1128

Deutsch Connectors

Step 6. (Cont)

STEP 7. Using wire cutters, cut the wire behind the old pin and discard old pin.

STEP 8. Using wire strippers, Yale Part No. 150121841, strip the wire to the recommended length shown in Table 1.

Deutsch Connectors STEP 9. Using the Deutsch Crimping Tool (Yale Part No. 150121900), crimp the new pin on the wire as shown in How to Crimp With the Deutsch Crimping Tool.

NOTE: The rear seal/grommet must be seated properly before inserting wires. STEP 10. Insert the wires into the back of the new connector receptacle according to the number or letter on the tag and connector receptacle. Push the wire straight into the back of the receptacle until a click is felt. Slightly tug each wire to verify the wire is properly locked in place. Remove tags.

STEP 11. Install receptacle into mounting structure. Install the lock nut and washer to retain the receptacle to the mounting structure.

2200 YRM 1128

Deutsch Connectors

STEP 12. Connect the connector plug to the connector receptacle.

Connector Plug Socket Replacement STEP 1. Separate the connector plug from the connector receptacle.

Deutsch Connectors NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual. STEP 2. Insert a Deutsch extraction tool over the wire being removed.

NOTE: Do not twist the tool or insert the tool at an angle. STEP 3. Push the tool into the connector about 25 mm (1 in.) until it bottoms on the contact flange.

2200 YRM 1128

Deutsch Connectors

STEP 4. Hold the tool on the contact flange and pull the wire and the connection socket out of the connector.

STEP 5. If more than one wire is being removed, tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

Deutsch Connectors STEP 6. Using wire cutters, cut the wire behind the old socket and discard old socket.

STEP 7. Using wire strippers, 150121841, strip the wire to the recommended length shown in Table 1.

STEP 8. Using the Deutsch Crimping Tool (Yale Part No. 150121900), crimp the new socket on the wire as shown in How to Crimp With the Deutsch Crimping Tool.

2200 YRM 1128

Deutsch Connectors

NOTE: The rear seal/grommet must be seated properly before inserting wires. STEP 9. Insert the wires into the back of the new connector plug according to the number or letter on the tag and connector plug. Push the wire straight into the back of the plug until a click is felt. Slightly tug wire to verify the wire is properly locked in place. Remove tags.

STEP 10. Connect the connector plug to the connector receptacle.

SEALING PLUGS All empty contact cavities must be filled with a sealing plug. See Figure 24.

A. 6 AWG (DARK RED) B. 8 AWG (CLEAR WHITE)

C. 12 TO 18 AWG (WHITE) D. 20 AWG (RED)

Figure 24. Sealing Plugs

Deutsch Connectors STEP 1. Hold the sealing plug with the large diameter end away from the connector.

STEP 2. Insert the sealing plug into the connector contact cavity. Gently apply downward pressure to force the sealing plug into the cavity.

2200 YRM 1128

Metri-Pack Connectors

STEP 3. Apply pressure until sealing plug is forced to stop by the connector rear grommet. Visually inspect the sealing plug to ensure it is flush with the cavity opening.

Metri-Pack Connectors Some connectors use terminals called Metri-Pack Series 150. These may be used at the coolant sensor and TBI units on ICE lift trucks.

REMOVE AND INSTALL

They are also called push-to-seat terminals because to install a terminal on a wire, the wire is first inserted through the seal and connector. The terminal is then crimped on the wire and the terminal pulled back into the connector to seat it in place.

2. Hold the wire and use it to push the terminal to its forward position in the connector body. Hold the terminal in this position. See Figure 25.

1. Slide the seal back on the wire.

NOTE: DO NOT cut contacts from reel, use loose contacts only.

1. FEMALE TERMINAL 2. LOCKING TAB 3. TOOL KIT

4. CONNECTOR BODY 5. SEAL

Figure 25. Metri-Pack Terminal Removal

Metri-Pack Connectors

2200 YRM 1128

3. Find the lock tab for the terminal in the connector channel. Push a removal tool (pick) (YALE Part No. 150121850) of the correct size into the connector channel. See Figure 26 and Figure 27.

4. Use the removal tool (YALE Part No. 150121850) to move the lock tab to release the terminal from its seat. Push-to-Seat - Gently pull the wire to remove the terminal from the back of the connector. Pull-to-Seat - Gently push the wire to remove the terminal through the front of the connector. See Figure 28.

1. TOOL (PICK) 2. LOCK TAB 3. TERMINAL

4. CONNECTOR BODY

Figure 26. Metri-Pack Push-to-Seat Connector

1. TOOL (PICK) 2. LOCK TAB 3. TERMINAL

4. CONNECTOR BODY

Figure 27. Metri-Pack Pull-to-Seat Connector

1. TERMINAL 2. LOCK TAB 3. TOOL KIT

4. CONNECTOR BODY 5. SEAL

Figure 28. Metri-Pack Pull-to-Seat Terminal Removal

2200 YRM 1128

Micro-Pack Connectors

CAUTION Work carefully and do not use enough force to damage the terminal or the connector. 5. Inspect the terminal and connector for damage. See Figure 29. NOTE: If reusing the terminal, reshape the locking tab. 6. If the terminal will be used again, make sure the lock tab is correctly bent so that the terminal will be locked in the connector again. 7. Push the terminal into the connector channel. Make sure that the lock tab correctly locks the terminal in position. 8. Push the seals into their position and install any secondary locks.

NOTE: THE GREATER DISTANCE D, A FAULT CAN OCCUR IN THE CONNECTION. 1. CONTACT TAB

Figure 29. Metri-Pack Terminal Inspection

Micro-Pack Connectors The Micro-Pack connector is shown in Figure 30. This connector is normally used to connect the wire harness to the ECM. The repair procedures for the Micro-Pack connectors are the same as the Metri-Pack connectors. Refer to the section Metri-Pack Connectors for the repair procedures.

1. CABLE 2. TERMINAL 3. LOCKING TAB

4. TOOL KIT (YALE PART NO. 150121852

Figure 30. Micro-Pack Connector

Weather-Pack Connectors

2200 YRM 1128

Weather-Pack Connectors A Weather-Pack connector can be identified by a rubber seal at the rear of the connector. This connector, which is used in the engine compartment, protects against moisture and dirt which could create oxidation and deposits on the terminals. This protection is important because of the very low voltage and current levels found in the electronic system. Repair of a Weather-Pack terminal is shown in WeatherPack Terminal Repair. Use the tool kit to remove the pin and sleeve terminals. See Special Tools. If removal is attempted with an ordinary pick, there is a good chance that the terminal will be bent or deformed.

Unlike standard blade-type terminals, these terminals cannot be straightened once they are bent. Make certain that the connectors are properly seated and all of the sealing rings are in place when connecting leads. The hinge-type flap provides a backup or secondary locking feature for the connector. They are used to improve the connector reliability by retaining the terminals if the small terminal lock tabs are not positioned properly. Weather-Pack connections cannot be replaced with standard connections. Instructions are provided with Weather-Pack connector and terminal packages.

WEATHER-PACK TERMINAL REPAIR STEP 1. Open secondary lock hinge on connector.

1. FEMALE CONNECTOR 2. MALE CONNECTOR 3. SECONDARY LOCK HINGE STEP 2. Remove terminal, using tool YALE Part No. 150121851.

1. TERMINAL 2. TOOL

2200 YRM 1128

Weather-Pack Connectors

STEP 3. Cut wire immediately behind cable seal.

1. WIRE 2. SEAL STEP 4. Replace terminal. a. Slip new seal onto wire. b. Strip 5 mm (0.2 in.) of insulation from wire. c. Crimp terminal over wire and seal. STEP 5. Push terminal and connector onto wire and engage locking tabs. STEP 6. Close secondary lock hinge.

1. SEAL

AMPSEAL Crimping Tools

2200 YRM 1128

AMPSEAL Crimping Tools AMP HAND CRIMPING TOOL WITH CERTI-CRIMP Description The tool, Yale Part No. 580093883, features two upper inserts, two anvils, an insulation crimp adjustment lever, a contact support, a locator, an ejector, and a CERTICRIMP ratchet. The contact is inserted into the FRONT of the tool. The wire is inserted into the BACK of the tool. See Figure 31. The insulation adjust lever regulates the crimp height. See Insulation Crimp Adjustment. The contact support prevents the contact from bending during crimping. The locator functions two ways: • position the contact between the upper insert and the anvil before crimping • limits the insertion distance of the stripped wire into the contact. The ejector pulls the locator down, and ejects the crimped contact when the tool handles are fully opened.

CAUTION The crimping jaws bottom before the CERTI-CRIMP ratchet releases. This is a design feature that ensures maximum electrical and tensile performance of the crimp DO NOT readjust the ratchet. The CERTI-CRIMP ratchet assures full crimping of the contact. Once engaged, the ratchet will not release until the handles have been fully closed.

A. FRONT OF TOOL

B. BACK OF TOOL

1. UPPER INSERT 2. ANVIL 3. INSULATION CRIMP ADJUSTMENT LEVER

4. CONTACT SUPPORT 5. LOCATOR 6. CERTI-CRIMP RATCHET 7. STRIPPED WIRE

Figure 31. AMP Hand Crimping Tool

2200 YRM 1128

AMPSEAL Crimping Tools

Stripping Wire for Use with AMP Hand Crimping Tool

3) large. If the crimped insulation barrel is too tight or too loose, change the setting accordingly. The crimp should hold the insulation firmly without cutting into it.

1. Choose the correct AWG for the contact being used. 2. See Table 2 for recommended strip length.

CAUTION DO NOT cut or nick the wire strands. 3. Strip wire to recommended strip length. A small piece of insulation should come off the wire after stripping. See Figure 32. NOTE: SEE TABLE 2 FOR WIRE STRIP LENGTH.

Insulation Crimp Adjustment The insulation barrel crimp height is regulated by the insulation adjustment lever. To determine the proper setting, test crimp a contact using the setting which approximates the insulation size: 1) small, 2) medium, or

1. STRIPPED WIRE 2. LOCATOR SLOT

Figure 32. Strip Length

Table 2. Wire Size (AWG) Wire Size (AWG)

Insulation Diameter Range

Tool Wire Size Marking

1.7 to 2.7 mm (0.067 to 0.106 in.)

5.5 mm (0.215 in.)

20 - 18

4.7 mm (0.185 in.)

20 - 18

Contact

Wire Strip Length

AMPSEAL Crimping Tools

2200 YRM 1128

Maintenance and Inspection for AMP Hand Crimping Tool AMP Hand Crimping Tool 1. Perform maintenance and inspections as specified by AMP.

Crimp Height Inspection 1. This inspection requires the use of a micrometer with a modified anvil as shown in Figure 33. 2. Refer to Table 3 and select contact and wire (maximum size) for each crimp section listed. 3. Crimp a contact on to the wire according to How to use AMP Hand Crimping Tool procedure. 4. Using a modified micrometer, measure wire barrel crimp height as shown in Figure 33. If the crimp height conforms to measurement in Table 3 the tool is correct. If not, replace tool.

A. CRIMP HEIGHT - SEE TABLE 3 1. 2. 3. 4. 5.

TOOL CRIMP SECTION MARKING WIRE SLOT IN LOCATOR WIRE BARREL LOCATOR SLOT IN CONTACT MODIFIED ANVIL ON MICROMETER

Figure 33. AMP Crimp Tool Inspection Table 3. Crimp Height Contact Part No.

Yale Part No. 520202601

Wire Size (AWG)

Tool Crimp Section Marking

Crimp Height

20-18

1.22 ±0.05 mm (0.048 ±0.002 in.)

20-18

1.22 ±0.05 mm (0.048 ±0.002 in.)

1.40 ±0.05 mm (0.055 ±0.002 in.)

2200 YRM 1128

AMPSEAL Crimping Tools

HOW TO USE AMP HAND CRIMPING TOOL 1. Strip insulation from wire. See Stripping Wire for Use with AMP Hand Crimping Tool.

8. Allow tool handles to open fully and remove crimped contact from tool.

AMP PRO-CRIMPER II TOOL

2. Hold tool so BACK side (wire side) faces you.

Description

3. Release tool ratchet by squeezing tool handles then allowing them to open.

This tool has a tool frame with stationary jaw and handle, a moving jaw and handle, and an adjustable ratchet to ensure full contact crimping. The tool frame contains a die assembly with two crimping sections.

4. Holding contact by its mating portion and looking straight into crimp section, insert contact from the FRONT of tool into BACK of crimp section. Position contact as shown in Figure 34.

The die assembly contains a wire anvil, an insulation anvil, a wire crimper and an insulation crimper. See Figure 35. The locator assembly, on the outside of the frame, contains a locator, a spring retainer, and a contact support. The dies are secured to the frame with retaining pins and retaining screws. A nut on the upper retaining screw holds the locator assembly in place.

1. BACK OF TOOL 2. STRIPPED WIRE 3. WIRE BARREL

4. CONTACT 5. LOCATOR

Figure 34. Crimp Contact to Wire NOTE: Make sure wire barrel is not deformed during crimping procedure. 5. Holding contact in this position, squeeze tool handles together. 6. Insert properly stripped wire through locator and into wire barrel of contact. 7. Crimp contact onto wire while holding wire in place by squeezing tool handles together until ratchet releases.

A. TOOL FRONT

B. TOOL BACK

1. STATIONARY JAW 2. STATIONARY HANDLE 3. MOVING JAW

4. MOVING HANDLE 5. DIE ASSEMBLY 6. LOCATOR ASSEMBLY

Figure 35. AMP PRO-CRIMPER II Tool

AMPSEAL Crimping Tools

2200 YRM 1128

Remove and Install Die Set and Locator Assembly NOTE: Perform Step 1 through Step 3 for removal of die set and locator assembly. Follow Step 4 through Step 12 for installation of die set and locator assembly. 1. Close tool handles until ratchet releases. 2. Remove nut, locator assembly, upper and lower die retaining screws, and upper and lower die retaining pins. See Figure 36.

and crimpers in position. Tighten upper and lower die retaining screws. 11. Install locator assembly over the end of upper die retaining screw and position against the side of the tool jaw. See Figure 36. 12. Install nut onto the end of upper die retaining screw and tighten enough to hold locator assembly in place while allowing the locator to slide up and down. See Figure 36.

3. Slide wire anvil, insulation anvil, wire crimper, and insulation crimper out of tool frame. See Figure 36. 4. Install wire anvil and insulation anvil into moving jaw of tool frame, with chamfered sides and marked surfaces facing outward. See Figure 36. 5. Insert lower die retaining pins. See Figure 36. 6. Insert lower die retaining screw through moving jaw and both anvils. Tighten screw enough to hold the anvils in place, but DO NOT tighten completely. See Figure 36. 7. Insert wire crimper and insulation crimper into stationary jaw, with chamfered sides and marked surfaces facing outward. See Figure 36. 8. Insert upper die retaining pins. See Figure 36. 9. Insert upper die retaining screw through stationary jaw and both crimpers. See Figure 36. Tighten screw enough to hold crimpers in place, but DO NOT tighten completely. 10. Carefully close tool handles. Make sure anvils and crimpers align properly. Completely close tool handles until ratchet is engaged enough to hold anvils

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

UPPER DIE RETAINING SCREW LOWER DIE RETAINING SCREW WIRE ANVIL INSULATION ANVIL LOWER DIE RETAINING PIN WIRE CRIMPER INSULATION CRIMPER UPPER DIE RETAINING PIN LOCATOR ASSEMBLY NUT LOCATOR TOOL FRAME

Figure 36. Die Set and Locator Assembly

2200 YRM 1128

AMPSEAL Crimping Tools

Stripping Wire for Use With AMP PRO-CRIMPER II Tool 1. Choose the correct AWG for the contact being used. 2. See Table 4 for recommended strip length.

Table 4. Strip Length for PRO-CRIMPER II Tool Wire Size (AWG)

Wire Insulation Diameter

Strip Length

1.7 to 2.7 mm (0.07 to 0.11 in.)

5.1 ±0.4 mm (0.20 ±0.02 in.)

18-20

Contact Support Adjustment 1. Make a sample crimp. Determine if contact is straight, bent upward or downward. 2. If adjustment is required, loosen adjustment screw, DO NOT remove screw. See Figure 38. 3. Insert contact and wire into tool as shown in Figure 37. Close tool handles until the ratchet reaches the sixth clip or the contact support touches the contact. 4. Loosen the nut, slightly, that holds the locator assembly onto the tool frame. See Figure 38. 5. Move the contact support to eliminate bending the contact.

CAUTION DO NOT cut or nick the wire strands.

6. Tighten the nut and squeeze handles until ratchet releases.

3. Strip wire to recommended strip length. See Figure 37.

7. Remove and inspect the contact. 8. Make another sample crimp. If the contact is straight, tighten the adjustment screw. If the contact is bent, repeat Step 2 through Step 8.

1. 2. 3. 4.

CONTACT LOCATOR (IN WIRE STOP SLOT) WIRE (INSERTED TO STOP) STRIP LENGTH

Figure 37. Contact and Wire Strip

1. 2. 3. 4. 5.

ADJUSTMENT SCREW CONTACT SUPPORT LOCATOR WIRE BACK OF TOOL

Figure 38. Contact Support Adjustment

AMPSEAL Crimping Tools

Crimp Height Adjustment 1. Remove lockscrew from ratchet adjustment wheel. See Figure 39. 2. Using screwdriver, adjust ratchet wheel as indicated in Step 3 or Step 4. 3. To tighten crimp, rotate ratchet adjustment wheel COUNTERCLOCKWISE. See Figure 39. 4. To loosen crimp, rotate ratchet adjustment wheel CLOCKWISE. See Figure 39. 5. Replace lockscrew onto ratchet adjustment wheel. See Figure 39. 6. Make a sample crimp and measure the crimp height.

2200 YRM 1128 2. Inspect the crimping dies on a regular basis to ensure they are not worn or damaged. If crimp sections are flattened, chipped, worn or broken replace tool.

Crimp Height Inspection 1. This inspection requires the use of a micrometer with a modified anvil as shown in Figure 40. 2. Refer to Table 5 to select wire for each crimp section listed. 3. Crimp a contact onto the selected wire according to How to Use AMP PRO-CRIMPER II Tool procedure. 4. Using a modified micrometer, measure wire barrel height as shown in Figure 40. If the crimp height matches measurement shown in Table 5 the tool is correct. If not, follow Crimp Height Adjustment procedure.

A. POSITION POINT ON CENTER OF WIRE BARREL OPPOSITE SEAM. 1. LOCKSCREW 2. RATCHET ADJUSTMENT WHEEL 3. SCREWDRIVER

Figure 39. Ratchet Adjustment Wheel

Maintenance and Inspection Procedures PRO-CRIMPER II Tool 1. Make sure the tool and dies are clean by wiping them with a clean, soft cloth. If debris is present, clear away with a soft brush. Keep handles closed when not in use to prevent objects from becoming stuck in crimping dies. Store in clean, dry area.

1. MODIFIED ANVIL ON MICROMETER 2. CRIMP HEIGHT, SEE TABLE 5

Figure 40. Crimp Height Table 5. Crimp Measurement Wire Size (AWG)

Crimp Height

1.22 ±0.05 mm (0.048 ±0.002 in.)

1.41 ±0.05 mm (0.056 ±0.002 in.)

2200 YRM 1128

HOW TO USE AMP PRO-CRIMPER II TOOL 1. Strip insulation from wire. See Stripping Wire for Use With AMP PRO-CRIMPER II Tool procedure. 2. Hold PRO-CRIMPER II tool so BACK side (wire side) is facing you. 3. Squeeze tool handles together, then allow to fully open. 4. Holding contact by mating end, insulation barrel first, insert contact through front of tool and into appropriate crimp section. 5. Mating end of contact should be on locator side of tool; the open "U" of wire barrel and insulation barrel should face the top of the tool. The contact to be placed to that movable locator drips into slot in the contact. Butt the front end of the wire barrel against locator.

AMPSEAL Crimping Tools NOTE: Make sure neither wire barrel nor insulation barrel are damaged. 6. Hold contact in position and squeeze tool handles until ratchet engages enough to hold contact. 7. Insert stripped wire into contact insulation and wire barrels until butted against wire stop. 8. Squeeze tool handles, while holding wire in position, until ratchet releases. 9. Allow tool handles to open and remove crimped contact from tool. 10. Check crimp height as described in Crimp Height Inspection.

AMPSEAL Connector Assemblies

2200 YRM 1128

AMPSEAL Connector Assemblies DESCRIPTION FOR PLUG CONNECTOR ASSEMBLY The plug assembly consists of a housing, a wedge lock, a wire seal, and a mating seal. See Figure 41. For current ratings of special use connectors, AMPSEAL, refer to Table 6.

Table 6. Current Rating Single Circuit Plating

Wire Size (AWG)

Current Rating (Max.)

Tin

16, 18, and 20

Gold

14.5A

13A

11.5A

1. 2. 3. 4. 5. 6. 7.

HOUSING WEDGE LOCK WIRE SEAL MATING SEAL DIAPHRAGM CONTACT RETENTION FINGERS

Figure 41. AMPSEAL Plug Connector

2200 YRM 1128

AMPSEAL Connector Assemblies

Seal Plug All circuits are sealed by a diaphragm in the rubber wire seal. When assembling the connector, the diaphragm is pierced as the contact passes through it. Unused circuit cavities will remain sealed unless perforated by accidental insertion and removal of contact in the wrong cavity. The seal plug is designed to keep out contaminants if the diaphragm is pierced. 1. Insert the seal plug, large end first, into the circuit cavity as far as it will go. No insertion tool is usually required for this procedure. See Figure 42.

1. PLUG CONNECTOR 2. SEAL PLUG 3. CIRCUIT CAVITY

Figure 42. Seal Plug

AMPSEAL Connector Assemblies

2200 YRM 1128

Contact Crimping Information on contact crimping can be found in AMPSEAL Crimping Tools.

Contact Removal NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts. STEP 1. Insert a screwdriver blade between the mating seal and one of the red wedge lock tabs. Pry open the wedge lock to the OPEN position.

NOTE: SCREWDRIVER TO BE MOVED IN DIRECTION OF ARROW. A. CLOSED POSITION B. OPEN POSITION 1. WEDGE LOCK TAB

2200 YRM 1128

AMPSEAL Connector Assemblies

STEP 2. While rotating the wire back and forth over a half turn (1/4 turn each direction), gently pull the wire until the contact is removed.

STEP 3. Tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed. STEP 4. Repeat STEP 2 and STEP 3 to remove remaining wires.

AMPSEAL Connector Assemblies

2200 YRM 1128

Contact Insertion NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts. NOTE: Check to be sure the wedge lock is in the OPEN position. Perform STEP 1 if wedge lock is closed STEP 1. Insert a screwdriver blade between the mating seal and one of the red wedge lock tabs. Pry open the wedge lock to the OPEN position.

NOTE: SCREWDRIVER TO BE MOVED IN DIRECTION OF ARROW. A. CLOSED POSITION B. OPEN POSITION 1. WEDGE LOCK TAB

2200 YRM 1128

AMPSEAL Connector Assemblies

STEP 2. Insert contact by pushing it straight into the appropriate circuit cavity as far as it will go.

STEP 3. Pull back on the contact wire with a force of 4 to 9 N (1 to 2 lbf) to be sure the retention fingers are holding the contact.

NOTE: PULL WIRE IN DIRECTION OF ARROW. 1. RETENTION FINGERS STEP 4. After all required contacts have been inserted, the wedge lock must be closed to its LOCKED position. Release the locking latches by squeezing them inward.

1. LOCKING LATCHES STEP 5. Slide the wedge lock into the housing until it is flush with the housing.

1. WEDGE LOCK

AMPSEAL Connector Assemblies

2200 YRM 1128

DESCRIPTION FOR PLUG CONNECTOR AND HEADER ASSEMBLY The plug assembly will accept multiple socket contacts. See Figure 43. The head assembly is designed to be fastened to the enclosure by four self-tapping screws. The screw length will depend on panel thickness. Panel mounting cutout requirements shown in Figure 44. Maximum panel thickness to be 2 mm (0.08 in.) for proper clearance. Use screwdriver slot to lift latch for unmating. To mate the plug and head must be identical in color. Securely fasten the locking latch when mating plug and header. See Figure 45. The wedge lock has slotted openings in the mating, forward, end. The slots are for circuit test tabs approximately 3.3 × 0.6 mm (0.13 × 0.02 in.), which prevent damage to the receptacle. Circuit testing in the field to be done by a flat probe, DO NOT use a sharp point.

NOTE: PLUG AND HEADER ASSEMBLY COLORS ARE MECHANICALLY KEYED TO MATE ONLY WITH IDENTICAL COLORS. A. PLUG ASSEMBLY B. HEADER ASSEMBLY 1. 2. 3. 4.

MATING SEAL HOUSING WEDGE LOCK RETENTION LEG

Figure 43. AMPSEAL Plug and Header Assembly

Figure 44. AMPSEAL Plug and Header Assembly Panel Mounting

2200 YRM 1128

AMPSEAL Connector Assemblies

A. WIRE STRANDS MUST BE VISIBLE IN THIS AREA B. WIRE STRANDS AND INSULATION MUST BOTH BE VISIBLE IN THIS AREA C. CUTOFF TAB MUST BE VISIBLE 1. SCREWDRIVER SLOT

2. LOCKING LATCH

3. PLUG AND HEADER

Figure 45. Contact, Plug, and Header

Voltage Reading CAUTION DO NOT pierce wire insulation to take voltage readings.

When using AMPSEAL plug assembly DO NOT pierce wire insulation with a sharp point. Pin holes in the insulation allow moisture to invade the sealed connector system nullifying effectiveness and resulting in possible system failure.

AMPSEAL Connector Assemblies

2200 YRM 1128

Seal Plug

Contact Crimping

All circuits are sealed by a diaphragm in the rubber wire seal. This diaphragm is pierced when the contact is pressed through it. Unused circuit cavities will remain sealed unless perforated by accidental insertion and removal of contact in the wrong cavity. The seal plug is designed to keep out contaminants if the diaphragm is accidentally pierced.

1. Information on contact crimping can be found in AMPSEAL Crimping Tools.

1. Insert the seal plug, large end first, into the circuit cavity as far as it will go. No insertion tool is required for this procedure. See Figure 46.

NOTE: DO NOT cut contacts from "reel", use loose contacts only. 2. Crimped contacts to meet conditions shown in Figure 47 and Table 7.

CAUTION Cable far end to be sealed or isolated from the environment. DO NOT damage insulation. NOTE: Wire stripping tools may leave indentations on the surface of the wire insulation. If these indentations are present at the wire seal, leakage can occur. Insulation surface within 26 mm (1.02 in.) of contact tip must be smooth and free of indentations. Ensure wire insulation is not damaged during crimping procedure. The insulation bars to be wrapped around the wire insulation, leaving not sharp points to damage rubber wire seal. 3. The crimped contact to be a 2 mm (.08 in.) diameter cylinder. See Figure 48.

1. PLUG CONNECTOR 2. SEAL PLUG 3. CIRCUIT CAVITY

Figure 46. Seal Plug

2200 YRM 1128

A. B. C. D. E. F.

AMPSEAL Connector Assemblies

WIRE STRAND ENDS MUST BE VISIBLE IN THIS AREA WIRE BARREL SHALL BE CLOSED AT SEAM WITH NO STRANDS PROTRUDING OR SHOWING WIRE STRANDS AND INSULATION SHALL BOTH BE VISIBLE FRONT BELLMOUTH SHALL BE 0.25 mm (0.01 in.)MAX; 0.13 mm (0.005 in.)MIN REAR BELLMOUTH SHALL BE 0.13 to 0.75 mm (0.005 to 0.03 in.) CUTOFF TAB SHALL BE 0.25 mm (0.01 in.)MAX

Figure 47. Crimp Conditions Table 7. Crimp Conditions Wire Size (AWG)

Insulation Diameter Range

Wire Barrel Strip Length

20 18 16

Crimp Height

Insulation Barrel

Crimp Width (Nom)

Crimp Height Max

Crimp Width ±0.1

2.03

3.2

3.1

1.17 ±0.08 1.7 to 2.7

5.1

1.27 ±0.05 1.40 ±0.05

AMPSEAL Connector Assemblies

2200 YRM 1128

A. CENTERLINE

B. DIA 2 mm (0.08 in.)

1. CONTACT (PARTIALLY INSERTED) 2. WIRE SEAL 3. RETENTION FINGERS

4. DIAPHRAGM 5. MATING SEAL 6. WEDGE LOCK (OPEN POSITION)

Figure 48. Contact Concentricity

2200 YRM 1128

AMPSEAL Connector Assemblies

NOTE: SCREWDRIVER TO BE MOVED IN DIRECTION OF ARROW. A. CLOSED POSITION B. OPEN POSITION 1. WEDGE LOCK TAB

AMPSEAL Connector Assemblies STEP 2. Wile rotating the wire back and forth over a half turn (1/4 turn each direction), gently pull the wire until the contact is removed.

STEP 3. Repeat STEP 2 to remove remaining wires.

2200 YRM 1128

AMPSEAL Connector Assemblies

Contact Insertion NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts. NOTE: Check to be sure the wedge lock is in the OPEN position. Perform STEP 1 if wedge lock is closed. STEP 1. Insert a screw driver blade between the mating seal and one of the red wedge lock tabs. Pry open the wedge lock to the OPEN position.

NOTE: SCREWDRIVER TO BE MOVED IN DIRECTION OF ARROW. A. CLOSED POSITION B. OPEN POSITION 1. WEDGE LOCK TAB

AMPSEAL Connector Assemblies

2200 YRM 1128

STEP 2. Insert contact straight into circuit cavity as far as it will go.

STEP 3. Pull back on contact wire with 4 to 9 N•m (1 to 2 lbf) to be sure the retention fingers are holding the contact.

1. RETENTION FINGERS STEP 4. After all required contacts have been inserted, the wedge lock must be closed to the LOCKED position. Release the locking latches by squeezing them inward.

1. LOCKING LATCHES STEP 5. Slide the wedge lock into the housing until it is flush with the housing.

1. WEDGE LOCK

2200 YRM 1128

AMP Superseal 1.5 Crimping Tools

AMP Superseal 1.5 Crimping Tools MINI MIC RECEPTACLE AND TAB CONTACTS Description Contacts are for 16-22 AWG wire, with single wire seals. Each wire is inserted into a discrete wire seal before crimping into contact. Insulation barrel is crimped so wire seal is gripped to avoid any movement of seal. Contacts are suitable for single wires only.

Crimping Conditions and Measurements 1. Cut-off tab length = 0.3 mm (0.01 in.) max. See Figure 49. 2. Front bellmouth = 0.10 mm (0.004 in.) × 45° max. See Figure 49.

4. Bend up = 5° max. See Figure 51. 5. Bend down = 5° max. See Figure 51. 6. Bend right = 5° max. See Figure 50. 7. Bend left = 5° max. See Figure 50. 8. Rolling = 5° max. See Figure 50. 9. Cable end protrusion = 0.2 to 0.7 mm (0.008 to 0.03 in.). See Figure 49. 10. Insulation stripping length = 3.0 to 3.5 mm (0.12 to 0.14 in.). 11. Wire barrel seam must be neatly closed. See Figure 49.

3. Rear bellmouth = 0.25 mm (0.009 in.) × 45° max. See Figure 49.

AMP Superseal 1.5 Crimping Tools

2200 YRM 1128

A. TOP VIEW

B. SIDE VIEW

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13.

WIRE BARREL SEAM WIRE BARREL CABLE END PROTRUSION LENGTH WIRE BARREL CRIMP WIDTH INSULATION BARREL CRIMP WIDTH RUBBER SEAL CABLE

INSULATION BARREL FRONT BELLMOUTH REAR BELLMOUTH INSULATION BARREL CRIMP HEIGHT CUT-OFF TAB LENGTH WIRE BARREL CRIMP HEIGHT

Figure 49. Crimping Conditions

2200 YRM 1128

AMP Superseal 1.5 Crimping Tools

1. BEND RIGHT 2. BEND LEFT

3. ROLLING 4. DATUM LINE

Figure 50. Crimping Conditions Bend Right/Left

1. BEND UP

2. BEND DOWN

3. DATUM LINE

Figure 51. Crimping Conditions Bend Up/Down

Insertion of Rubber Seal on Cable NOTE: Rubber seals are lubricated, lubrication must not be removed. The end of cable insulation to be positioned from edge of rubber seal when rubber seal is installed on cable. See Figure 52.

A. 0.5 mm (0.02 in.)MAX 1. WIRE INSULATION

2. RUBBER SEAL

Figure 52. Rubber Seal Installed on Cable

AMP Superseal 1.5 Crimping Tools

2200 YRM 1128

Correction or Replacement of Parts STEP 1. When defects or improper applications are found on parts to be installed, rework or replace with new parts. STEP 2. Cut end of wire shall appear neat without any bend or stranded conductor.

STEP 3. Conductor shall be free from nick, cut or scrape.

STEP 4. Wire insulation must have smooth surface in a round form without damage, groove, or recessed surface.

2200 YRM 1128

AMP Superseal 1.5 Crimping Tools

STEP 5. wire end shall be straight without bend or untidiness after insertion of rubber seal.

STEP 6. Flanges of rubber seal to be free of cuts or damage.

STEP 7. Insertion of rubber seal to be done straight and even. If flanges are tilted, plug must be corrected so flanges are perpendicular to contact center line.

STEP 8. After crimping, cable insulation inside rubber seal to be in good condition and within requirements as specified in Crimping Conditions and Measurements in this section.

A. 0.2 to 0.7 mm (0.008 to 0.03 in.) B. 0.2 mm (0.008 in.)

AMP Superseal 1.5 Crimping Tools

2200 YRM 1128

STEP 9. Rubber seal must protrude from insulation crimp without damage. Check by visual inspection in the transition area (between wire and insulation barrel) as shown.

1. RUBBER SEAL STEP 10. No parts of insulation or rubber are allowed in the wire crimp, after crimping.

STEP 11. Part of rubber seal must stick out of transition hole.

1. RUBBER SEAL STEP 12. Tilt shape of rubber seal is unacceptable.

A. 8° MAX

2200 YRM 1128

AMP Superseal 1.5 Crimping Tools

STEP 13. Crimped contacts should appear as shown.

A. TOP VIEW

B. SIDE VIEW

AMP Superseal 1.5 Crimping Tools

2200 YRM 1128

AMP HAND APPLICATION TOOL

Crimp Height Inspection

Description

1. This inspection requires the use of a micrometer with a modified anvil. See Figure 54.

This tool is designed for use with AMP Superseal 1.5 series contacts. The tool has two crimp sections, contact locator, wire stop, and ratchet. See Figure 53.

2. Use Table 8 to select wire for crimp height inspection. 3. Crimp a contact onto the selected wire according to How to use AMP Hand Application Tool procedure. 4. Using crimp height comparator, measure wire barrel crimp height as shown in Figure 54. If crimp height matches that shown in Table 8, the tool is considered dimensionally correct. If not, follow Crimp Height Adjustment procedure.

1. 2. 3. 4. 5. 6.

FRONT OF TOOL (LOCATOR SIDE) BACK OF TOOL (WIRE SIDE) DIE SET MOVABLE LOCATOR RATCHET ADJUSTMENT WHEEL PIVOT PIN

Figure 53. AMP Hand Application Tool for AMP Superseal 1.5 Contacts

A. POSITION POINT ON CENTER OF WIRE BARREL OPPOSITE SEAM. 1. MODIFIED ANVIL 2. CRIMP HEIGHT (SEE TABLE 8)

Figure 54. Crimp Height

Maintenance and Inspection 1. Ensure tool and dies are clean by wiping with a clean, soft cloth. Remove any debris with clean, soft brush. DO NOT use objects that could damage tool. When not in use, keep handles closed to prevent debris from lodging in dies. Store in clean, dry area. 2. Crimping dies to be inspected on a regular basis for wear or damage. Inspect crimp sections for flattened, chipped, worn, or broken areas. Replace tool if damaged.

Table 8. Wire Strip Lengths Wire Size (AWG)

Strip Length

Crimp Height ±0.05 mm (0.002 in.)

3.0 to 3.5 mm (0.12 to 0.13 in.)

1.12 mm (0.044 in.)

3.0 to 3.5 mm (0.12 to 0.13 in.)

1.30 mm (0.051 in.)

3.0 to 3.5 mm (0.12 to 0.13 in.)

1.45 mm (0.057 in.)

2200 YRM 1128

Crimp Height Adjustment 1. Remove lockscrew from ratchet adjustment wheel. See Figure 55.

AMP Superseal 1.5 Crimping Tools 4. Holding contact by insulation barrel, insert it through back of tool into appropriate crimp section, receptacle/tab end first. NOTE: Ensure both sides of insulation barrel are started evenly into the crimper jaws. DO NOT attempt to crimp improperly positioned contacts. 5. Align contact wire stop slot with the wire stop in the crimping jaws. Contact insulation and wire barrels must be position in crimp section as shown in Figure 57.

1. 2. 3. 4. 5. 6.

RATCHET ADJUSTMENT WHEEL LOCKSCREW LOOSEN-TIGHTEN BACK OF TOOL FRONT OF TOOL SCREWDRIVER

Figure 55. Ratchet Wheel Adjustment 2. Using a screwdriver, adjust ratchet wheel from front of tool. See Figure 55. 3. To tighten crimp, rotate ratchet adjustment wheel COUNTERCLOCKWISE. See Figure 55. 4. To loosen crimp, rotate ratchet adjustment wheel CLOCKWISE. See Figure 55. 5. Make a sample crimp and measure crimp height. If crimp height is acceptable, replace and tighten lockscrew. If crimp height is unacceptable, follow Step 3 or Step 4 until acceptable crimp height is achieved.

HOW TO USE AMP HAND APPLICATION TOOL 1. Strip insulation from wire. See Figure 56 and Table 9.

1. 2. 3. 4. 5. 6.

WIRE STRIP LENGTH WIRE SEAL INSULATION BARREL WIRE BARREL WIRE STOP SLOT MATING END

Figure 56. Wire and Receptacle Table 9. Wire Strip Lengths Wire Size (AWG)

Insulation Diameter

Strip Length

20-16

1.7 to 2.4 mm (0.07 to 0.09 in.)

3.0 to 3.5 mm (0.12 to 0.13 in.)

22-20

1.7 to 2.4 mm (0.07 to 0.09 in.)

3.0 to 3.5 mm (0.12 to 0.13 in.)

2. Hold tool so BACK (wire side) faces you. 3. Release tool handles by squeezing them together then allowing them to open fully. NOTE: Insert contact with open side of insulation and wire barrel toward movable crimping jaw.

AMP Superseal 1.5 Crimping Tools

2200 YRM 1128

1. WIRE INSERTED TO STOP 2. STRIP LENGTH (SEE TABLE 9)

Figure 57. Wire Stop Slot 6. Squeeze handles together until ratchet engages sufficiently to hold contact in position. DO NOT deform insulation or wire barrel. 7. Insert stripped wire into contact insulation and wire barrels until butted against wire stop. See Figure 57. 8. Holding wire in position, squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped contact.

AMP PRO-CRIMPER II TOOL

A. FRONT OF TOOL (LOCATOR SIDE) B. BACK OF TOOL (WIRE SIDE) 1. 2. 3. 4. 5. 6. 7. 8.

LOCATOR ASSEMBLY STATIONARY JAW DIE ASSEMBLY MOVING JAW RATCHET ADJUSTMENT WHEEL PIVOT PIN STATIONARY HANDLE MOVING HANDLE

Figure 58. AMP PRO-CRIMPER II Tool and Die

Description

Remove and Install Die Set and Locator Assembly

This tool has a tool frame with stationary jaw and handle, a moving jaw and handle, and an adjustable ratchet to endure full contact crimping. The tool frame contains a die assembly with three crimping sections.

1. Close tool handles until ratchet releases, remove the nut, locator assembly, upper retaining screw, lower retaining screw and four die retaining pins from tool frame. See Figure 59.

The die assembly contains a wire anvil, an insulation anvil, a wire crimper and an insulation crimper. See Figure 58.

2. Slide wire anvil, insulation anvil, wire crimper, and insulation crimper out of tool frame. See Figure 59.

Die retaining pins and retaining screws are used to position and secure the dies in the tool frame. A nut is used on upper retaining screw to hold locator assembly in place. See Figure 58.

3. Install wire anvil and insulation anvil, with chamfered sides and marked surfaces facing outward, into moving jaw. See Figure 59. 4. Insert two die retaining pins. See Figure 59.

2200 YRM 1128

AMP Superseal 1.5 Crimping Tools 10. Install locator assembly over the end of upper retaining screw and position against tool frame. See Figure 59. 11. Install nut onto end of upper retaining screw and tighten enough to hold locator assembly in position while allowing locator to slide up and down. See Figure 59.

Adjustments Contact Support 1. TOOL FRAME 2. LOCATOR ASSEMBLY 3. NUT 4. DIE RETAINING PIN 5. UPPER RETAINING SCREW 6. LOWER RETAINING SCREW

7. 8. 9. 10. 11. 12. 13. 14. 15.

WIRE CRIMPER WIRE ANVIL CHAMFER OFFSET INSULATION CRIMPER INSULATION ANVIL CHAMFER MOVING JAW STATIONARY JAW

Figure 59. Die Set and Locator Assembly 5. Insert lower retaining screw through moving jaw, insulation anvil, and wire anvil. Tighten lower retaining screw just enough to hold anvils in position. DO NOT tighten lower retaining screw completely. See Figure 59. 6. Install wire crimper and insulation crimper, with chamfered sides and marked surfaces facing outward, into stationary jaw. See Figure 59. 7. Insert two die retaining pins. See Figure 59. 8. Install upper die retaining screw through stationary jaw, insulation crimper, and wire crimper. Tighten upper retaining screw just enough to hold crimpers in position. DO NOT tighten upper retaining screw completely. See Figure 59. 9. Carefully close tool handles making sure anvils and crimpers align properly. Continue closing tool handles until ratchet in tool frame engages enough to hold anvils and crimpers in position. Tighten upper and lower retaining screws.

NOTE: Contact support is preset prior to shipment but minor adjustment may be necessary. 1. Make a sample crimp and determine if the contact is straight, bending upward, or bending downward. 2. If adjustment is required, loosen the adjustment screw holding contact support onto locator assembly. See Figure 60. NOTE: The ratchet has detents that create audible clicks as the tool handles are closed. 3. Position contact with wire in the proper nest and close the tool handles until the ratchet reaches the sixth click, or until the contact support touches the contact. 4. Slightly loosen the nut holding the locator assembly onto the tool frame. 5. Move the contact support as needed to eliminate the bending of the contact. 6. Tighten the nut and close the handles until the ratchet releases. 7. Remove and inspect the contact. 8. Make another sample crimp. If the contact is straight, tighten the adjustment screw. If the contact is still being bent during crimping, repeat adjustment procedure.

AMP Superseal 1.5 Crimping Tools

2200 YRM 1128

A. BACK OF TOOL

B. STRIP LENGTH

1. 2. 3. 4.

5. 6. 7. 8.

LOCATOR CONTACT SUPPORT ADJUSTMENT SCREW WIRE

WIRE SEAL CONTACT LOCATOR IN WIRE STOP SLOT WIRE INSERTED TO STOP

Figure 60. Contact Support and Wire Strip Crimp Height 1. Remove lockscrew from ratchet adjustment wheel. See Figure 61.

the dimension is unacceptable, continue to adjust the ratchet and measure a sample crimp.

2. Using a screwdriver, adjust the ratchet wheel from locator side of tool. See Figure 61. Observe ratchet adjustment wheel. 3. If a tighter crimp is required, rotate ratchet adjustment wheel COUNTERCLOCKWISE to a highernumbered setting. 4. If a looser crimp is required, rotate ratchet adjustment wheel CLOCKWISE to a lower-numbered setting. 5. Replace lockscrew. See Figure 61. 6. Make a sample crimp and measure the crimp height as specified in Crimp Height Inspection section. If the dimension is acceptable, secure lockscrew. If

Figure 61. Ratchet Adjustment Wheel

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AMP Superseal 1.5 Crimping Tools

Legend for Figure 61 1. LOCKSCREW 2. RATCHET ADJUSTMENT WHEEL 3. SCREWDRIVER

Inspections and Maintenance Crimp Height Inspection

Visual Inspection The crimping dies should be inspected on a regular basis to ensure they have not become worn or damaged. Inspect the crimping chamfers for flattened, chipped, worn or broken areas. If damage or abnormal wear is present, replace tool.

Maintenance

1. This inspection requires the use of a micrometer with a modifier anvil as shown in Figure 62

1. Wipe tool and dies with clean, soft cloth. Remove any debris with a clean, soft brush. DO NOT use objects that could damage the tool. When not in use, keep handles closed to prevent debris from becoming lodged in the crimping dies, and store in a clean, dry area.

HOW TO USE PRO-CRIMPER II TOOL NOTE: This tool is provided with a crimp adjustment feature. Initially the crimp height should be verified as stipulated in Crimp Height Inspection and Crimp Height Adjustment sections to verify height before using the tool to crimp desired contacts and wire sizes. 1. POSITION POINT ON CENTER OF WIRE BARREL OPPOSITE SEAM 2. MODIFIED ANVIL 3. CRIMP HEIGHT (SEE TABLE 10)

Figure 62. Crimp Height 2. See Table 10 and select a wire (maximum size) for each crimping chamber listed.

Table 10. Crimp Height - Dimension "3" in Figure 62 Wire Size AWG

Crimping Chamber (Wire Size Marking)

Crimp Height ± 0.05 mm (0.002 in.)

1.12 mm (0.044 in.)

1.30 mm (0.051 in.)

1.45 mm (0.057 in.)

3. See How to Use AMP Pro-Crimper II Tool section and crimp contact accordingly. 4. Using crimp height comparator, measure the wire barrel crimp height as shown in Figure 62. If crimp height conforms to dimensions shown in Table 10 the tool is considered dimensionally correct. If not, the tool must be adjusted; seeCrimp Height section.

1. Using Table 9 select wire of specified size and insulation diameter. Assemble wire seal onto wire as specified in Mini Mic Receptacle and Tab Contact section. 2. Strip wire to the length indicated in Table 9 taking care not to nick or cut wire strands. Select contact and identify appropriate crimping chamber according to the wire size markings on the tool. 3. Hold tool so that the back (wire side) is facing you. Squeeze tool handles together and allow them to open fully. 4. Holding contact by mating end, insert the contact, insulation barrel first, through the front of the tool and into the appropriate crimping chamber. 5. Position the contact tho that the mating end of contact is on locator side of tool and the open "U" of the wire and insulation barrels face the top of the tool. Fit the contact into the nest so the movable locator drops into the slot in the contact. See Figure 60. Butt front end of wire barrel against movable locator.

AMP Superseal 1.5 Connector Assemblies

2200 YRM 1128

NOTE: Make sure both sides of insulation barrel are started evenly into the crimping chamber. DO NOT attempt to crimp and improperly positioned contact.

NOTE: The crimped contact may stick in the crimping area, but the contact can be easily removed by pushing downward on the top of the locator. See Figure 60.

6. Hold contact in position and squeeze the tool handles together until ratchet engages enough to hold contact in position. DO NOT deform insulation barrel or wire barrel.

8. Holding wire in position, squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped contact.

7. Insert stripped wire, with wire seal, into insulation and wire barrels until it is butted against wire stop. See Figure 60.

9. Check contact crimp height as described in Crimp Height Inspection section. If necessary, adjust the crimp height as specified in Crimp Height section.

AMP Superseal 1.5 Connector Assemblies DESCRIPTION The AMP Superseal 1.5 connectors are designed to meet the performance requirements in the automotive

field. The following information is intended as a general guide for the best use of the connectors for wire harnesses and their maintenance.

Harness Assembly STEP 1. Contacts can only be inserted into housing cavities in one position. The correct placing is shown. After insertion of a contact, pull back lightly on the wire to check that the contact is securely locked in position.

STEP 2. Cavity plug, Yale Part No. 580050847, must be used when a cavity is not loaded with a contact. This prevents the ingress of water. Insert cavity plug deeply into the cavity by means of a pin as shown. If necessary, the cavity plug can be removed by a pin point.

1. CAVITY PLUG

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AMP Superseal 1.5 Connector Assemblies

Positioning of Anti-Backout Device STEP 1. These connectors are supplied with an anti-backout device for both receptacle and tab housings. After loading all of the crimped contacts, these devices must be pushed into CLOSED position. If one contact is not properly seated in the cavity, the plastic locking lance remains deflected and the anti-backout device cannot be closed. This serves as a warning for the user. If the anti-backout device is not closed, the mating with a counterpart cannot be completed.

A. CONTACT NOT PROPERLY SEATED 1. 2. 3. 4.

TAB HOUSING PLUG HOUSING ANTI-BACK OUT DEVICE ANTI-BACK OUT DEVICE

NOTE: Perform STEP 2 for manually operated, position 2 to 6 plugs. STEP 2. Rotate the anti-back out device to deflect the central lances inward then push until the side arms lock.

1. ANTI-BACK OUT DEVICE

AMP Superseal 1.5 Connector Assemblies

2200 YRM 1128

NOTE: Perform STEP 3 for position 2 to 6 plugs inserted by a harness maker machine. STEP 3. Push the two lances for position 2 housing, the central lance for positions 3 and 5 housing, and the two central lances for positions 4 and 6 housing inward. Then push until the side arms lock.

1. ANTI-BACK OUT DEVICE STEP 4. For position 1, manually or machine operated, push the anti-backout device until its upper end is the same level as the housing mating face.

1. ANTI-BACK OUT DEVICE NOTE: Different jigs are needed for position 1 and 2 housings and position 3 to 6 housings. STEP 5. To close the anti-backout device for tab housings, either manually or by machine, push the device in with a jig until it meets the stop.

1. ANTI-BACK OUT DEVICE

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AMP Superseal 1.5 Connector Assemblies

Removal of Contacts Since the locking lance of contacts can be reached from the mating side of the housings, it is necessary to remove the anti-backout device first. NOTE: Perform STEP 1 and STEP 2 for removal of receptacle contact. STEP 1. Deflect the side arms of the anti-back out device and pull it away.

1. ANTI-BACK OUT DEVICE 2. EXTRACTION TOOL

101

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2200 YRM 1128

CAUTION Be careful not to insert the extraction tool in the contacting area of the receptacle. STEP 2. Insert the contact extraction tool Yale Part No. 580093887 between contact and lance nose, then rotate slightly as shown. Pull the wire.

1. CONTACT 2. CONTACT EXTRACTION TOOL

102

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AMP Superseal 1.5 Connector Assemblies

NOTE: Perform STEP 3 and STEP 4 for removal of tab contact. STEP 3. Insert the extraction tool Yale Part No. 58093886 in one of the central holes of the anti-backout device and pull it away.

NOTE: Pull extraction tool in direction of arrow. 1. EXTRACTION TOOL

103

AMP Superseal 1.5 Connector Assemblies

2200 YRM 1128

CAUTION When rotating the extraction tool, be careful not to deform the tab. STEP 4. Insert the contact extraction tool Yale Part No. 580093887 between contact and lance note, then rotate slightly as shown. Pull the wire up as shown.

1. CONTACT EXTRACTION TOOL

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REPAIR AND MAINTENANCE During repair and maintenance operation for wiring, replacement of contacts may be required. Following is the recommended procedure.

AMP Superseal 1.5 Connector Assemblies shape according to the requirements. See example in Figure 63.

1. Cut the wire of the defective contact. 2. Strip the wire insulation to appropriate length. 3. Slide a new wire seal onto the wire. 4. Crimp the new contact on the wire using a hand crimping tool.

PANEL MOUNT OPTION NOTE: SLIDE CLIP IN DIRECTION OF ARROW. The tab housings come with two "L" shaped guides for the insertion of a special elastic clip, allowing panel mounting of the connector. The clip can be different

Figure 63. Panel Mount Clip Example

105

AMP Fastin-Faston Hand Tools

2200 YRM 1128

AMP Fastin-Faston Hand Tools DESCRIPTION - AMP DOUBLE ACTION HAND TOOL Hand-crimping tools that accommodate full wire size range are designed for repair applications. This tool is designed for use with AMP micro and mini relay receptacles. The tool has two crimping jaws, each consisting

1. 2. 3. 4.

CRIMPER ANVIL CRIMPING CHAMBER MARKINGS WIRE CRIMPING JAW

of an anvil and a crimper. When jaws are closed they form two crimping chambers, marked on BACK of tool as "A" and "B". Crimping jaws "bottom" before ratchet releases. This is a design feature to assure maximum electrical and tensile performance of crimp; DO NOT readjust ratchet. See Figure 64.

5. 6. 7. 8.

INSULATION CRIMPING JAWS BACK OF TOOL CERTI-CRIMP RATCHET LINK

Figure 64. AMP Double Action Hand Tool

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AMP Fastin-Faston Hand Tools

MAINTENANCE AND INSPECTION PROCEDURES

not available, wipe tool with soft lint-free cloth. DO NOT use objects that could damage tool.

Daily Maintenance

2. Ensure retaining pins are in place and secured with retaining rings. See Figure 65.

1. Immerse tool, with handles partially closed, in reliable commercial de-greasing compound to remove accumulated debris. If de-greasing compound is

3. When not in use, keep handles closed to prevent debris from lodging in jaws. Store in clean dry area.

1. RETAINING RING

2. RETAINING PIN

3. HANDLE SPRING

Figure 65. Tool Inspection

Periodic Tool Inspection

Visual Inspection

Lubrication

NOTE: Manufacturer’s replacement and repair procedures included in documentation received with tool.

1. Coat all pins, pivot points, and bearing surfaces with thin layer of SAE 20 motor oil per schedule below: 1. Tool used daily: lubricate weekly 2. Tool used weekly: lubricate monthly 2. Wipe excess oil from tool paying close attention to crimp area. Oil transferred from crimping area onto terminations can affect electrical characteristics of application.

1. Close handles until ratchet releases and handles open freely. If handles DO NOT open quickly and fully, the spring is defective and must be replaced. See Figure 65. If spring is defective, follow manufacturers’ replacement and repair procedures. 2. Inspect tool for worn, cracked, or broken jaws. If jaws are damaged follow manufacturers’ replacement and repair procedures.

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Crimp Height Inspection 1. This inspections requires the use of a modified micrometer with modified anvil and spindle. Modified micrometer to be used when crimp height is specified. See Figure 66.

4. Using modified micrometer, measure wire barrel crimp height as shown in Figure 67. If crimp height matches measurement in Table 11, the tool is considered dimensionally correct. If not, follow manufacturers’ replacement and repair procedure.

1. POSITION POINT ON CENTER OF WIRE BARREL OPPOSITE SEAM 2. MODIFIED ANVIL 3. CRIMP HEIGHT (SEE TABLE 11)

Figure 67. Crimp Height NOTE: SAMPLE READING SHOWN IN ILLUSTRATION EQUALS 3.489 mm (0.1374 in.). 1. ANVIL 2. SPINDLE 3. STATIONARY HANDLE

4. MOVABLE HANDLE 5. TYPICAL CONTACT

Certi-Crimp Ratchet Inspection The ratchet on this tool should be checked to ensure it does not release prematurely, allowing jaws to open before they have fully bottomed. Use a 0.025 mm (0.001 in.) shim suitable for checking clearance between bottoming surfaces of crimping jaws.

Figure 66. Modified Micrometer

1. Select receptacle and maximum size wire for tool.

2. Use Table 11 to select maximum size wire for each crimping chamber.

2. Position receptacle and wire between jaws as shown in Figure 68.

Table 11. Wire Size and Crimp Height

3. While holding wire in position, squeeze tool handles together until ratchet releases. Hold handles in closed position.

Crimp Chamber

Wire Size (AWG)

Crimp Height

18-20

1.27 ±0.076 mm (0.05 ±0.003 in.)

14-16

1.65 ±0.076 mm (0.065 ±0.003 in.)

3. Crimp receptacle onto selected wire according to How to Use AMP Double Action Hand Tool procedure.

108

4. Check clearance between bottoming surfaces of crimping jaws. If clearance is 0.025 mm (0.001 in.) or less, the ratchet is satisfactory. If clearance exceeds 0.025 mm (0.001 in.) follow manufacturers’ replacement and repair procedure.

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AMP Fastin-Faston Hand Tools

1. 2. 3. 4.

WIRE BARREL INSULATION BARREL LOCATOR SLOT WIRE STRIP LENGTH (SEE TABLE 12)

Figure 69. Wire and Receptacle 2. Hold tool so BACK side is facing you. 3. Release tool handles by squeezing them together until ratchet releases.

A. RECEPTACLE BARREL ALIGNMENT 1. 2. 3. 4. 5.

4. Insert receptacle barrel into crimping area as shown in Figure 68.

RECEPTACLE CRIMPING BARREL STRIPPED WIRE WIRE CRIMPING JAW INSULATION CRIMPING JAW BACK SIDE OF TOOL

5. Squeeze tool handles together just enough to hold receptacle in place.

Figure 68. Crimp Alignment

NOTE: Make sure insulation DOES NOT enter wire barrel.

HOW TO USE AMP DOUBLE ACTION HAND TOOL NOTE: Wire size and insulation diameter must be within specified range for receptacle. See Table 12. 1. Strip insulation from wire. See Table 12 and Figure 69.

6. Insert stripped wire into receptacle crimping barrel from BACK of tool. 7. While holding wire position, squeeze tool handles together until ratchet releases. Open tool handles and remove crimped receptacle.

Table 12. Wire Strip Length Crimp Chamber B

Wire Size (AWG)

Strip Length

20-16

4.2 to 5.2 mm (0.16 to 0.20 in.)

18-14

5.1 to 6.1 mm (0.20 to 0.24 in.)

Insulation Diameter 2.2 to 3.1 mm (0.09 to 0.12 in.)

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AMP Fastin-Faston Hand Tools

2200 YRM 1128

DESCRIPTION - AMP EXTRACTION TOOL Extraction tools are designed to release locking lance inside connector housing without damaging housing or connectors. The extraction tip is used with the universal

1. UNIVERSAL HANDLE

handle as shown in Figure 70. Extraction tip, installed, is aligned with mating face of connector housing to depress locking lance of receptacle holding it in housing.

2. EXTRACTION TIP

3. DRIVE SCREW

Figure 70. AMP Extraction Tool With Tip

MAINTENANCE AND INSPECTION For proper operation, tool to conform to measurements indicated in Figure 71. Inspections to be performed

A. TOP VIEW

at regular intervals, refer to manufacturers data for specifics.

B. SIDE VIEW

Figure 71. Tool Tip Inspection

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AMP Fastin-Faston Hand Tools

Clean extraction tool with clean, soft, lint-free cloth and store in clean, dry place.

HOW TO USE AMP EXTRACTION TOOL It is necessary to depress locking lance of receptacle from its cavity inside connector housing. Procedure below describes steps of extraction. 1. Orient extraction tool tip with mating face of connector. See view A of Figure 72.

2. Insert tip of extraction tool, aligned in center of housing cavity where locking lance is located. See view B of Figure 72. 3. Push wire from BACK of housing TOWARD tool and depress locking lance. See view C of Figure 72. 4. Pull BACK on wire and remove receptacle from housing. See view D of Figure 72. 5. Remove extraction tool from housing.

A. EXTRACTION TOOL ORIENTATION B. TOOL TIP ALIGNMENT

C. WIRE DEPRESSIONS D. RECEPTACLE REMOVAL

1. EXTRACTION TOOL 2. HOUSING

3. RECEPTACLE 4. LOCKING LANCE

Figure 72. Contact Extraction

111

AMP Fastin-Faston Receptacles and Housings

2200 YRM 1128

AMP Fastin-Faston Receptacles and Housings DESCRIPTION

This manual section covers FASTIN-FASTON receptacle installation. These connectors are the multiple circuit connectors use primarily as wire harness connectors.

g. After crimping, wire conductor and insulation to be visible in areas shown in Figure 76.

CAUTION

Acceptable dimensions for wire barrel flash shown in section A-A, Figure 76.

h. Conductor may extend beyond wire barrel to maximum dimension shown in Figure 76.

DO NOT nick, scrape, or cut the wire conductor during the striping operation.

Wire barrel seam to be closed, no loose wire strands visible.

1. Install receptacles as specified in How to Use AMP Double Action Hand Tool. See Figure 73 for tool image.

There shall be no twist, roll, deformation, or other damage to mating portion of crimped receptacle that will prevent proper mating. See Figure 77.

Receptacle contact should appear as shown in Figure 74. a. The most critical and compressed area is the crimp applied to the wire portion of the contact to ensure optimum electrical and mechanical performance of crimped receptacle. See Figure 75 and Table 13. b. Crimp length must be within dimensions indicated in Table 13. c. Front and rear bellmouths to match images and dimensions shown in Figure 76. d. The cutoff tab to be cut as shown in Figure 76. e. Max burr on cutoff tab shall not exceed dimensions indicated in enlarged view of Figure 76.

112

Figure 73. AMP Double Action Hand Tool

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AMP Fastin-Faston Receptacles and Housings

A. WIRE CONDUCTORS AND INSULATION BOTH VISIBLE IN THIS AREA

B. CONDUCTOR VISIBLE C. INSULATION BARREL CRIMP WIDTH

1. 2. 3. 4.

5. 6. 7. 8.

FRONT BELLMOUTH CRIMP LENGTH REAR BELLMOUTH WIRE BARREL CRIMP WIDTH

WIRE BARREL CRIMP HEIGHT WIRE BARREL FLASH CUTOFF TAB MAX BURR

Figure 74. Typical Crimped Receptacle

113

AMP Fastin-Faston Receptacles and Housings

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1. WIRE INSULATION 2. STRIP LENGTH (SEE TABLE 13)

Figure 75. Wire Strip Length Table 13. Wire Strip Length and Crimp Measurements Wire Size (AWG)

Insulation Diameter 1.52 to 2.54 mm (0.06 to 0.10 in.)

20 2.16 to 3.18 mm (0.085 to 0.125 in.) 3.05 to 4.32 mm (0.120 to 0.170 in.)

Wire Barrel

5.82 to 6.48 mm (0.229 to 0.255 in.)

Crimp Width

Crimp Height

2.24 to 2.34 mm (0.088 to 0.092 in.)

1.07 to 1.32 mm (0.042 to 0.052 in.)

Crimp Width 2.49 to 2.59 mm (0.98 to 0.102 in.) 3.5 to 3.61 mm (0.138 to 0.142 in.)

6.23 to 6.48 mm (0.245 to 0.255 in.)

3.05 to 4.06 mm (0.120 to 0.160 in.) 3.5 to 3.68 mm (0.120 to 0.145 in.)

Insulation Barrel

Strip Length

5.41 to 5.66 mm (0.213 to 0.223 in.)

1.5 to 1.6 mm (0.059 to 0.063 in.)

4.01 to 4.11 mm (0.158 to 0.162 in.)

1.37 to 1.42 mm (0.054 to 0.058 in.)

4.52 to 4.62 mm (0.178 to 0.182 in.)

1.47 to 1.57 mm (0.054 to 0.062 in.)

4.01 to 4.11 mm (0.158 to 0.162 in.)

2.74 to 2.84 mm (0.108 to 0.112 in.)

2.54 to 4.42 mm (0.100 to 0.170 in.) 18 2.16 to 3.18 mm (0.085 to 0.125 in.)

1.52 to 2.54 mm (0.060 to 0.100 in.) 2.2 to 4.44 mm (0.090 to 0.175 in.)

114

6.22 to 6.48 mm (0.245 to 0.255 in.) 5.82 to 6.07 mm (0.229 to 0.239 in.) 6.22 to 6.48 mm (0.245 to 0.255 in.)

1.35 to 1.45 mm (0.053 to 0.057 in.) 2.24 to 2.34 mm (0.088 to 0.092 in.)

5.82 to 6.07 mm (0.229 to 0.239 in.) 5.1 to 6.1 mm (0.200 to 0.240 in.)

1.17 to 1.27 mm (0.046 to 0.050 in.) 1.35 to 1.45 mm (0.053 to 0.057 in.) 1.17 to 1.27 mm (0.046 to 0.050 in.)

2.74 to 2.84 mm (0.108 to 0.112 in.)

1.42 to 1.52 mm (0.056 to 0.060 in.)

3.5 to 3.61 mm (0.138 to 0.142 in.)

2.49 to 2.59 mm (0.098 to 0.102 in.) 4.52 to 4.62 mm (0.178 to 0.182 in.)

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AMP Fastin-Faston Receptacles and Housings

Table 13. Wire Strip Length and Crimp Measurements (Continued)

Wire Size (AWG)

Insulation Diameter

Wire Barrel Crimp Width

4.06 to 5.33 mm (0.160 to 0.210 in.) 3.81 to 4.83 mm (0.150 to 0.190 in.)

5.82 to 6.07 mm (0.229 to 0.239 in.)

3.0 to 3.11 mm (0.118 to 0.122 in.)

3.3 mm (0.130 in.)MAX (2 Wires) 3.05 to 4.32 mm (0.120 to 0.170 in.) 16

5.41 to 5.66 mm (0.213 to 0.223 in.)

2.74 to 2.84 mm (0.108 to 0.112 in.)

2.54 to 4.32 mm (0.100 to 0.170 in.) 2.2 to 4.44 mm (0.090 to 0.175 in.) 4.06 to 5.33 mm (0.106 to 0.210 in.) 3.81 to 4.83 mm (0.150 to 0.190 in.) 3.05 to 4.32 mm (0.120 to 0.170 in.)

5.1 to 6.1 mm (0.200 to 0.240 in.)

1.5 to 1.83 mm (0.059 to 0.072 in.)

6.3 to 6.4 mm (0.248 to 0.252 in.)

1.73 to 1.83 mm (0.068 to 0.072 in.)

5.28 to 5.38 mm (0.208 to 0.212 in.)

1.85 to 2.18 mm (0.073 to 0.086 in.)

6.3 to 6.4 mm (0.248 to 0.252 in.)

1.65 to 1.75 mm (0.065 to 0.069 in.)

4.01 to 4.11 mm (0.158 to 0.162 in.)

1.32 to 1.42 mm (0.052 to 0.056 in.)

4.52 to 4.62 mm (0.178 to 0.182 in.)

1.6 to 1.7 mm (0.063 to 0.067 in.)

4.01 to 4.11 mm (0.158 to 0.162 in.)

1.57 to 1.68 mm (0.062 to 0.066 in.)

4.52 to 4.62 mm (0.178 to 0.182 in.)

1.7 to 2.03 mm (0.067 to 0.080 in.)

6.3 to 6.4 mm (0.248 to 0.252 in.)

1.93 to 2.03 mm (0.076 to 0.080 in.)

5.28 to 5.38 mm (0.208 to 0.212 in.)

3.0 to 3.1 mm (0.118 to 0.122 in.)

7.01 to 7.26 mm (0.276 to 0.286 in.)

2.74 to 2.84 mm (0.108 to 0.112 in.)

1.88 to 1.98 mm (0.074 to 0.078 in.)

4.01 to 4.11 mm (0.158 to 0.162 in.)

6.60 to 6.86 mm (0.260 to 0.270 in.)

3.25 to 3.35 mm (0.128 to 0.132 in.)

1.78 to 1.88 mm (0.070 to 0.074 in.)

4.52 to 4.62 mm (0.178 to 0.182 in.)

1.88 to 1.98 mm (0.074 to 0.078 in.) 5.82 to 6.07 mm (0.229 to 0.239 in.)

2.54 to 4.32 mm (0.100 to 0.170 in.) 2.2 to 4.44 mm (0.090 to 0.175 in.)

Crimp Width

6.22 to 6.45 mm (0.245 to 0.255 in.)

3.05 to 4.06 mm (0.120 to 0.160 in.) 3.05 to 3.68 mm (0.120 to 0.145 in.)

Crimp Height

6.22 to 6.48 mm (0.245 to 0.255 in.)

3.05 to 4.06 mm (0.120 to 0.160 in.) 3.05 to 3.68 mm (0.120 to 0.145 in.)

Insulation Barrel

Strip Length

5.1 to 6.1 mm (0.201 to 0.240 in.)

2.74 to 2.84 mm (0.108 to 0.112 in.)

4.01 to 4.62 mm (0.158 to 0.182 in.) 4.01 to 4.11 mm (0.158 to 0.162 in.)

1.55 to 1.65 mm (0.061 to 0.065 in.)

4.52 to 4.62 mm (0.178 to 0.182 in.)

1.83 to 1.93 mm (0.072 to 0.076 in.)

4.01 to 4.11 mm (0.158 to 0.162 in.)

1.8 to 1.9 mm (0.071 to 0.075 in.)

4.52 to 4.62 mm (0.178 to 0.182 in.)

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AMP Fastin-Faston Receptacles and Housings

2200 YRM 1128

A. WIRE CONDUCTORS AND INSULATION BOTH VISIBLE IN THIS AREA

B. CONDUCTOR VISIBLE C. INSULATION BARREL CRIMP WIDTH

1. 2. 3. 4.

5. 6. 7. 8.

FRONT BELLMOUTH CRIMP LENGTH (SEE TABLE 13) REAR BELLMOUTH WIRE BARREL CRIMP WIDTH (SEE TABLE 13)

WIRE BARREL CRIMP HEIGHT (SEE TABLE 13) WIRE BARREL FLASH CUTOFF TAB MAX BURR

Figure 76. Typical Crimp - Fastin-Faston Receptacle Legend for Figure 77 1. FRONT OF RECEPTACLE 2. WIRE BARREL k. Force applied during crimping can cause bending between the crimped wire barrel and mating portion of receptacle. Bending is acceptable within limits shown in Figure 78.

Figure 77. Mating Portion

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AMP Fastin-Faston Receptacles and Housings 4. Damaged crimped receptacles or housings must be removed, discarded, and replaced with new components. See Figure 79 and Figure 80 for tools used during removal.

NOTE: ANGLES DRAWN FOR CLARIFICATION ONLY, NOT TO SCALE. ANGLES ARE MAXIMUM DISTANCE FROM DATUM LINE. A. UP AND DOWN

B. SIDE TO SIDE

Figure 79. AMP Extraction Tool Universal Handle

1. DATUM LINE

Figure 78. Receptacle Bending Limits 3. Crimped receptacle should hold wire firmly and have a pull-test tensile value as specified in Table 14.

Table 14. Crimp Pull-Out Test Minimum Force

Wire Size (AWG)

Newtons

Pounds

57.8

89.0

133.4

222.4

Figure 80. AM Extraction Tool Tip 5. For procedure to remove receptacles for connector housings, see How to Use AMP Extraction Tool section.

117

Wire Repair

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Wire Repair WIRE SPLICING REQUIREMENTS Refer to the following for determining which procedure to use for wire repairs.

3. 10 to 20 Gauge wire in area allowing use of a heat gun - repair using Del-City crimp-solder-shrink splice.

1. 8 Gauge or heavier wire - no splicing, replace full length of wire or replace harness.

4. 12 to 14 Gauge wire in area allowing 12.7 mm (0.5 in.) diameter × 63.5 mm (2.5 in.) long splice use Deutsch jiffy splice.

2. Wires not meeting requirements of Step 3 through Step 5 - no splicing, replace full length of wire or replace harness.

5. 14 to 20 Gauge wire in area allowing 9.78 mm (0.385 in.) diameter × 62.74 mm (2.47 in.) long splice - use Deutsch jiffy splice.

Table 15. Wire Strip Length Specifications Contact Part Number

Type

Wire Gauge Range

Recommended Strip Length

580039516

20 AWG (0.5 mm 2)

3.96 to 5.54 mm (0.156 to 0.218 in.)

118

580039517

Socket

20 AWG (0.5 mm )

3.96 to 5.54 mm (0.156 to 0.218 in.)

580094445

20 AWG (0.5 mm 2)

4.0 to 5.5 mm (0.157 to 0.217 in.)

505972554

16 to 20 AWG (1.0 to 0.5 mm 2)

6.35 to 7.92 mm (0.250 to 0.312 in.)

505064713

Socket

16 to 20 AWG (1.0 to 0.5 mm 2)

6.35 to 7.92 mm (0.250 to 0.312 in.)

580082335

16 to 20 AWG (1.0 to 0.5 mm 2)

6.4 to 7.9 mm (0.252 to 0.311 in.)

580082337

Socket

16 to 20 AWG (1.0 to 0.5 mm 2)

6.4 to 7.9 mm (0.252 to 0.311 in.)

520038865

14 AWG (2.0 mm 2)

6.35 to 7.92 mm (0.250 to 0.312 in.)

505064747

Socket

14 AWG (2.0 mm )

6.35 to 7.92 mm (0.250 to 0.312 in.)

580079525

Socket

14 AWG (2.0 mm 2)

6.4 to 7.9 mm (0.252 to 0.311 in.)

150121835

12 to 14 AWG (3.0 to 2.0 mm 2)

5.64 to 7.21 mm (0.222 to 0.284 in.)

580050627

Socket

12 to 14 AWG (3.0 to 2.0 mm 2)

5.64 to 7.21 mm (0.222 to 0.284 in.)

2200 YRM 1128

Wire Repair

DEUTSCH JIFFY SPLICE This splicing procedure adds 19.05 mm (0.75 in.) to the length of the wire and may be used when slight lengthening of the wire is desired.

Assemble STEP 1. Strip both wire ends to the specifications in Table 15.

STEP 2. On one wire, crimp the appropriate pin onto the wire using the Deutsch Crimping Tool (Yale Part No. 150121900). See How to Crimp With the Deutsch Crimping Tool.

STEP 3. On second wire, crimp the appropriate socket onto the wire using the Deutsch Crimping Tool (Yale Part No. 150121900). See How to Crimp With the Deutsch Crimping Tool.

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Wire Repair STEP 4. Insert the wire with the socket contact into one end of the jiffy splice.

STEP 5. Push the contact into the jiffy splice until a positive stop is felt. An audible snap will occur when correctly installed. Slightly tug the wire to verify the wire is properly locked in place.

STEP 6. Insert the wire with the pin contact into opposite end of the jiffy splice.

STEP 7. Push the contact into the jiffy splice until a positive stop is felt. An audible snap will occur when correctly installed. Slightly tug the wire to verify the wire is properly locked in place.

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2200 YRM 1128

Wire Repair

Disassemble STEP 1. Insert appropriate Deutsch extraction tool over the wire being removed.

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Wire Repair

2200 YRM 1128

NOTE: Do not twist the tool or insert the tool at an angle. STEP 2. Push the tool into the splice connector about 25 mm (1 in.), until it bottoms on the contact flange.

NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees and reinsert the tool into the connector. STEP 3. Hold the tool on the contact flange and pull the wire and the connection socket or pin out of the connector.

STEP 4. Repeat STEP 1 through STEP 3 on opposite end.

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2200 YRM 1128

Wire Repair

DEL-CITY CRIMP-SOLDER-SHRINK SPLICE Refer to Table 16 for the correct splice part number for the wire gauge being repaired.

Table 16. Wire Splice Size Part Number

Wire Gauge Range

150121847

10 to 12 AWG (5.0 to 3.0 mm 2)

150121848

14 to 16 AWG (2.0 to 1.0 mm 2)

150121849

18 to 20 AWG (0.8 to 0.5 mm 2)

STEP 1. Strip approximately 9.525 mm (0.375 in.) from both wire ends.

CAUTION Do not crimp solder sleeve in the center of the connector. This will make the connector unserviceable. STEP 2. Insert one wire into the connector. Make sure wire is properly seated and crimp the connector using an insulated connector crimping tool nest that matches the color or gauge of the connector.

1. SOLDER SLEEVE

2. CRIMP POINT

CAUTION Do not crimp solder sleeve in the center of the connector. This will make the connector unserviceable. STEP 3. Insert the second wire into the opposite end of the connector. Make sure wire is properly seated and crimp the connector using an insulated connector crimping tool nest that matches the color or gauge of the connector.

1. CRIMP POINT

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Twisted/Shielded Cable and Leads Repair

2200 YRM 1128

STEP 4. Using a heat gun, apply heat evenly, to approximately 135°C (275°F), around the length of the tubing (including the crimp area) from the center out to the ends until the tubing fully recovers and adhesive flows. Continue distributing the heat over the solder sleeve until solder flows into the terminal barrel. Remove from the heat and let cool for ultimate connection performance.

1. EXPOSED NOTCHES AFTER SOLDER BAND MELTS

Twisted/Shielded Cable and Leads Repair TWISTED/SHIELDED CABLE REPAIR STEP 1. Remove outer jacket. STEP 2. Unwrap aluminum mylar tape. Do not remove mylar tape.

1. DRAIN WIRE 2. OUTER JACKET 3. MYLAR

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2200 YRM 1128

Twisted/Shielded Cable and Leads Repair

STEP 3. Untwist conductors and strip insulation as necessary.

STEP 4. Splice wires using splice clips and rosin core solder. Wrap each splice to insulate.

1. SPLICE AND SOLDER STEP 5. Splice the drain (uninsulated) wire using splice clip and rosin core solder. STEP 6. Wrap with mylar and drain (uninsulated) wire.

1. DRAIN WIRE STEP 7. Apply electrical tape over whole bundle to secure.

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Twisted/Shielded Cable and Leads Repair

2200 YRM 1128

TWISTED LEADS REPAIR STEP 1. Locate damaged wire and remove insulation as required.

STEP 2. Splice the two wires using splice clips and rosin core solder.

1. SPLICE AND SOLDER STEP 3. Cover splice with electrical tape to insulate from other wires. STEP 4. Twist and tape with electrical tape.

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2200 YRM 1128

Special Tools

Special Tools Illustration

Tool Description

Not Illustrated

Deutsch Connector Kit Yale Part No. 150121833

Not Illustrated

Deutsch Connector/ Crimp/ Stripper Kit Yale Part No. 150121822 Wire Stripper Yale Part No. 150121841 Used for stripping wires.

Wire Stop for Wire Stripper Yale Part No. 150121842

Wire Crimping Pliers Used for crimping connectors. (Except Deutsch and AMP Connectors)

Deutsch Hand Crimping Tool Yale Part No. 150121900 Used for crimping pins and sockets for Deutsch connectors.

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Special Tools

2200 YRM 1128

Illustration

Tool Description Deutsch Wedge Removal Tool Yale Part No. 150121838 Used to remove secondary lock for Deutsch connectors. Yellow Extracting Tool Yale Part No. 150121836 Used to repair Deutsch HD 12 to 14 AWG connectors.

Orange Extracting Tool (E-Seal) Yale Part No. 150121843 Extra thin wall tool. Used to repair Deutsch HD 12 to 14 AWG connectors.

Light Blue Extracting Tool Yale Part No. 150121834 Used to repair Deutsch HD 16 to 18 AWG connectors.

Dark Blue Extracting Tool (E-Seal) Yale Part No. 150121844 Extra thin wall tool. Used to repair Deutsch HD 16 to 18 AWG connectors.

Red Extracting Tool Yale Part No. 150121845 Used to repair Deutsch HD 20 to 24 AWG connectors.

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2200 YRM 1128

Special Tools

Illustration

Tool Description Deutsch G454 Testing Tool Yale Part No. 150121846 Used to check calibration of Deutsch Hand Crimping Tool Flat Blade Screwdriver Used to open wedge lock for AMP plug connectors

AMP Hand Crimping Tool Yale Part No. 580093883 (AMP Part No. 58440-1) Use for crimping AMPSEAL contacts

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Special Tools

2200 YRM 1128

Illustration

Tool Description AMP Pro-Crimper II Yale Part No. 580096885 with Die Set 580093884 Use for crimping AMPSEAL contacts

AMP Extracting Tool Yale Part No. 580093887 AMP Receptacle and Tab Contact Extraction Tool for AMPSeal connectors

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2200 YRM 1128

Special Tools

Illustration

Tool Description AMP Extracting Tool Yale Part No. 580093886 AMP Tab Contact Extraction Tool for AMPSeal connectors

AMP Hand Application Tool 580093888 with Die Set Yale Part No. 580093889 Use for crimping AMP Superseal 1.5 Series Contacts

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Special Tools

2200 YRM 1128

Illustration

Tool Description AMP Pro-Crimper II Yale Part No. 580093890 with Die Set Yale Part No. 580093891 Used for crimping AMP Superseal 1.5 Series Contacts

Heat Gun Used to repair connector wires.

Tool Kit for Terminal Repair Terminals cannot be removed from their connectors or repaired without special tools. This kit has the special removal and installation tools and crimping tools required to make repairs in Micro-Pack, Metri-Pack, and Weather-Pack connectors. This repair kit does not have the terminals or the connectors.

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2200 YRM 1128

Special Tools

Illustration

Tool Description AMP Double Action Hand Tool Yale Part No 580094770 Use for crimping Fastin-Faston receptacle connectors.

AMP Universal Handle Assembly with Strap Yale Part No. 580094772 Use with Extraction Tool Tip for Fastin-Faston receptacle connector extraction from connector housings.

AMP Extraction Tool Tip Yale Part No. 580094771 Use with Universal Handle Assembly for Fastin-Faston receptacle connector extractions.

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Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 1128

7/11 (1/11)(5/10)(2/10)(9/09)(4/09)(8/08)(7/08)(3/07)(6/06)(3/06) Printed in U.S.A.