Page 1

GDP/GLP80-120DB (D876), GDP/GLP130-160EB (D877) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

OPERATOR'S CAB........................................................................................................ FRAME............................................................................................................................ OPERATOR'S CAB........................................................................................................ CAB HEATER (PRIOR TO OCT. 2008).......................................................................... CUMMINS ENGINE FAULT CODE GUIDE.................................................................... MULTIPLE ALIGNED COOLING SYSTEM.................................................................... TRANSMISSION REPAIR.............................................................................................. TRANSMISSION OPERATION AND DIAGNOSTICS.................................................... APC200 FAULT CODE GUIDE...................................................................................... DIFFERENTIAL............................................................................................................... PLANETARY DRIVE AXLE (WET SYSTEM)................................................................. PLANETARY DRIVE AXLE (DRY SYSTEM)................................................................. STEERING AXLE............................................................................................................ STEERING SYSTEM...................................................................................................... BRAKE SYSTEM (DRY)................................................................................................. BRAKE SYSTEM (WET)................................................................................................. HYDRAULIC SYSTEM.................................................................................................... MAIN CONTROL VALVE................................................................................................ TILT CYLINDERS........................................................................................................... INSTRUMENT PANEL INDICATORS AND SENDERS................................................. ELECTRICAL SYSTEM.................................................................................................. MAST AND CARRIAGES............................................................................................... 2-STAGE MAST.............................................................................................................. METRIC AND INCH (SAE) FASTENERS....................................................................... ASSEMBLY GUIDE........................................................................................................ DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS...........................................................................

524206063 524300812 550033400 550033397 524211827 524300813 524302733 524304019 550022606 524150779 524150780 524150781 524150783 524150782 524150784 524150785 524150787 524150788 524150790 524206632 524300814 524203754 550088524 524150797 524230692 524298462 524298463 524298464

0100 YRM 1100 0100 YRM 1349 0100 YRM 1390 0100 YRM 1458 0600 YRM 1101 0700 YRM 1350 1300 YRM 1356 1300 YRM 1358 1300 YRM 1435 1400 YRM 0046 1400 YRM 0944 1400 YRM 0945 1600 YRM 0326 1600 YRM 0936 1800 YRM 0937 1800 YRM 0951 1900 YRM 0938 2000 YRM 0943 2100 YRM 0103 2200 YRM 1105 2200 YRM 1351 4000 YRM 1062 4000 YRM 1647 8000 YRM 0231 8000 YRM 1181 8000 YRM 1346 8000 YRM 1347 8000 YRM 1348

09/08 01/11 11/13 04/11 07/14 05/12 03/11 11/11 02/12 08/12 08/12 08/11 03/07 03/07 04/10 03/11 03/07 03/07 03/07 03/07 04/07 08/12 05/14 10/13 12/14 05/07 09/13 07/13

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 524295484 (12/14)


100 YRM 1100

General

General A fully-enclosed operators cab is positioned on four large rubber anti-vibration mounts to isolate operator from shock, noise, and vibration. See Figure 1. Operator’s compartment includes electronic controls for hydraulic systems, steering wheel, instrument panel, transmission, brake system controls, and operators seat. An overhead guard forms an integral part of the

operators cab. The cab is installed on a platform above main frame members. Step plates on both sides of lift truck give access to cab. The operators cab can be tilted, providing access to major components. For major repairs to cab, cab can be completely removed from frame of lift truck.

1. 2. 3. 4.

5. FRONT, REAR, AND TOP WINDOWS 6. OPERATOR’S CONSOLE, CONTROLS, AND ARMREST 7. HEATER SECTION

INCHING, BRAKE, AND THROTTLE PEDALS SEAT STEERING COLUMN FRONT, REAR, AND TOP WIPER ASSEMBLIES

Figure 1. Operators Cab

1


Cab Repair

100 YRM 1100

Cab Repair REAR CAB ASSEMBLY See Figure 2 for rear cab assembly.

1. 2. 3. 4. 5.

COVER PLATE FUSE SECTION RELAY SECTION HYDRAULIC VALVE CONTROLLER FOAM COVER

NOTE: Interior covers are affixed with self-tapping screws.

6. 7. 8. 9. 10.

HEADLINER REAR DUCT ASSEMBLY CONSOLE COVER CONSOLE TOP INSTRUMENT PANEL

Figure 2. Rear Cab Assembly

2


100 YRM 1100

Cab Repair

BOTTOM CAB ASSEMBLY

1. Tilt mast fully forward.

See Figure 3 for bottom cab assembly.

2. Remove all unsecured items from cab. 3. Close and securely latch both cab doors. 4. Clear all obstacles from right-hand side (as seen from driver’s position) of truck. Provide minimum of 2 m (7 ft) of clearance space. 5. Use pump lever to turn direction valve clockwise to "Raise" position. See Figure 4.

1. WIPER MOTOR ASSEMBLY 2. WIPER COUPLING 3. AIR FILTER

4. COVER PLATE 5. STEERING PUMP 6. HORN

Figure 3. Bottom Cab Assembly

1. PUMP LEVER CONNECTION 2. DIRECTION VALVE SELECTION: CLOCKWISE RAISE, COUNTERCLOCKWISE - LOWER Figure 4. Pump and Direction Valve

RAISING AND LOWERING CAB

6. Operate pump with pump lever until cab locks in partially open position.

Raise Cab WARNING Make sure no one is under cab when raising or lowering cab.

WARNING Before you place any part of your body under cab, always make sure that cab is fully tilted, or when partially open, is locked by tilt latch.

CAUTION Cab damage may occur if mast is not completely tilted forward.

NOTE: Just before fully open position is reached, movement may be gravity controlled. 7. Pull tilt latch release and continue to raise cab to fully open position. See Figure 5. NOTE: If cab will not fully raise, lower cab until cab locks in partially open position, and fill tilt system with oil. See Oil Filling for Tilt System. NOTE: Raising cab gives access to components such as engine, transmission/hydraulic compartment, throttle/brake and steering control, heater, air conditioner, and electrical connectors.

3


Cab Repair

100 YRM 1100 pump direction control. Procedure to raise or lower is the same.

CAB REPAIR Remove WARNING Before removing heater hoses, allow time for heater hoses to cool down. Hot water may cause severe burns.

WARNING 1. 2. 3. 4.

CAB FRAME TILT LATCH RELEASE PUMP LEVER

Make sure the lifting device has a minimum capacity to lift 1000 kg (2205 lb). A lifting device that does not have the minimum capacity can break causing the cab to drop and may result in serious personal injury.

Figure 5. Pump Lever and Tilt Latch Release Knob

Lower Cab WARNING Make sure no one is under cab when raising or lowering cab.

CAUTION Lift the operator’s cab carefully. Make sure all wires and attachments are disconnected and loose components are not obstructing the movement. 1. Switch off engine. 2. Disconnect battery ground lead.

WARNING Before you place any part of your body under cab, always make sure that cab is fully tilted, or when partially open, is locked by tilt latch.

CAUTION

3. Raise operator’s cab. See Raise Cab. 4. Remove four hex bolts holding steering pump. See Figure 6. 5. Remove two bolts holding brake valve.

Cab damage may occur if mast is not completely tilted forward.

6. Disconnect electrical cable to throttle pedal sensor. See Figure 11.

1. Use pump lever to turn direction valve counterclockwise to "Lower" position. See Figure 4.

7. Disconnect electrical cable.

2. Check that all foreign items/tools are cleared away.

8. Disconnect electrical plugs that are located to right of heater unit.

3. Operate pump with pump lever until cab locks in partially open position.

9. Disconnect window washer hoses and mark their positions.

4. Pull tilt latch release and continue to lower cab until it is in fully lowered position and latched. See Figure 5.

10. Remove three bolts and swing heater unit down.

NOTE: An electric-powered cab tilt system is available to replace standard manual tilt system. The electric tilt system contains a push button located on left side of

4

11. Disconnect electrical connections, control cables, and air duct from heater unit. 12. Disconnect ground lead.


100 YRM 1100

Cab Repair 19. Remove four rubber isolation mounts from frame and inspect for damage. Reinstall or replace if necessary.

Install 1. Connect lift strap under overhead guard structure. Provide cushion at top of door area to prevent damage. 2. Make sure that insulators are in place. See Figure 7.

1. 2. 3. 4. 5.

STEERING PUMP HEX BOLTS BRAKE VALVE BOLTS STEERING PUMP BRAKE VALVE ELECTRICAL CONNECTIONS Figure 6. Steering Pump, Throttle and Inching Connections

1. 2. 3. 4. 5.

TOP PART OF INSULATOR BOTTOM PART OF INSULATOR BOLT WASHER LOCKWASHER Figure 7. Insulators

CAUTION When lowering cab, make sure loose components are not obstructing the movement. 13. Lower operator’s cab. See Lower Cab. 14. Remove left and right side panels giving access to cab mounting bolts.

3. Lift operator’s cab. 4. Carefully lower cab on insulators and make sure that it is properly centered. 5. Mount cab with washers and bolts. 6. Tighten cab mounting bolts to 66 N•m (49 lbf ft).

15. Remove four mounting bolts, two on left side and two on right side of truck.

7. Raise cab. See Raise Cab.

16. Remove cab doors before attaching a lifting device.

8. Connect electrical cables, ground wire, hoses, steering pump, and brake valve. Make sure that all connections have been restored.

17. Connect a lift strap under overhead guard structure. Provide a cushion at top of door area to prevent damage. 18. Carefully lift cab away from lift truck. Set cab assembly in a suitable storage area and put blocks under cab to stabilize and prevent damage.

9. Mount heater unit to hinge. Connect control cables and electrical connections. Pivot unit up and install with three bolts. 10. Connect inching and throttle cables. See Inching and Brake Pedals.

5


Oil Filling for Tilt System

100 YRM 1100

11. Lower cab. See Lower Cab.

13. Connect battery ground lead.

12. Install doors.

14. Install side panels.

Oil Filling for Tilt System CAUTION When oil has been added, put oil-absorbing material around filler plug before lowering cab. Excess oil may bleed out of relief valve, which is fitted in filler plug. NOTE: When cab does not reach the maximum opening the oil level is low. 1. Lower cab until it locks in partially open position. See Lower Cab. 2. Put pump lever connection in fully down position to gain access to the fill cap. See Figure 8. 3. Remove fill cap. See Figure 8. 4. Add hydraulic oil into filler opening until level is within 30 to 35 mm (1.18 to 1.38 in.) of top of reservoir. See Figure 9.

1. FILL CAP Figure 8. Hand Pump

5. Install fill cap. See Figure 8. 6. Raise cab and make sure that maximum tilt can be reached. See Raise Cab. 7. Repeat procedure if necessary. 8. Lower cab until it is in fully lowered position and completely latched.

Figure 9. Cab Tilt Label

6


100 YRM 1100

Inching and Brake Pedals

Inching and Brake Pedals BRAKE PEDAL, ADJUST

3. Proceed with inching pedal sensor adjustment.

1. Adjust bolt (3), behind the brake pedal, on the brake pedal assembly so that the roller has contact with the bolt on the valve until there is no free travel. See Figure 10.

INCHING PEDAL SENSOR, ADJUST NOTE: When the brake pedals are not activated, the analog output of the inch sensor should be between 600 and 700 mV. This means the sensor is slightly turned as the lowest possible reading is 400 mV. 1. Loosen the two, one shown, sensor mounting bolts. See Figure 11. NOTE: To read the voltage, use the "Inching Pedal Calibration" mode of the UserlinkÂŽ program as explained in the section Transmission 1300 YRM 1082. 2. Rotate sensor in the slotted holes underneath the inching pedal so that the output voltage of the sensor of the released inching pedal is between 600 and 700 mV.

1. 2. 3. 4.

BRAKE PEDAL INCHING PEDAL ADJUSTMENT BOLT FOR BRAKE PEDAL ADJUSTMENT BOLT FOR INCHING/BRAKE PEDAL COUPLING 5. ADJUSTMENT BOLT FOR INCHING PEDAL

3. Tighten the mounting screws and recheck the voltage output at the sensor. 4. Calibrate the inching pedal. See the section Transmission 1300 YRM 1082.

Figure 10. Brake Pedal System 2. Proceed with inching pedal adjustment.

INCHING PEDAL, ADJUST NOTE: Adjust the inching pedal so that the brake pedal moves at the same time, which means there is no free play with the brake pedal. NOTE: When brake pedal and inching pedal are in released position their position must be equally high or in line. 1. When activating inching pedal, brake pedal should be activated as soon as top of inching pedal and top of brake pedal are on same plane. Use adjustment bolt (4) for inching/brake pedal coupling adjustment. See Figure 10.

1. MOUNTING BOLT Figure 11. Sensor Adjustment

2. Adjust bolt (5) for inching pedal to eliminate free travel of inching pedal before braking action occurs.

7


Throttle Pedal Sensor

100 YRM 1100

Throttle Pedal Sensor CHECK

7. Lower cab. See Lower Cab.

NOTE: When a new throttle pedal sensor is installed, rotate the throttle pedal sensor counterclockwise, when looking inside the throttle box, until the end of the slotted holes. See Figure 12. 1. Switch engine ON. 2. Operate throttle pedal. See Figure 12. 3. Check position, dimension A, of the throttle pedal at which the engine rpm goes from idle to higher rpm value. 4. If dimension A is not within 6 to 10 mm (0.236 to 0.394 in.), adjust the mechanical position of the electronic throttle potentiometer. See Adjust.

ADJUST 1. Raise cab. See Raise Cab. 2. Make sure the throttle pedal stop is adjusted so that it is against the cabin floor plate. 3. Position a 5 mm (0.197 in.) spacer between the throttle pedal and throttle pedal stop. 4. Loosen mounting screws and turn the throttle pedal sensor to position at which engine rpm increases from idle or decreases rpm to idle. 5. Tighten mounting screws. 6. Remove the 5 mm (0.197 in.) spacer between the throttle pedal and throttle pedal stop.

8

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

DIMENSION A THROTTLE PEDAL THROTTLE PEDAL ADJUSTMENT THROTTLE PEDAL SENSOR MOUNTING SCREW COUPLING CABIN FLOOR PLATE THROTTLE PEDAL STOP COUNTERCLOCKWISE SLOTTED HOLE Figure 12. Throttle Arrangement


100 YRM 1100

Power Assist Armrest

Seat Assembly Removal NOTE: Use a lifting device for removal of seat. NOTE: For mechanical seat, there will be one connector. For air suspension seat, there will be two connectors. 1. Disconnect battery ground lead. 2. Disconnect connector(s). See Figure 13. 3. Disconnect plug to side console. 4. Loosen four bolts connecting seat to cab. 5. Remove seat. Legend for Figure 13 1. ELECTRICAL CONNECTORS AND PLUG TO SIDE CONSOLE (REAR OF SEAT) 2. BOLTS Figure 13. Operators Seat

Power Assist Armrest ADJUST 1. Disconnect cable from lever. See Figure 14. 2. Remove the mounting bolts that hold the gas spring assembly. 3. Loosen nut. 4. Adjust top section, clockwise or counterclockwise, to obtain a free lever movement of 1.5 to 2.0 mm (0.06 to 0.079 in.). NOTE: Apply small bead of non permanent LoctiteÂŽ to bolt treads. 5. Install gas spring assembly using the two bolts. 6. Install and adjust cable on lever to obtain correct operation. Legend for Figure 14 1. LEVER 2. TOP SECTION 3. NUT

4. BOLT 5. LEVER 6. CABLE Figure 14. Power Assist Armrest

9


Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING

NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.


Steering Column Repair

100 YRM 1100

Steering Column Repair REMOVE 1. Raise cab. See Raise Cab. 2. Disconnect battery ground lead. 3. Disconnect steering column connector. See Figure 15 and Figure 16. 4. Remove four hex bolts fastening steering pump to cab and carefully remove steering pump. 5. Remove two cab mounting bolts holding steering column to the floor. 6. Lower cab. See Lower Cab. 7. Remove two hex bolts holding steering column to bracket.

1. STEERING COLUMN TO BRACKET BOLTS 2. STEERING COLUMN TO FLOOR PLATE BOLTS Figure 15. Steering Column

8. Remove steering column. Push grommet out of hole and slide connector through hole.

INSTALL 1. Slide connector through hole in floor and push grommet into hole. 2. Connect steering column to bracket with two cab mounting bolts. 3. Raise cab. See Raise Cab. 4. Mount steering column to cab base with two steering column hex bolts. 5. Carefully mount steering pump with four steering pump hex bolts to allow non-forced coupling between steering pump and steering column. 6. Connect electrical connector. 7. Connect battery ground lead. 8. Lower cab. See Lower Cab.

10

1. STEERING COLUMN CONNECTOR 2. STEERING COLUMN BOLTS 3. STEERING PUMP BOLTS Figure 16. Steering Pump


100 YRM 1100

Window Wipers Replacement

Window Wipers Replacement NOTE: Three window wiper motor assemblies are installed in the cab. The front window has a single-arm, parallelogram-type, wiper motor system to give a large wiped surface area. The wiper motor is mounted under the cab so as not to obstruct visibility. The top window is provided with a wiper motor assembly that has one wiper arm with wiper blade. The rear window is provided with a wiper motor assembly that has one wiper arm with wiper blade. A washer system is connected to all wipers.

FRONT WINDOW WIPER MOTOR ASSEMBLY, REPLACE 1. Disconnect battery ground lead. 2. Disconnect connector. See Figure 18. 3. Remove clamp tightening bolt and arm. 4. Remove three bolts. 5. Remove motor assembly.

WINDOW WIPER ASSEMBLY, REPLACE 1. Lift cover. See Figure 17.

6. Install new motor assembly. Proceed in reverse order.

2. Loosen and remove nut and washer. 3. Mark position of blade on window. 4. Disconnect wiper. 5. Disconnect washer hose if applicable. 6. Install new wiper assembly. Make sure that wiper assembly is properly positioned to give optimal coverage of window. Proceed in reverse order.

1. 2. 3. 4.

CLAMP TIGHTENING BOLT AND ARM BOLTS MOTOR ASSEMBLY CONNECTOR

Figure 18. Front Window Wiper Motor Assembly

1. COVER 2. COVER OPEN

3. NUT WITH WASHER

Figure 17. Wiper Assembly

11


Window Wipers Replacement

100 YRM 1100

REAR WINDOW WIPER MOTOR ASSEMBLY, REPLACE

TOP WINDOW WIPER MOTOR ASSEMBLY, REPLACE

1. Disconnect battery ground lead.

1. Disconnect battery ground lead.

2. Remove wiper assembly. See Window Wiper Assembly, Replace.

2. Remove 10 screws fastening headliner to cab. See Figure 20.

3. Remove cover of motor assembly unit.

3. Remove headliner.

4. Disconnect connector. See Figure 19.

4. Follow procedure as listed under Rear Window Wiper Motor Assembly, Replace.

5. Remove nuts and washers. 6. Remove motor assembly. 7. Install new motor assembly. Proceed in reverse order.

5. Replace cab headliner. 6. Connect battery ground lead.

1. SCREWS 1. CONNECTOR 2. NUTS AND WASHERS Figure 19. Rear Wiper Motor Assembly

12

Figure 20. Cab Headliner

Profile for 1634853

YALE D876 GLP80DB LIFT TRUCK (EUROPE)Service Repair Manual  

YALE D876 GLP80DB LIFT TRUCK (EUROPE)Service Repair Manual  

Profile for 1634853
Advertisement