Page 1

GDP80DC, GDP90DC, GDP100DC, GDP100DCS, GDP120DC (GDP190DC, GDP210DC, GDP230DC, GDP230DCS, GDP250DC, GDP280DC) (F876); GDP130EC, GDP140EC, GDP160EC (GDP300EC, GDP330EC, GDP360EC) (F877) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

OPERATOR'S CAB........................................................................................................ CAB HEATER................................................................................................................. FRAME............................................................................................................................ CUMMINS ENGINE FAULT CODE GUIDE.................................................................... COOLING SYSTEM........................................................................................................ ZF TRANSMISSION OPERATION AND DIAGNOSTICS............................................... TRANSMISSION REPAIR (ZF-WG161)......................................................................... DIFFERENTIAL............................................................................................................... PLANETARY DRIVE AXLE (WET SYSTEM)................................................................. STEERING SYSTEM...................................................................................................... BRAKE AND HYDRAULIC COOLING SYSTEM........................................................... HYDRAULIC SYSTEM.................................................................................................... HYDRAULIC CONTROL SYSTEM................................................................................. ELECTRICAL SYSTEM.................................................................................................. 2-STAGE MAST.............................................................................................................. METRIC AND INCH (SAE) FASTENERS....................................................................... ASSEMBLY GUIDE........................................................................................................ DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS...........................................................................

550033400 550033398 550061801 524211827 550061806 550035502 550035503 524150779 524150780 550035504 550035505 550035506 550035498 550061811 550088524 524150797 524230692 550061816 550061821 550061826

0100 YRM 1390 0100 YRM 1459 0100 YRM 1594 0600 YRM 1101 0700 YRM 1595 1300 YRM 1455 1300 YRM 1456 1400 YRM 0046 1400 YRM 0944 1600 YRM 1479 1800 YRM 1498 1900 YRM 1478 2200 YRM 1481 2200 YRM 1592 4000 YRM 1647 8000 YRM 0231 8000 YRM 1181 8000 YRM 1591 8000 YRM 1593 8000 YRM 1596

11/13 08/12 08/12 07/14 09/13 09/13 08/12 08/12 08/12 08/12 03/13 11/14 08/12 09/13 05/14 10/13 12/14 10/13 07/12 07/13

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 550061831 (12/14)


SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death. 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.


Table of Contents

TABLE OF CONTENTS General ..................................................................................................................................................................... 1 Description of Operation ........................................................................................................................................... 3 Cab Structure ....................................................................................................................................................... 3 Cab Tilt System .................................................................................................................................................... 3 Cab Tilt System, Raise .....................................................................................................................................4 Cab Tilt System, Lower .................................................................................................................................... 4 Oil Filling for Cab Tilt System ....................................................................................................................................6 Raising and Lowering Cab ........................................................................................................................................7 Raise Cab .............................................................................................................................................................7 Lower Cab ............................................................................................................................................................ 8 Cab Door Assembly ..................................................................................................................................................8 Cab Door .............................................................................................................................................................. 8 Remove ............................................................................................................................................................8 Install ................................................................................................................................................................8 Door Hinge ........................................................................................................................................................... 9 Remove ............................................................................................................................................................9 Install ................................................................................................................................................................9 Door Striker Pin .................................................................................................................................................. 10 Door Striker Pin Adjustment ...........................................................................................................................10 Door Latch .......................................................................................................................................................... 10 Remove ..........................................................................................................................................................10 Install ..............................................................................................................................................................10 Door Handle ....................................................................................................................................................... 11 Remove ..........................................................................................................................................................11 Install ..............................................................................................................................................................11 Door Release ......................................................................................................................................................11 Remove ..........................................................................................................................................................11 Install ..............................................................................................................................................................12 Door Push Button ............................................................................................................................................... 12 Remove ..........................................................................................................................................................12 Install ..............................................................................................................................................................12 Cab Tilt System .......................................................................................................................................................12 Electric Tilt Pump ................................................................................................................................................12 Remove ..........................................................................................................................................................12 Install ..............................................................................................................................................................13 Hand Pump .........................................................................................................................................................13 Remove ..........................................................................................................................................................13 Install ..............................................................................................................................................................13 Cab Tilt Cylinder ................................................................................................................................................. 15 Remove ..........................................................................................................................................................15 Disassemble ...................................................................................................................................................15 Clean ..............................................................................................................................................................16 Inspect ............................................................................................................................................................16 Assemble ....................................................................................................................................................... 17 Install ..............................................................................................................................................................17 Latch ...................................................................................................................................................................17 Remove ..........................................................................................................................................................17 Install ..............................................................................................................................................................18 Brake and Inching Pedals .......................................................................................................................................19 Remove .............................................................................................................................................................. 19

©2014 Yale Materials Handling Corp.

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Table of Contents

TABLE OF CONTENTS (Continued) Install .................................................................................................................................................................. 19 Brake Pedal Adjustment ..................................................................................................................................... 19 Dry Brake ....................................................................................................................................................... 19 Wet Brake ...................................................................................................................................................... 19 Inching Pedal Adjustment ...................................................................................................................................20 Inching Pedal Sensor Adjustment Using Dana Dashboard Software .................................................................20 Inching Pedal Sensor Calibration Procedure Using Dana Dashboard Software ................................................ 21 Inching Pedal Sensor Adjustment Using the APC200 Display ........................................................................... 21 Inching Pedal Sensor Calibration Procedure Using the APC200 Display .......................................................... 22 Inching Sensor Adjustment for trucks with ZF Transmission ..............................................................................22 Inching Pedal Calibration for trucks with ZF Transmission .................................................................................23 Accelerator Pedal and Sensor ................................................................................................................................ 23 Accelerator Pedal ............................................................................................................................................... 23 Remove ..........................................................................................................................................................23 Install ..............................................................................................................................................................23 Accelerator Pedal Sensor ...................................................................................................................................23 Adjust ............................................................................................................................................................. 23 Seat Assembly ........................................................................................................................................................24 Seat .................................................................................................................................................................... 24 Remove ..........................................................................................................................................................24 Install ..............................................................................................................................................................24 Seat Cushion ...................................................................................................................................................... 25 Remove ..........................................................................................................................................................25 Install ..............................................................................................................................................................25 Back Cushion ..................................................................................................................................................... 26 Remove ..........................................................................................................................................................26 Install ..............................................................................................................................................................26 Seat Suspension Replacement .......................................................................................................................... 26 Boot Replacement .............................................................................................................................................. 26 Suspension Scissor and Shock Absorber .......................................................................................................... 27 Remove ..........................................................................................................................................................27 Install ..............................................................................................................................................................32 Compressor ........................................................................................................................................................ 39 Remove ..........................................................................................................................................................39 Install ..............................................................................................................................................................43 Power Assist Armrest ..............................................................................................................................................49 Release Cable .................................................................................................................................................... 49 Remove ..........................................................................................................................................................49 Install ..............................................................................................................................................................49 Gas Spring ..........................................................................................................................................................50 Remove ..........................................................................................................................................................50 Install ..............................................................................................................................................................50 Joystick ...............................................................................................................................................................50 Remove ..........................................................................................................................................................50 Install ..............................................................................................................................................................50 Electrical Levers ................................................................................................................................................. 51 Remove ..........................................................................................................................................................51 Install ..............................................................................................................................................................51 Armrest Rocker Switches ................................................................................................................................... 51 Remove ..........................................................................................................................................................51

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Table of Contents

TABLE OF CONTENTS (Continued) Install ..............................................................................................................................................................51 Armrest Top Cover ............................................................................................................................................. 52 Remove ..........................................................................................................................................................52 Install ..............................................................................................................................................................52 Instrument Panel .....................................................................................................................................................52 Key Switch ..........................................................................................................................................................52 Remove ..........................................................................................................................................................52 Install ..............................................................................................................................................................52 12V Power Socket .............................................................................................................................................. 52 Remove ..........................................................................................................................................................52 Install ..............................................................................................................................................................53 Electric-Operated Heat Control and Air Recirculation Control (Airco Only) ........................................................53 Remove ..........................................................................................................................................................53 Install ..............................................................................................................................................................53 Cable-Operated Heater Control (Heater Only) ................................................................................................... 53 Remove ..........................................................................................................................................................53 Install ..............................................................................................................................................................54 Air Conditioning Switch Replacement ................................................................................................................ 54 Instrument Panel Rocker Switches Replacement .............................................................................................. 55 Parking Brake Switch ......................................................................................................................................... 55 Remove ..........................................................................................................................................................55 Install ..............................................................................................................................................................55 Indicator Display Replacement ...........................................................................................................................55 Instrument Panel Top Console ........................................................................................................................... 56 Remove ..........................................................................................................................................................56 Install ..............................................................................................................................................................56 Steering Wheel and Column Assembly .................................................................................................................. 57 Steering Wheel and Horn ................................................................................................................................... 57 Remove ..........................................................................................................................................................57 Install ..............................................................................................................................................................57 Steering Column Assembly ................................................................................................................................ 57 Remove ..........................................................................................................................................................57 Install ..............................................................................................................................................................57 Adjustment Handle ............................................................................................................................................. 60 Remove ..........................................................................................................................................................60 Install ..............................................................................................................................................................60 Main Warning Lights ...........................................................................................................................................60 Remove ..........................................................................................................................................................60 Install ..............................................................................................................................................................60 Shift Lever .......................................................................................................................................................... 60 Remove ..........................................................................................................................................................60 Install ..............................................................................................................................................................61 Turn Signal Lever ............................................................................................................................................... 61 Remove ..........................................................................................................................................................61 Install ..............................................................................................................................................................61 Window Wipers Replacement .................................................................................................................................61 Window Wiper Assembly, Replace .....................................................................................................................61 Remove ..........................................................................................................................................................61 Install ..............................................................................................................................................................62 Window Wiper Motor Replacement ........................................................................................................................ 62

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Table of Contents

TABLE OF CONTENTS (Continued) Front Window Wiper Motor Assembly ................................................................................................................ 62 Remove ..........................................................................................................................................................62 Install ..............................................................................................................................................................62 Rear Window Wiper Motor Assembly .................................................................................................................63 Remove ..........................................................................................................................................................63 Install ..............................................................................................................................................................63 Top Window Wiper Motor Assembly .................................................................................................................. 63 Remove ..........................................................................................................................................................63 Install ..............................................................................................................................................................63 Window Washer System .........................................................................................................................................64 Window Washer Reservoir and Pumps ..............................................................................................................64 Remove ..........................................................................................................................................................64 Install ..............................................................................................................................................................64 Window Washer Hoses ...................................................................................................................................... 65 Hoses for Top and Rear Window ................................................................................................................... 65 Remove ......................................................................................................................................................65 Install ..........................................................................................................................................................65 Hoses for Front Window .................................................................................................................................66 Remove ......................................................................................................................................................66 Install ..........................................................................................................................................................66 Window Washer Spray Nozzles ......................................................................................................................... 67 Front ...............................................................................................................................................................67 Remove ......................................................................................................................................................67 Install ..........................................................................................................................................................67 Rear ............................................................................................................................................................... 67 Remove ......................................................................................................................................................67 Install ..........................................................................................................................................................67 Top ................................................................................................................................................................. 67 Remove ......................................................................................................................................................67 Install ..........................................................................................................................................................67 Window Replacement .............................................................................................................................................68 Front Window ..................................................................................................................................................... 69 Remove ..........................................................................................................................................................69 Install ..............................................................................................................................................................69 Rear Window ...................................................................................................................................................... 69 Remove ..........................................................................................................................................................69 Install ..............................................................................................................................................................69 Top Window ........................................................................................................................................................70 Remove ..........................................................................................................................................................70 Install ..............................................................................................................................................................70 Door Window ...................................................................................................................................................... 71 Upper/Lower Window .....................................................................................................................................71 Remove ......................................................................................................................................................71 Install ..........................................................................................................................................................71 Sliding Window and Sliding Tracks .................................................................................................................... 71 Remove ..........................................................................................................................................................71 Install ..............................................................................................................................................................73 Weather Strip Replacement ........................................................................................................................... 73 Window Stopper Replacement .......................................................................................................................73 Window Seal Replacement ............................................................................................................................ 73

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Table of Contents

TABLE OF CONTENTS (Continued) Sliding Window Frame ................................................................................................................................... 73 Remove ......................................................................................................................................................73 Install ..........................................................................................................................................................74 Floor Mat .................................................................................................................................................................74 Front Floor Mat ................................................................................................................................................... 74 Remove ..........................................................................................................................................................74 Install ..............................................................................................................................................................75 Rear Floor Mat ....................................................................................................................................................75 Remove ..........................................................................................................................................................75 Install ..............................................................................................................................................................75 Radio Console ........................................................................................................................................................ 76 Remove .............................................................................................................................................................. 76 Install .................................................................................................................................................................. 76 Air Duct Replacement .............................................................................................................................................77 Front ................................................................................................................................................................... 77 Rear ....................................................................................................................................................................77 Remove ..........................................................................................................................................................77 Install ..............................................................................................................................................................77 Accessories ............................................................................................................................................................ 78 Mirror Replacement ............................................................................................................................................ 78 Sunshade Replacement ..................................................................................................................................... 78 Top ................................................................................................................................................................. 78 Rear ............................................................................................................................................................... 79 Map Light Replacement ......................................................................................................................................79 Interior Fan Replacement ................................................................................................................................... 79 Remove ..........................................................................................................................................................79 Training Seat ...................................................................................................................................................... 79 Field Installation ............................................................................................................................................. 79 Remove ..........................................................................................................................................................79 Label Replacement .................................................................................................................................................80 This section is for the following models: GDP/GLP80-120DB (GDP170-280DB) [D876]; GDP/GLP130-160EB (GDP/GLP300-360EB) [D877]; GDP80DC, GDP90DC, GDP100DC, GDP100DCS, GDP120DC (GDP190DC, GDP210DC, GDP230DC, GDP230DCS, GDP250DC, GDP280DC) [E876]; GDP130EC, GDP140EC, GDP160EC (GDP300EC, GDP330EC, GDP360EC) [E877]; GDP80-120DC, GDP100DCS (GDP190-280DC, GDP230DCS) [F876]; GDP130-160EC (GDP360-360EC) [F877]

v


0100 YRM 1390

General

General This YRM describes the functions of the cab and the replacement instructions for the cab components. See Figure 1. Some of the described components are options that may not be present on each cab. The operation of the various switches and controls can be found in the Operating Manual.

Information on systems that are related to the cab are in YRM for the Electrical System, Hydraulic System, Brake System, Steering System and Diagrams specific to each model lift truck. Before making any repairs to the lift truck, complete the following procedures:

The description and repair instructions for the heater assembly are in Cab Heater (Prior to Oct. 2008) 0100YRM1458 for lift trucks built prior to October, 2008, and in Cab Heater 0100YRM1459 for lift trucks built after October, 2008.

1. Place the lift truck on a solid, level surface.

The remove and replace instructions for the cab as an assembly are in the frame YRM specific to each model lift truck.

5. Shut down the engine.

2. Lower the mast completely and tilt forward. 3. Place the shift lever in NEUTRAL. 4. Apply the parking brake.

1


Description of Operation

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

0100 YRM 1390

HEATER SECTION INCHING PEDAL BRAKE PEDAL ACCELERATOR PEDAL STEERING COLUMN FRONT, REAR, AND TOP WINDOWS FRONT, REAR, AND TOP WIPER ASSEMBLIES

8. INTEGRATED OVERHEAD GUARD 9. OPERATOR'S CONSOLE, CONTROLS, AND ARMREST 10. AIR CONDITIONING CONDENSER, DRYER, AND FAN ASSEMBLY (OPTIONAL) 11. SEAT

Figure 1. Operator's Cab

2


0100 YRM 1390

Description of Operation

Description of Operation CAB STRUCTURE The cab frame is a welded structure. The overhead guard is an integral part of the cab frame. See Figure 1. In order to maintain maximum overhead protection, changes to the cab frame and integrated overhead guard are not allowed. There are two cab options: an open cab and a closed cab. The closed cab features windows and wipers, doors, a heater, and optional air conditioning. Both cab types feature interior components.

CAB TILT SYSTEM On lift trucks with a cab tilt system, the cab can tilt to the right-hand side, providing service access to the engine compartment and components under the cab. The cab tilt system consists of a cab support frame, cab tilt cylinder, cab tilt hand pump assembly, cab latches, and an optional electrical cab tilt pump. See Figure 2. The cab is attached to the lift truck in the lowered position by the cab support pivots on the right-hand frame channel, the two cab latches on the left-hand frame channel, and the cab tilt cylinder.

A. PULL DIRECTION OF THE TILT LATCH RELEASE 1. 2. 3. 4.

CAB SUPPORT FRAME CAB TILT HAND PUMP CAB LATCH CAB TILT CYLINDER Figure 2. Cab Tilt System

Hydraulic pressure is required to unlock the cab latches and extend the cab tilt cylinder. The cab can be raised by rotating the cab tilt hand pump directional valve clockwise and operating the cab tilt hand pump. See Figure 3. To lower the cab from the raised position, rotate the cab tilt hand pump directional valve counterclockwise and operating the cab tilt hand pump. The cab tilt cylinder retracts to lower the cab. The optional electrical cab tilt pump is push-button operated. See Raising and Lowering Cab, Raise Cab, Figure 8. NOTE: If the optional electrical cab tilt pump is inoperable, the cab can be raised or lowered by using the manually operated cab tilt hand pump. A. LOWER B. RAISE 1. PUMP LEVER CONNECTION 2. PUMP DIRECTIONAL VALVE Figure 3. Cab Tilt Hand Pump

3


Description of Operation When the cab has been raised to the partially open position, the safety latch will engage with a retainer plate that is welded to the frame. To raise or lower the cab after the safety latch has engaged, pull and hold the tilt latch release and raise or lower the cab until the safety latch has passed the retainer plate. Just before the fully open position is reached, movement becomes gravity-controlled by the weight of the cab. The cab is in the fully open position when the cab tilt cylinder is fully extended.

Cab Tilt System, Raise When the directional valve is in the raise position, the pump push port and pump pull port are connected to each other. See Figure 4. Hydraulic pressure is transferred to the cab latches and both the piston and rod side of the cab tilt cylinder. Hydraulic oil extruded at the rod side enters the piston side of the cylinder through the directional valve in the hand pump. The end of stroke is determined by a retaining ring in the cab tilt cylinder.

4

0100 YRM 1390

Cab Tilt System, Lower When the directional valve is in the lower position, the pump push port is connected to the pump reservoir through a reservoir check valve. The reservoir check valve retains enough pressure to keep the cab locks open. The pump pull port is connected to the hand pump. While the hand pump provides sufficient pressure, the cylinder check valve will raise to allow the oil at the piston side of the cylinder to return to the reservoir. The cylinder cannot lower when there is insufficient pressure at the pull connection. When the piston has reached the free fall area, the oil at the piston side will escape to the rod side and the cab will drop under the influence of its own weight. When the cab drops, the oil in the cab lock cylinders is pushed out through the reservoir check valve. After the cab has dropped, the cab is locked into position by the cab latches.


0100 YRM 1390

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

Description of Operation

ROD AREA CAB TILT CYLINDER FREE FALL INTERCONNECTION CHECK VALVE PULL ELECTRIC CAB TILT PUMP (OPTIONAL) RESERVOIR RELIEF VALVE

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

CAB TILT HAND PUMP RESERVOIR CHECK VALVE LOWER PUMP DIRECTIONAL VALVE RAISE LATCH PUSH

Figure 4. Cab Tilt System

5


Oil Filling for Cab Tilt System

0100 YRM 1390

Oil Filling for Cab Tilt System CAUTION When oil is added to the cab tilt system, place an oil absorbing material around the fill cap before lowering the cab. Excess oil may bleed out of the relief valve, which is located in the fill cap. NOTE: If the oil level is low, the cab will not tilt/raise completely.

4. Remove the fill cap. See Figure 5. 5. Add hydraulic oil through the filler opening until the level is within 30 to 35 mm (1.18 to 1.38 in.) of the top of the reservoir. See Figure 6. For your lift truck, refer to the appropriate Periodic Maintenance YRMfor the correct hydraulic oil specification.

NOTE: If the cab is lowered, perform Step 1. If the cab is raised, go to Step 2. 1. Tilt/Raise raise the cab until it locks in the partially open position. Refer to the section Raising and Lowering Cab. 2. Lower the cab until it locks in the partially open position. Refer to the section Raising and Lowering Cab. 3. Place the pump lever connection in the fully down position to create easy access to the fill cap. See Figure 5.

Figure 6. Cab Tilt Label 6. Install the fill cap. See Figure 5. 7. Tilt/raise the cab and make sure the maximum tilted/raised (fully opened) position can be reached. Refer to the section Raising and Lowering Cab. 8. If necessary, repeat Step 1 through Step 7. 9. Lower the cab until it is in the fully lowered position and completely latched. Refer to the section Raising and Lowering Cab.

1. FILL CAP 2. PUMP LEVER CONNECTION Figure 5. Hand Pump

6


0100 YRM 1390

Raising and Lowering Cab

Raising and Lowering Cab RAISE CAB WARNING Make sure no one is under the cab when tilting/ raising or lowering the cab, or serious personal injury may occur.

WARNING Before doing any work under the cab, always make sure the cab is fully tilted/raised, or if partially open, is locked with the tilt latch, or serious personal injury may occur.

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

A. LOWER

B. RAISE

1. PUMP LEVER CONNECTION 2. PUMP DIRECTIONAL VALVE

1. Tilt the mast fully forward.

Figure 7. Pump and Direction Valve

2. Remove all unsecured items from the cab. 3. Close and securely latch the left-hand and righthand cab doors. 4. Clear all obstacles from the right-hand side of the lift truck. Provide a minimum of 2 m (7 ft) clearance space. 5. Use the pump lever to turn the pump directional valve clockwise to the "Tilt/Raise" position. See Figure 7. 6. Operate the pump with the pump lever (or pushbutton, if equipped with an electric pump), until the cab locks in the partially open position. See Figure 8. NOTE: Just before the fully open position is reached, movement becomes gravity-controlled by the weight of the cab. 7. Pull the tilt latch release and continue to tilt/raise the cab to the fully open position. See Figure 8. NOTE: If the cab will not fully tilt/raise, lower the cab until the cab locks in the partially open position, and check the oil level. Refer to the section Oil Filling for Cab Tilt System.

1. 2. 3. 4.

CAB FRAME TILT LATCH RELEASE KNOB ELECTRIC CAB TILT PUSH-BUTTON (OPTIONAL) 5. PUMP LEVER Figure 8. Pump Lever and Tilt Latch Release Knob

7


Cab Door Assembly

0100 YRM 1390

LOWER CAB

1. Make sure all foreign items/tools are removed from under the cab.

WARNING Make sure no one is under the cab when raising or lowering the cab, or serious personal injury may occur.

WARNING Before doing any work under the cab, always make sure the cab is fully tilted/raised, or if partially open, is locked with the tilt latch, or serious personal injury may occur.

2. Use the pump lever to turn the pump directional valve counterclockwise to the "Lower" position. See Figure 7. 3. Operate the pump with the pump lever (or pushbutton, if equipped), until the cab locks in the partially open position. See Figure 8. 4. Pull the tilt latch release knob and continue to lower the cab until the cab is in the fully lowered and latched position.

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

Cab Door Assembly CAB DOOR Remove 1. Open the sliding windows.

2. Attach a lift strap to the left-hand and right-hand side of the sliding windows inside the sliding window frame. Place a cushion between the sliding window frame and the lift straps (left-hand and right-hand sides) to prevent damage.

2. Attach a lift strap at the left-hand and right-hand side of the sliding windows inside the sliding window frame. Place a cushion between the sliding window frame and the lift straps (left-hand and right-hand sides) to prevent damage.

3. Raise the cab door and place it in position above the hinges.

3. Position the cab door at a 90° angle to the frame, so the cab door can be lifted out the hinges.

5. Remove the lift strap.

CAUTION

4. Slowly lower the cab door until the cab door is seated on the hinges.

6. Make sure the cab door is opening, closing, and moving properly on the hinges.

Use caution when lifting the cab door to avoid damage to the cab frame.

7. Make sure the locking system functions properly.

4. Lift the cab door out of the cab door hinges. See Figure 9.

8. If necessary, adjust the hinge location when the door is closed. Door clearance must be evenly divided around the door and door opening of the cab.

5. Move the cab door away from the lift truck and place it on the ground. 6. Close the sliding windows.

Install 1. Open the sliding windows.

8

NOTE: Adjust one hinge at a time.

9. Loosen the three capscrews and use a nylon hammer to adjust the hinge. Retighten the capscrews. 10. If necessary, adjust the door striker pin. Refer to the section Door Striker Pin Adjustment.


0100 YRM 1390

Cab Door Assembly

Install 1. Position the two hinges to the cab frame as marked and install the six capscrews to retain the hinges to the cab frame. 2. Install the cab door. Refer to the section Cab DoorInstall. 3. Make sure the locking system functions properly. NOTE: Adjust one hinge at a time.

A. VIEW TURNED 90° COUNTERCLOCKWISE 1. 2. 3. 4. 5.

DOOR HINGE DOOR PUSH-BUTTON DOOR RELEASE DOOR LATCH DOOR HANDLE Figure 9. Cab Door

DOOR HINGE Remove 1. Remove the cab door. See the section Cab DoorRemove. 2. Mark the location of the two hinges on the cab frame. 3. Remove the six capscrews retaining the two hinges to the cab frame and remove the two hinges. See Figure 10.

1. DOOR HINGE 2. CAPSCREW

3. CAB FRAME

Figure 10. Door Hinge

9


Cab Door Assembly 4. If necessary, adjust the hinge location when the door is closed. 5. Loosen the three capscrews and use a nylon hammer to adjust the hinge. Retighten the capscrews.

DOOR STRIKER PIN Door Striker Pin Adjustment 1. Make sure the door hinges are correctly installed. 2. Loosen the securing nut that retains the door striker pin to the cab frame. See Figure 11. 3. Place the door striker pin in the expected latching position. 4. Push and hold the release button and close the door with normal force so that the door is positioned correctly in the door opening of the cab. 5. Open the door with the release button still engaged.

0100 YRM 1390

DOOR LATCH Remove 1. Remove the capscrew and washer that retain the plastic cover to the door latch. See Figure 12. 2. Remove the two capscrews that retain the door latch to the door frame. 3. Disconnect the connector rod from the door latch attached to the door release.

Install 1. Connect the connector rod to the door latch attached to the door release. 2. Install the two capscrews to retain the door latch to the door frame. 3. Install the capscrew and washer that retain the plastic cover to the door latch. 4. Make sure the locking system functions correctly.

6. Carefully tighten the securing nut that retains the door striker pin to the cab frame. 7. Close the door and make sure the door is correctly seated against the door seals. 8. If necessary, repeat Step 1 through Step 7.

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

CAPSCREW WASHER PLASTIC COVER CAPSCREW DOOR LATCH CAB DOOR CONNECTOR ROD Figure 12. Door Latch

1. CAB FRAME 2. SECURING NUT 3. DOOR STRIKER PIN Figure 11. Door Striker Pin

10


0100 YRM 1390

DOOR HANDLE Remove 1. Remove the door latch. Refer to the section Door LatchRemove. 2. Remove the plastic plug at the inside of the door frame. See Figure 13. 3. Remove the capscrew and washer that retain the door handle, through the hole from the plastic plug.

Cab Door Assembly 3. Install the washer and capscrew through the hole from the plastic plug. 4. Install the plastic plug at the inside of the door frame. 5. Install the latch. Refer to the section Door LatchInstall. 6. Make sure the locking system functions correctly.

DOOR RELEASE Remove

4. Remove the large nut and washer that retain the door handle on the release button side of the door handle.

1. Remove the door latch. Refer to the section Door LatchRemove.

5. Remove the door handle and two rubber cushions.

2. Remove the capscrew that retains the door release inside the bar located at the inside of the door frame. See Figure 15.

Install 1. Position the door handle and two rubber cushions on the door. See Figure 13.

3. Remove the connector rod and door release from inside the bar.

2. Install the washer and large nut on the release button side of the door handle.

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

WASHER CAPSCREW PLASTIC PLUG CAB DOOR RUBBER CUSHION (LARGE) DOOR HANDLE RUBBER CUSHION (SMALL) Figure 13. Door Handle

1. 2. 3. 4.

CAPSCREW DOOR RELEASE CONNECTOR ROD CAB DOOR Figure 14. Door Release

11


Cab Tilt System

0100 YRM 1390

4. Disconnect the connector rod from the door release.

Install

2. Position the cab door in the locking system. 3. Tighten the three nuts.

1. Connect the connector rod to the door release. See Figure 14.

4. Make sure the door holder is positioned properly by placing the door in the lock system. Adjust the door holder (push button) as needed.

2. Install the connector and door release inside the bar, located at the inside of the door frame.

5. Install the three plastic caps to the nuts located at the inside of the door frame.

3. Install the capscrew that retains the door release inside the bar. 4. Install the door latch. Refer to the section Door LatchInstall.

DOOR PUSH BUTTON Remove 1. Remove the three plastic caps from the nuts located at the inside of the door frame. See Figure 15. 2. Remove the three nuts, washers, and capscrews that retain the door holder (push button), washer, and seal to the door frame.

Install 1. Install the three capscrews, washers, and nuts that retain the door holder (push button), washer, and seal to the door frame. Hand tighten the nuts. See Figure 15.

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

CAB DOOR WASHER SEAL DOOR HOLDER (PUSH BUTTON) WASHER NUT CAPSCREW Figure 15. Door Push Button

Cab Tilt System ELECTRIC TILT PUMP Remove 1. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab. 2. Disconnect the electrical connector, located at the left-hand panel, from the cab tilt push-button. See Raising and Lowering Cab, Raise Cab, Figure 8. 3. Remove the two capscrews and washers that retain the left-hand panel to the frame and remove the left-hand panel.

12

4. Disconnect the electrical connector from the electrical tilt pump. 5. Tag and disconnect the two hydraulic hoses from the electrical tilt pump and place plugs on the hose ends. 6. Remove the two nuts that retain the bracket with the electrical tilt pump to the frame. 7. Remove the bracket with the electrical tilt pump from the frame. 8. Remove the two capscrews that retain the electrical tilt pump to the bracket.


0100 YRM 1390 9. Remove the electrical tilt pump from the bracket.

Install 1. Position the electrical tilt pump on the bracket.

Cab Tilt System 2. If equipped, disconnect the electrical connector located at the left-hand panel, from the cab tilt push-button. See Raising and Lowering Cab, Raise Cab, Figure 8.

2. Install the two capscrews that retain the electrical tilt pump on the bracket.

3. Remove the two capscrews and washers that retain the left-hand panel to the frame and remove the left-hand panel.

3. Position the bracket with the electrical tilt pump on the frame.

4. Remove the two capscrews and washers that retain the hand pump to the frame. See Figure 16.

4. Install the two nuts that retain the bracket with the electrical tilt pump to the frame.

NOTE: Keep the hydraulic hose connection locations from the hand pump facing upward to avoid spilling hydraulic oil.

5. Remove the plugs and connect the two hoses to the electrical tilt pump. 6. Connect the electrical connector to the electrical tilt pump. 7. Position the left-hand panel on the frame and install the two capscrews and washers to retain the panel to the frame. 8. Connect the electrical connector to the cab tilt push-button. See Raising and Lowering Cab, Raise Cab, Figure 8. 9. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab. 10. Operate the electric tilt pump to check for leaks and to remove air from the cab tilt system. 11. Check the hydraulic oil level. Refer to the section Oil Filling for Cab Tilt System. 12. Operate the cab tilt system to check for correct operation.

HAND PUMP

5. Tag and disconnect the three hydraulic hoses and place plugs on the three hose ends. See Figure 16.

Install 1. Remove the plugs from the three hose ends and connect the three hydraulic hoses to the hand pump. See Figure 16. 2. Position the hand pump on the frame and install the two capscrews and washers that retain the hand pump to the frame. See Figure 16. 3. Position the left-hand panel to the frame and install the two capscrews and washers to retain the left-hand panel to the frame. 4. If equipped, connect the electrical connector to the cab tilt push-button. See Raising and Lowering Cab, Raise Cab, Figure 8. 5. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab.

Remove

6. Remove the fill cap of the hand pump and fill the reservoir with hydraulic oil. Refer to the section Oil Filling for Cab Tilt System.

1. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab.

7. Make sure the cab tilt system functions correctly.

13


Cab Tilt System

0100 YRM 1390

A. 180 DEGREES TURNED 1. FRAME 2. HAND PUMP 3. HYDRAULIC HOSE

4. WASHER 5. CAPSCREW Figure 16. Hand Pump

14


0100 YRM 1390

Cab Tilt System

CAB TILT CYLINDER Remove 1. Tilt/raise the cab until it locks in the partially open position. Refer to the section Raising and Lowering Cab. 2. Place wooden blocks between the frame and the cab to prevent the cab from suddenly lowering.

CAUTION Be careful not to damage the grooves when removing O-rings, sleeve, U-cup, and retaining rings. 8. Remove the shaft retaining ring (10,Figure 18) that retains the piston to the piston rod. 9. Remove the piston from the piston rod.

3. Tag and disconnect the two hydraulic hoses from the cab tilt cylinder and install caps on the hydraulic fittings and plugs in the hydraulic hoses. See Figure 18. 4. Remove the snap ring from the pin that retains the cab tilt cylinder to the frame. See Figure 17. 5. Remove the snap ring from the pin that retains the cab tilt cylinder to the cab tilt frame. 6. Remove the cab tilt cylinder from the pins and remove the cab tilt cylinder from under the frame.

Disassemble 1. Place the cab tilt cylinder in a horizontal position with the fittings pointing downward in a vise with soft jaws. 2. Place a drain pan under the fittings. 3. Remove the caps from the fittings and drain the hydraulic oil from the cab tilt cylinder. 4. Remove the wiper from the cylinder shell. See Figure 18. 5. Press the gland inside the cylinder shell until the gland retaining ring is free. 6. Remove the gland retaining ring.

CAUTION Be careful not to damage the finished surface of the piston rod when removing the piston rod assembly from the cylinder shell in a horizontal position. 7. Remove the piston rod assembly from the cylinder shell by pulling it out of the cylinder shell.

1. 2. 3. 4. 5.

CAB TILT FRAME SNAP RING CAB TILT CYLINDER PIN FRAME Figure 17. Cab Tilt Cylinder

15


Cab Tilt System 10. Remove the end of stroke ring (9,Figure 18) from the piston rod. 11. Remove the gland from the piston rod. 12. Remove and discard the O-ring from the piston rod. 13. Remove and discard the O-ring and sleeve from the piston. 14. Remove and discard the O-ring and U-cup from the gland.

0100 YRM 1390 Legend for Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

FILTER HYDRAULIC FITTINGS SPACER WIPER GLAND RETAINING RING U-CUP O-RING GLAND END OF STROKE RING SHAFT RETAINING RING O-RING O-RING SLEEVE PISTON WASHER O-RING CHECK VALVE ASSEMBLY PILOT PISTON ASSEMBLY O-RING

15. Use a special tool to remove the check valve assembly, located inside the cylinder shell. 16. Remove and discard the pilot piston assembly, located inside the cylinder 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. 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. Clean all parts in solvent and dry with compressed air.

Inspect Inspect the parts of the cab tilt cylinder for damage, rust, or wear. Carefully inspect the rod surface for dents and scratches. Make sure that the internal stroke surface of the cylinder shell and grooves for the seals do not show any nicks, scratches, or other damage. Repair or replace parts as needed.

Figure 18. Cab Tilt Cylinder

16


0100 YRM 1390

Assemble NOTE: Make sure that all parts are clean before assembly. NOTE: Always use new O-rings, sleeve, and U-cup. Lubricate all parts with clean hydraulic oil. 1. Install the new pilot piston assembly, located inside the cylinder shell. 2. Use a special tool to install the check valve assembly into the cylinder shell and tighten to 40 to 45 N•m (30 to 33 lbf ft). 3. Install a new O-ring and U-cup to the gland. 4. Install a new O-ring and sleeve on the piston. 5. Install a new O-ring on the piston rod. 6. Assemble the gland on the piston rod. 7. Install the end of stroke ring (9,Figure 18) on the piston rod. 8. Install the piston on the piston rod. 9. Install the shaft retaining ring (10,Figure 18) that retains the piston to the piston rod.

CAUTION Be careful not to damage the finished surface of the piston rod when installing the piston rod assembly into the cylinder shell in a horizontal position. 10. Lubricate the cylinder shell bore with clean hydraulic oil. Place the piston rod assembly into the cylinder shell. 11. Press the gland inside the cylinder shell until the groove for the gland retaining ring is free. 12. Install the gland retaining ring. 13. Pressurize the push port until the extended rod locks the gland into the gland retaining ring.

Cab Tilt System 2. Install the cab tilt cylinder to the pin of the cab tilt frame and the pin of the frame. 3. Install the snap ring to the pin that retains the cab tilt cylinder to the cab tilt frame. 4. Install the snap ring to retain the cab tilt cylinder to the frame. 5. Remove the caps and plugs from the cab tilt cylinder and hydraulic hoses and connect the two hydraulic hoses to the cab tilt cylinder. NOTE: If the oil level is low, the cab will not tilt/raise completely. Refer to the section Oil Filling for Cab Tilt System. 6. Check the hydraulic oil level. Refer to the section Oil Filling for Cab Tilt System. 7. Completely tilt/raise the cab. Refer to the section Raising and Lowering Cab. 8. Remove the wooden blocks between the frame and the cab. 9. Lower the cab until it is in the fully lowered and latched position. 10. Operate the cab tilt system to check for leaks and correct operation.

LATCH Remove 1. Tilt/raise the cab until it locks in the partially open position. Refer to the section Raising and Lowering Cab. 2. Disconnect the hydraulic hose from the front latch and plug the hose end. See Figure 19. 3. Remove the T-adapter from the rear latch and place a cap at the T-adapter. See Figure 19. 4. Remove the eight capscrews and nuts, and 16 washers that retain the front and rear latches to the frame. See Figure 19.

14. Install the wiper.

Install 1. Position the cab tilt cylinder inside the frame with the hydraulic hose fittings positioned to the underside.

17


Cab Tilt System

0100 YRM 1390

Install 1. Position the front and rear latches on the frame and install the eight capscrews and nuts, and 16 washers to retain the front and rear latches to the frame. See Figure 19. 2. Remove the cap at the T-adapter and install the T-adapter to the rear latch. See Figure 19.

3. Remove the plug from the hose end and connect the hydraulic hose to the front latch. See Figure 19. 4. If required, remove the fill cap of the hand pump and fill the reservoir with hydraulic oil. Refer to the section Oil Filling for Cab Tilt System.

A. 180 DEGREES TURNED 1. 2. 3. 4.

FRONT LATCH REAR LATCH FRAME HYDRAULIC HOSE

5. 6. 7. 8.

CAPSCREW WASHER NUT T-ADAPTER

Figure 19. Latch

18


0100 YRM 1390

Brake and Inching Pedals

5. Lower the cab until it is in the fully lowered and latched position. Refer to the section Raising and Lowering Cab. Check the latches for correct operation.

Brake and Inching Pedals REMOVE 1. Remove the split pin and washer from the rod, located behind the inching pedal.

8. Check if adjustments to the inching and brake pedals are required, and adjust as needed. Refer to the sections Brake Pedal Adjustment and Inching Pedal Adjustment.

2. Disconnect the rod from the inching pedal.

BRAKE PEDAL ADJUSTMENT

3. Remove the two capscrews, washers, and nuts that retain the inching pedal to the bracket at the floor of the cab. 4. Remove the two capscrews, washers, and nuts that retain the brake pedal to the bracket at the floor of the cab.

Dry Brake 1. Adjust the capscrew (3,Figure 20) behind the pedal on the brake pedal assembly so that there is 5 to 10 mm (0.2 to 0.4 in.) travel until the brake lights come ON.

5. Remove the inching and brake pedal assembly.

Wet Brake

6. Separate the inching pedal from the brake pedal and remove the three shims.

1. Adjust the capscrew (3,Figure 20) behind the pedal on the brake pedal assembly so that the roller has contact with the capscrew on the valve and there is no free travel.

7. Remove the two bearings from the inching pedal.

INSTALL 1. Install the two bearings on the inching pedal. NOTE: Make sure the three shims are positioned correctly. 2. Position the three shims and install the inching pedal to the brake pedal. 3. Position the inching and brake pedal assembly between the brackets at the floor of the cab. 4. Install the two capscrews, washers, and nuts that retain the brake pedal to the bracket at the floor of the cab. 5. Install the two capscrews, washers, and nuts that retain the inching pedal to the bracket, at the floor of the cab. 6. Connect the rod to the inching pedal. 7. Install the washer and split pin to the rod, located behind the inching pedal.

1. BRAKE PEDAL 2. INCHING PEDAL 3. ADJUSTMENT BOLT FOR BRAKE PEDAL ASSEMBLY 4. ADJUSTMENT BOLT FOR INCHING/BRAKE PEDAL COUPLING 5. ADJUSTMENT BOLT FOR INCHING PEDAL ASSEMBLY Figure 20. Brake Pedal System

19


Brake and Inching Pedals

INCHING PEDAL ADJUSTMENT NOTE: Inching pedal adjustment influences inching sensor adjustment and inching sensor calibration. After the inching pedal has been adjusted, always correct inching sensor adjustment and inching sensor calibration. Incorrect inching sensor calibration triggers fault codes during operation. 1. Adjust the bolt (5,Figure 20) behind the inching pedal on the inching pedal assembly to the same plane with the brake pedal adjustment bolt (3,Figure 20). 2. Adjust the adjustment bolt for the inching/brake pedal coupling (4,Figure 20) so that the inching pedal has no free play. Both pedals should move together when applying the inching pedal. An additional spring installed under the inching pedal allows for flexibility when adjusting the brake/ inching overlap. See Figure 20 and Figure 21.

INCHING PEDAL SENSOR ADJUSTMENT USING DANA DASHBOARD SOFTWARE NOTE: When the inching pedal is not activated (pedal up position), the analog output of the inching pedal sensor should be between 600 and 700 mV.

0100 YRM 1390 NOTE: A slight preload of the potentiometer arm is required to achieve the output voltage for the inching pedal up position. Use the Dana Dashboard software to check the output voltage. 1. Connect a laptop computer to the diagnostic plug in the side console. 2. Turn the key switch to the ON position. 3. Select "Inching Pedal Calibration Mode". 4. Make sure the analog input of the inching pedal sensor is between 600 and 700 mV. 5. If the analog input is not within specifications, proceed as follows: a. Tilt/raise the cab until the latch locks in the partial open position. Refer to the section Raising and Lowering Cab. b. Loosen the two inching pedal sensor mounting capscrews. See Figure 22. c. Rotate the inching pedal sensor in the slotted holes underneath the inching pedal until the output voltage of the released (up position) inching pedal is between 600 and 700 mV.

1. SENSOR MOUNTING CAPSCREW 2. INCHING PEDAL SENSOR Figure 22. Sensor Adjustment

Figure 21. Brake Inching Pedal Adjustment

20


0100 YRM 1390 d. Tighten the two sensor-mounting capscrews and make sure the output voltage of the inching pedal sensor is still between 600 and 700 mV, with the inching pedal in the up position. e. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab. 6. Turn the key switch to the OFF position.

Brake and Inching Pedals

INCHING PEDAL SENSOR ADJUSTMENT USING THE APC200 DISPLAY NOTE: This procedure does not require a laptop. NOTE: Before calibrating the inching pedal sensor, the inching pedal must be adjusted correctly. See the section Brake Pedal Adjustment. 1. Press and hold the "S" button, and turn the key switch to the ON position. During the first 15 seconds, the display will show:

7. Disconnect the laptop computer from the diagnostic plug.

INCHING PEDAL SENSOR CALIBRATION PROCEDURE USING DANA DASHBOARD SOFTWARE 1. Make sure the pedals and inching sensor have been correctly adjusted.

2. Release the "S" button after 15 seconds when the display shows:

2. Connect a laptop computer to the diagnostic plug in the side console. 3. Turn the key switch to the ON position. 4. Use the "Automatic Calibration" mode of the Dana Dashboard software.

3. Push the "M" button until the APC200 display shows the analog input:

5. Select the "Inching Pedal Calibration" mode of the Dana Dashboard software and follow the instructions. 6. The following two points must be calibrated while the engine is running: •

Fully released pedal (600- 700 mV)

•

Fully depressed pedal (2500-4000 mV)

7. Check the inching percentage of the transmission by using the Dana Dashboard software. When the pedal is released, the inching percentage should be at 0%. If the value deviates from 0%, the "Inching Pedal Calibration" process must be repeated. 8. Turn the key switch to the OFF position. 9. Disconnect the laptop computer from the diagnostic plug.

4. Push the "S" button three times. The display will show 0.11, 1.28, 2.29, and a value. Pushing the "S" button one more time changes the display to 3.47. Releasing the "S" button shows the value in Ohms for the inching pedal sensor (for instance, "0.652"):

NOTE: The voltage reading of the inching pedal sensor will be shown after a 1-2 second delay. NOTE: The actual reading on the APC200 display must be between 0.600 and 0.700, which represents 600 to 700mV.

21


Brake and Inching Pedals

0100 YRM 1390

5. Check the voltage reading of the inching pedal sensor. The reading must be between 0.600 and 0.700. 6. If the reading is not within range, adjust the inching pedal sensor until the reading is within specifications. 7. Turn the key switch to the OFF position to leave the APC200 test function group.

6. Fully depress the inching pedal and push the "S" button again. 7. When the calibration has been completed, the APC200 display will show:

INCHING PEDAL SENSOR CALIBRATION PROCEDURE USING THE APC200 DISPLAY NOTE: This procedure does not require a laptop. 1. Press and hold the "S" button, and turn the key switch to the ON position. During the first 15 seconds, the display will show:

2. Release the "S" button after 15 seconds when the display shows:

NOTE: Calibration procedure must be repeated if the ignition is turned back ON too early. 8. Turn the key switch to the OFF position to save the calibration settings. Observe the APC200 display and wait until all segments no longer light up. When the display remains OFF, new calibration has been entered into the APC200 memory. The new calibration settings will be lost if the key switch is turned back ON too early.

INCHING SENSOR ADJUSTMENT FOR TRUCKS WITH ZF TRANSMISSION

3. Push the "M" button several times until the APC200 display shows:

1. Connect a laptop, loaded with Testman software, to the diagnostic connector which is located in the side console. 2. Select Analog Inputs in Testman. 3. Verify Inch Sensor 1 (AU1 [V]) voltage for the inching sensor is between 0.8-0.9V (800-900 mV). 4. If voltage is incorrect, proceed as follows:

4. Push the "S" button once to start the inching pedal sensor calibration. The APC200 display will show:

a. Raise the Cab until the latch locks in the partial open position. b. Loosen the two mounting bolts of the inching sensor. c. Rotate the sensor in the slotted holes until output voltage is between 0.8-0.9V (800-900 mV) in released pedal position.

5. Push the "S" button while in the pedal up position. The APC200 display will show:

22

d. Tighten the two mounting bolts and verify output voltage is still correct.


0100 YRM 1390

Accelerator Pedal and Sensor

INCHING PEDAL CALIBRATION FOR TRUCKS WITH ZF TRANSMISSION 1. Park truck on level ground and apply the park brake. 2. Make sure pedals and inch sensor have been correctly adjusted. 3. Verify the Forward/Reverse lever is in NEUTRAL. 4. Turn the ignition key in the OFF position. 5. Turn the transmission calibration switch in the side console to the ON position (flip the switch to the down position). 6. Be seated in the operator’s seat.

8. The LCD display shows: • tP_dn. Slowly press the inch pedal all the way down to the end position in 2 to 3 seconds and hold. 9. The LCD display shows: • tP_UP. Slowly release the inch pedal in 2 to 3 seconds to the completely released position. 10. When all values are within range, the LCD display shows: • tPSEt, indicating inch pedal calibration is finished. If inch pedal calibration is not successful, the LCD display shows a fault code. See Transmission 1300YRM1455, Description for rectification. 11. After calibration is finished, switch OFF ignition and turn the calibration switch OFF (flip the switch to the up position).

7. Turn the ignition key switch to the ON position but DO NOT start the truck. The inch pedal calibration mode is now active.

Accelerator Pedal and Sensor ACCELERATOR PEDAL

ACCELERATOR PEDAL SENSOR

Remove

Adjust

1. Remove the spring and capscrew on which the pedal pivots. See Figure 23.

1. Start the engine and verify that idle speed will raise after the pedal has been depressed between 6 and 10 mm (0.236 and 0.394 in.). See Dimension A in Figure 23.

2. Turn the pedal 90 degrees and maneuver the lower part of the pedal through the hole in the floorplate into the cab.

Install

2. If adjustment is incorrect, raise the cab until it rests in the partially open position. Refer to the section Raising and Lowering Cab.

1. Maneuver the lower part of the pedal from the cab interior through the hole in the floorplate.

3. Place a 5 mm (0.197 in.) spacer between the pedal and the rubber pedal bumper.

2. Grease and install the bushing and pedal pivot onto the capscrew. Position the end of the sensor connecting rod into the pedal and fit the assembly onto the mounting plate. Tighten the nut. See Figure 23.

4. Loosen the mounting screws of the pedal sensor and turn the sensor until engine speed is about to increase from idle.

3. Fit the spring and check the adjustment of the accelerator pedal sensor.

5. Tighten the mounting screws and remove the spacer between pedal and pedal bumper. Stop the engine.

23


Seat Assembly

0100 YRM 1390 Legend for Figure 23 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

DIMENSION A ACCELERATOR PEDAL ACCELERATOR PEDAL ADJUSTMENT ACCELERATOR PEDAL SENSOR MOUNTING SCREW CONNECTING ROD CAB FLOOR PLATE ACCELERATOR PEDAL STOP COUNTERCLOCKWISE SLOTTED HOLE

Figure 23. Accelerator Arrangement

Seat Assembly SEAT

5. Remove the seat. See Figure 24.

Remove

Install

NOTE: Use a lifting device for the removal of the seat.

NOTE: Use a lifting device to install the seat.

NOTE: The ground cable is attached with a capscrew at the right rear corner of the suspension. 1. Disconnect the battery ground cable. NOTE: There is one electrical connector on the mechanical seat. There are two electrical connectors on the air suspension seat. 2. Disconnect the electrical connector(s). 3. Turn the electrical plug counterclockwise and disconnect the electrical plug located at the instrument panel side console. NOTE: The seat must be positioned completely to the front to allow access to the two front capscrews inside the sliding system. The seat must be positioned completely to the rear to allow access to the two rear capscrews inside the sliding system. 4. Remove the four capscrews, washers, and nuts located above the sliding system that retain the seat to the seat suspension.

24

1. Position the seat onto the seat suspension. NOTE: The seat must be positioned completely to the front to allow access to the two front capscrews inside the sliding system. The seat must be positioned completely to the rear to allow access to the two rear capscrews inside the sliding system. 2. Install the four capscrews, washers, and nuts located above the sliding system that retain the seat to the seat suspension. 3. Connect the electrical plug located at the instrument panel side console. NOTE: There is one electrical connector on the mechanical seat. There are two electrical connectors on the air suspension seat. 4. Connect the connector(s). NOTE: The ground cable is attached with the capscrew at the right rear corner of the suspension. 5. Connect the battery ground cable.


0100 YRM 1390

Seat Assembly 7. Lift the seat cushion until the guide block becomes detached. 8. Rotate the seat cushion clockwise. 9. Lift the cushion upward to detach the front of the seat cushion. 10. Grip the seat cushion at about the halfway point toward the rear of the cushion. NOTE: Increase the lifting force until the rear of the cushion detaches. 11. Lift the seat cushion from right to left. 12. Cut the cable tie securing the connector block to the seat cushion. 13. Disconnect the spade connectors from the connector block. 14. Remove and discard the seat cushion.

Install 1. 2. 3. 4.

SEAT CUSHION BACK CUSHION BOOT SEAT SUSPENSION Figure 24. Seat

SEAT CUSHION Refer to Figure 24 for the following procedures.

Remove 1. Slide the seat forward. 2. Adjust the steering wheel upward to its maximum height position.

1. Feed the cables of the new cushion through the hole in the armrest bracket. 2. Connect the spade connectors to the connector block. 3. Use a cable tie to attach the connector block to the seat cushion. 4. Locate the rear tab on the underside of the seat cushion over the rectangular hole in the metal pan. 5. Apply downward pressure over the tab. 6. Slide the cushion around until the tab is partially located in the rectangular hole.

3. Remove and discard the screw from the front right side.

7. With the cushion angled at approximately 35° to 45°, apply a sharp blow to the front of the seat cushion. The tab will enter the hole with an audible click.

4. Remove and discard the three clips from the cushion front.

8. Pull the cushion upward to make sure the cushion is correctly locked into position.

5. Slide the seat fully backward.

9. Install three new clips to the cushion front.

6. Grip the seat cushion on the front right corner.

10. Install a new screw to the front right side.

25


Seat Assembly

BACK CUSHION Refer to Figure 24 for the following procedures.

Remove 1. Slide the seat assembly to the maximum forward position. 2. If equipped, remove the headrest out of the two guides. 3. Remove the two guides, located at the top side of the back cushion, that retain the back cushion to the back pan. 4. Remove the two screws that retain the back cushion to the back pan. 5. Remove the back cushion.

Install

0100 YRM 1390 1. Remove the seat. Refer to the section SeatRemove. 2. Remove the four capscrews that retain the seat suspension to the cab floor. 3. Remove the seat suspension from the cab floor. 4. Position the new seat suspension onto the cab floor. 5. Install the four capscrews that retain the seat suspension to the cab floor. 6. Install the seat. Refer to the section SeatInstall.

BOOT REPLACEMENT Refer to Figure 24 for the following procedures. 1. Remove the seat. Refer to the section SeatRemove.

1. Position the back cushion.

2. Use a small pry bar to remove the 22 plastic plugs that retain the boot to the seat suspension.

2. Install the two screws that retain the back cushion to the back pan.

3. Remove the boot.

3. Install the two guides, located at the top side of the back cushion, that retain the back cushion to the back pan. 4. If equipped, install the headrest in the two guides. 5. Reposition the seat assembly to the correct operating position.

SEAT SUSPENSION REPLACEMENT Refer to Figure 24 for the following procedures.

26

4. Install the new boot. 5. Install the 22 plastic plugs that retain the boot to the seat suspension. 6. Install the seat. Refer to the section SeatInstall.


0100 YRM 1390

Seat Assembly

SUSPENSION SCISSOR AND SHOCK ABSORBER Remove NOTE: Replacement instructions for the air seat and mechanical seat are similar. STEP 1. Remove the seat from the suspension. Refer to the section SeatRemove. STEP 2. Remove the seat suspension from the cab. Refer to the section Seat Suspension Replacement. STEP 3. Remove the boot. Refer to the section Boot Replacement. STEP 4. Position the suspension on a workbench with the lower housing facing upward. STEP 5. For air seats remove the retaining screws for the air bladder.

STEP 6. Using a 9/16� Allen wrench, remove the lower housing pivot shaft nut.

27


Seat Assembly STEP 7. Remove the pivot shaft.

STEP 8. For mechanical seats: Lift the lower housing and place the suspension scissor in the highest raised position.

STEP 9. For mechanical seats: Lift the rear of the lower housing while sliding the lower housing forward to disengage the height adjustment rollers from the roller channels of the lower housing.

28

0100 YRM 1390


0100 YRM 1390

Seat Assembly

STEP 10. Rotate the rear of the lower housing clockwise to disengage the front suspension scissor rollers from the roller channels of the lower housing.

STEP 11. Remove the lower housing from the suspension. STEP 12. For mechanical seats: Remove the tether belts from the suspension scissor lower pivot tubes.

STEP 13. Using a 9/16� Allen wrench, remove the upper housing pivot shaft nut.

29


Seat Assembly STEP 14. Remove the pivot shaft. STEP 15. Remove the weight indicator tension spring from the suspension scissor to avoid damage to the weight indicator tension spring.

STEP 16. Lift the suspension scissor while sliding the suspension scissor forward to disengage the front suspension scissor rollers from the roller channels of the upper housing.

STEP 17. For both types: Remove the suspension scissor from the upper housing and place the suspension scissor on one side. For air seats: Remove the bladder.

STEP 18. Remove the tether belts from the suspension scissor upper pivot tubes.

30

0100 YRM 1390


0100 YRM 1390

Seat Assembly

STEP 19. Remove the rear bearing tubes from the suspension scissor.

STEP 20. Remove the front suspension scissor rollers from the suspension scissor.

STEP 21. Remove the push-on PAL nut that retains the upper shock absorber bearing to the suspension scissor.

31


Seat Assembly STEP 22. Slide the shock absorber and the shock absorber bearings out of the suspension scissor.

Install STEP 1. Install a new upper shock absorber bearing onto the suspension scissor and slide the shock absorber onto the suspension scissor.

STEP 2. Install the new lower shock absorber bearing into the shock absorber and onto the suspension scissor.

32

0100 YRM 1390


0100 YRM 1390

Seat Assembly

STEP 3. Install a new push-on PAL nut to retain the shock absorber to the suspension scissor.

STEP 4. Use a hollow punch and a mallet to push the pushon PAL nut until the push-on PAL nut contacts the upper shock absorber bearing.

STEP 5. Install the front suspension scissor rollers onto the suspension scissor and apply MoS2 grease on the rollers.

33


Seat Assembly

0100 YRM 1390

STEP 6. Install the rear bearing tubes to the suspension scissor.

STEP 7. For mechanical seats: Place the tether belts over the suspension scissor upper pivot tubes. For air seats: Install the bladder.

CAUTION Make sure the front suspension scissor rollers are positioned completely within the roller channels or damage may occur. STEP 8. Position the front suspension scissor rollers into the roller channels of the upper housing and align the bearing shaft tubes of the suspension scissor with the upper housing holes.

34


0100 YRM 1390

Seat Assembly

STEP 9. Install the weight indicator tension spring on the suspension scissor.

NOTE: The pivot shaft must be aligned so the flat surface of the pivot shaft head faces the upper housing. This alignment prevents the pivot shaft from rotating when the pivot shaft is installed. STEP 10. Apply a coat of MoS2 grease on the pivot shaft and install the pivot shaft. Make sure the flat surface of the pivot shaft head faces the upper housing.

STEP 11. For mechanical seats: Install the pivot shaft nut and tighten to 38 to 56 N•m (28 to 41 lbf ft).

35


Seat Assembly STEP 12. For mechanical seats: Position the height adjustment mechanism so the suspension scissor is in the lowest position.

STEP 13. For mechanical seats: Place the tether belts over the suspension scissor lower pivot tubes.

STEP 14. Lift the suspension scissor to the highest raised position. STEP 15. Use a wooden block [approximate length 110 mm (4.33 in.)] to keep the suspension scissor in the highest raised position.

36

0100 YRM 1390


0100 YRM 1390

Seat Assembly

CAUTION The pivot shaft must be aligned so the flat surface of the pivot shaft head faces the upper housing. This alignment prevents the pivot shaft from rotating when the pivot shaft is installed. STEP 16. Rotate the lower housing counterclockwise and position the front suspension scissor rollers of the suspension scissor into the roller channels of the lower housing.

STEP 17. Remove the wooden block and place the height adjustment rollers in the roller channels of the lower housing. Place the wooden block back into position.

STEP 18. Align the bearing shaft tubes of the suspension scissor with the lower housing holes. NOTE: The pivot shaft must be aligned so the flat surface of the pivot shaft head faces the lower housing. This alignment prevents the pivot shaft from rotating when the pivot shaft is installed.

37


Seat Assembly STEP 19. Apply a coat of MoS2 grease on the pivot shaft and install the pivot shaft. Make sure the flat surface of the pivot shaft head faces the lower housing.

STEP 20. Install the pivot shaft nut and tighten to 38 to 56 N•m (28 to 41 lbf ft).

STEP 21. Remove the wooden block from the suspension. STEP 22. For air seats: Install the retaining screws for the air bladder.

STEP 23. Install the boot. Refer to the section Boot Replacement.

38

0100 YRM 1390


0100 YRM 1390

Seat Assembly

STEP 24. Install the seat suspension in the cab. Refer to the section Seat Suspension Replacement. STEP 25. Install the seat. Refer to the section SeatInstall.

COMPRESSOR Remove STEP 1. Remove the seat from the suspension. Refer to the section SeatRemove. STEP 2. Remove the seat suspension from the cab. Refer to the section Seat Suspension Replacement. STEP 3. Remove the boot. Refer to the section Boot Replacement. STEP 4. Using a 1/16" Allen wrench, remove the air control knob.

STEP 5. Remove the nut and lockwasher that retain the air valve to the upper housing and withdraw the air valve into the suspension.

39


Seat Assembly STEP 6. Using a 9/16" Allen wrench, remove the upper housing pivot shaft nut.

STEP 7. Remove the pivot shaft.

STEP 8. Lift the rear of the upper housing while sliding the housing forward to disengage the front rollers from the roller channels and remove the upper housing.

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0100 YRM 1390


0100 YRM 1390

Seat Assembly

STEP 9. Use a wooden block (approximate dimensions of 45 x 25 x 100 mm (1.77 x 0.98 x 3.94 in.) to chock the front roller bar of the suspension.

STEP 10. Deflate the suspension to remove all air in the pneumatic system.

STEP 11. Remove the tie wrap that retains the air valve electrical wire harness and tube to the suspension.

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Seat Assembly STEP 12. Disconnect the orange electrical wire connector from the air valve body.

STEP 13. Disconnect the compressor black electrical wire connector from the suspension harness at the rear of the compressor assembly.

STEP 14. Unscrew (counterclockwise) the plastic tube retaining nut from the output port of the compressor. Remove the nut and O-ring from the tube and discard.

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0100 YRM 1390


0100 YRM 1390

Seat Assembly

STEP 15. Remove and retain the two screws that retain the compressor and bracket to the suspension scissor. Remove the compressor and bracket from the suspension.

STEP 16. Note the orientation of the compressor in the bracket. Remove the compressor from the bracket.

Install STEP 1. Place the new compressor into the bracket as shown.

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Seat Assembly STEP 2. Position the compressor and bracket into the suspension and make sure the black electrical wire is routed toward the rear of the seat and the orange electrical wire is routed forward toward the air valve.

STEP 3. Align the compressor bracket with the suspension mounting holes and install the two retaining screws. Remove the protective cap from the compressor.

44

0100 YRM 1390


0100 YRM 1390

Seat Assembly

STEP 4. Trim the tube that enters the compressor port past the grooved/necked area created by the old O-ring. If the tube is damaged or kinked, replace the entire length of the tube and use the original tube as a guide.

STEP 5. Install a new plastic nut and O-ring on the tube as shown.

CAUTION DO NOT crossthread or overtighten the plastic nut, as damage can occur. STEP 6. Insert the tube into the compressor port and slide the plastic nut and O-ring up to the compressor and tighten (clockwise) the nut. Make sure while tightening the nut that the tube remains fully inserted into the compressor port. Tighten the plastic nut until the face of the nut is flush with the body of the compressor as shown.

45


Seat Assembly STEP 7. Connect the compressor black electrical wire connector to the black electrical wire connector of the suspension harness.

STEP 8. Route the orange electrical wire to the air valve and attach it to the air valve. Make sure the wires are routed without knots or kinks.

STEP 9. Install a new tie wrap to retain the electrical wire harness and tube to the suspension.

46

0100 YRM 1390


0100 YRM 1390

Seat Assembly

STEP 10. Power up the suspension and inflate the system for approximately 45 seconds. Use a leak detection spray or weak soapy water to check for leaks from the air system. Remove the wooden chock block from the suspension.

STEP 11. Position the front suspension scissor rollers into the roller channels of the upper housing and lower the upper housing onto the rear bearing shaft tubes of the suspension scissor.

STEP 12. Apply a coat of MoS2 grease on the pivot shaft and install the pivot shaft.

47


Seat Assembly STEP 13. Install the pivot shaft nut and tighten to 38 to 56 N•m (28 to 41 lbf ft).

STEP 14. Insert the air valve through the upper housing. Install the lockwasher and nut. Tighten the nut to 10 to 18 N•m (88 to 159 lbf in).

STEP 15. Using a 1/16" Allen wrench, install the air control knob.

STEP 16. Install the boot. Refer to the section Boot Replacement. STEP 17. Install the seat suspension in the cab. Refer to the section Seat Suspension Replacement.

48

0100 YRM 1390


0100 YRM 1390

Power Assist Armrest

STEP 18. Install the seat on the suspension. Refer to the section SeatInstall.

Power Assist Armrest RELEASE CABLE Remove 1. Raise the power assist armrest. 2. Loosen the two adjustment nuts that retain the cable to the armrest. See Figure 25. 3. Disconnect the cable from the armrest (1,Figure 25), and slide the cable out of the slot in the armrest. 4. Disconnect the cable at the rod end of the gas spring and slide the cable out of the slot. 5. Remove the cable from the power assist armrest through the front side of the power assist armrest.

Install 1. Install the cable through the power assist armrest from the front side of the power assist armrest. 2. Connect the cable at the rod end of the gas spring. 3. Connect the cable to the armrest (1,Figure 25). 4. Adjust the cable length with the two nuts to obtain a free lever movement of 1.5 to 2.0 mm before the gas spring will unlock. 5. Tighten the two nuts that retain the cable to the armrest (1,Figure 25). 6. Lower the power assist armrest.

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

LEVER ROD END LOCK NUT MOUNTING CAPSCREW ARMREST CABLE GAS SPRING WASHER ARMREST FRAME NUT Figure 25. Power Assist Armrest

49


Power Assist Armrest

GAS SPRING Remove 1. Raise the power assist armrest, and make sure the gas spring has reached its maximum extended length.

0100 YRM 1390 5. Completely remove the joystick from the power assist armrest. 6. Tag and disconnect the four electrical connectors from the joystick.

Install

2. Disconnect the cable from the rod end of the gas spring.

1. Connect the four electrical connectors to the joystick.

3. Support the power assist armrest and remove the bottom-mounting capscrew and washer that retain the gas spring rod to the armrest frame.

2. Position the joystick in the power assist armrest with the electric cable pointing to the right.

4. Manually lower the power assist armrest. 5. Remove the top-mounting capscrew and washer that retain the gas spring to the armrest frame. 6. Remove the gas spring.

3. Turn the joystick 90° clockwise. 4. Reroute the electrical cables and electrical connectors inside the power assist armrest. 5. Install the four joystick screws to retain the joystick to the power assist armrest.

1. Make sure that the gas spring has reached its maximum extended length.

6. Place the cover with the joystick label in position on the power assist armrest. Install the four screws to retain the cover to the power assist armrest.

2. Position the gas spring.

7. Make sure the joystick functions properly.

Install

3. Install the top-mounting capscrew and washer to retain the gas spring to the armrest frame. 4. Manually raise the power assist armrest. 5. Support the power assist armrest and install the bottom-mounting capscrew and washer to retain the gas spring to the armrest frame. 6. Connect and adjust the cable to the rod end of the gas spring.

JOYSTICK Remove 1. Remove the four screws that retain the cover with the joystick label to the power assist armrest. See Figure 26. 2. Remove the cover from the power assist armrest. 3. Remove the four joystick screws that retain the joystick to the power assist armrest. 4. Partially raise the joystick until it is possible to turn the joystick 90° counterclockwise with the electric cable inside the power assist armrest.

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1. 2. 3. 4. 5.

COVER SCREWS COVER JOYSTICK SCREWS JOYSTICK JOYSTICK ROTATION Figure 26. Joystick Removal


0100 YRM 1390

ELECTRICAL LEVERS NOTE: For lift trucks with hydraulic control levers, the remove and replace instructions are shown in the model specific Hydraulic System YRM.

Power Assist Armrest Remove the electrical connector from the failed switch and connect it to the replacement switch. Install the switch by pressing it into the opening in the panel until the holding clips of the switch are seated. 1. Remove six screws that retain the bottom plate and lower the plate.

Remove 1. Remove the four screws that retain the cover with the levers to the power assist armrest. See Figure 27. NOTE: Most connectors are equipped with symbol labels for identification. 2. If necessary, tag the electrical connector(s) for identification. 3. Disconnect the electrical connector(s) from the lever(s). 4. Remove the two screws that retain the lever to the cover.

2. Press the holding clips on the switches and push the rocker switch out of the armrest. 3. Disconnect the electrical connector.

Install 1. Connect the electrical connector to the rocker switch. 2. Install the switch by pressing it into the opening of the panel until the holding clips of switch are seated. 3. Install the bottom plate using six retaining screws.

5. Remove the lever from the underside of the cover.

Install 1. Install the lever from the underside to the cover. 2. Install the two screws to retain the lever to the cover. 3. Connect the electrical connector(s) to the lever(s). 4. Install the four screws that retain the cover with the levers to the power assist armrest. 5. Calibrate the lever. See the model specific Hydraulic System YRM.

ARMREST ROCKER SWITCHES Remove NOTE: If a failed switch is to be replaced by a new one, use a screw driver to force the failed switch out of the panel. The switch may suffer additional damage beyond repair.

1. 2. 3. 4.

COVER COVER SCREWS LEVER SCREWS LEVER Figure 27. Levers Removal

51


Instrument Panel

0100 YRM 1390

ARMREST TOP COVER

Install

Remove

1. Position the armrest top cover on the armrest plate.

1. Remove the joystick or lever cover. Refer to the section JoystickRemove or the section Electrical LeversRemove.

2. Install the eight screws to retain the armrest top cover to the armrest plate.

2. Remove all rocker switches. Refer to the section Armrest Rocker SwitchesRemove.

3. Install the six screws at the underside of the armrest frame to retain the armrest top cover to the armrest frame.

3. Remove the six screws at the underside of the armrest frame that retain the armrest top cover to the armrest frame.

4. Install the rocker switches. Refer to the section Armrest Rocker SwitchesInstall.

4. Remove the eight screws that retain the armrest top cover to the armrest plate.

5. Install the joystick or lever cover. Refer to the section JoystickInstall or the section Electrical LeversInstall.

5. Remove the armrest top cover from the armrest plate.

Instrument Panel KEY SWITCH Remove

3. Position the key switch correctly into the hole in the instrument panel top console.

1. Switch the key to the OFF position.

4. Install the nut to retain the key switch to the instrument panel top console.

2. Remove the key from the key switch.

5. Make sure that the key switch functions correctly.

3. Remove the nut that retains the key switch to the instrument panel top console.

6. Position the fuse panel cover to the right side of the instrument panel and install the four retaining screws. See Figure 28.

4. Remove the four screws that retain the fuse panel cover at the right side of the instrument panel and remove the cover to gain access to the underside of the instrument panel. See Figure 30. 5. Remove the key switch by sliding the key switch downward out of the hole to the inside of the instrument panel top console. 6. Disconnect the electrical connector from the key switch.

Install 1. Connect the electrical connector to the key switch. 2. Install the key switch by sliding the key switch upward into the hole to the outside of the instrument panel top console.

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12V POWER SOCKET Remove 1. Remove the four screws that retain the fuse panel cover to the right side of the instrument panel and remove the cover to gain access to the underside of the instrument panel. See Figure 28. 2. Disconnect the electrical connector from the 12V power socket. 3. Push the 12V power socket through the instrument panel top console from the inside to the outside.


0100 YRM 1390

Install 1. Install the 12V power socket to the instrument panel top console from the outside to the inside until the 12V power socket is secured to the instrument panel top console. See Figure 29.

Instrument Panel 5. Position the fuse panel cover to the right side of the instrument panel and install the four retaining screws. See Figure 28.

2. Connect the electrical connector to the 12V power socket. 3. Position the fuse panel cover to the right side of the instrument panel and install the four retaining screws.

ELECTRIC-OPERATED HEAT CONTROL AND AIR RECIRCULATION CONTROL (AIRCO ONLY) Remove 1. Remove the four screws that retain the fuse panel cover to the right side of the instrument panel and remove the cover to gain access to the underside of the instrument panel. See Figure 28. 2. Disconnect the electrical connector from the potentiometer at the inside of the instrument panel box. 3. Remove the air recirculation knob at the instrument panel top console. See Figure 29. 4. Remove the nut that retains the potentiometer to the instrument panel top console. 5. Remove the potentiometer by sliding it downward out of the hole to the inside of the instrument panel top console.

Install 1. Install the potentiometer by sliding it upward into the hole to the inside of the instrument panel top console. 2. Install the nut that retains the potentiometer to the instrument panel top console. 3. Install the air recirculation knob at the instrument panel top console. See Figure 29. 4. Connect the electrical connector to the potentiometer at the inside of the instrument panel box.

1. SCREWS

2. COVER

Figure 28. Fuse Panel and Cover Location

CABLE-OPERATED HEATER CONTROL (HEATER ONLY) Remove 1. Remove the four screws that retain the fuse panel cover to the right side of the instrument panel and remove the cover to gain access to the underside of the instrument panel. See Figure 28. 2. Remove the heat control knob at the instrument panel top console. See Figure 29. 3. Remove the nut that retains the heat rotary control assembly to the instrument panel top console. 4. Remove the heat rotary control assembly from the underside of the instrument panel top console. 5. Remove the cable clip and unlatch the inner cable from the rotary control.

53


Instrument Panel

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

0100 YRM 1390

KEY SWITCH POWER SOCKET 12V KEY SWITCH COVER FAN SPEED KNOB HEAT CONTROL KNOB AIR RECIRCULATION KNOB (OPTIONAL) AIR CONDITIONING SWITCH (OPTIONAL)

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

HEATER SWITCH COVER ROCKER SWITCHES PARKING BRAKE SWITCH COVER PARKING BRAKE SWITCH INSTRUMENT PANEL TOP CONSOLE INDICATOR DISPLAY

Figure 29. Switch Locations

Install 1. Pull the inner cable to make sure the water valve has reached its end position. 2. Turn the rotary control to the extended (full hot) position. 3. Position and latch the inner cable to the heat rotary control and install the cable clip. 4. Install the heat rotary control assembly from the underside of the instrument panel top console. 5. Install the nut to retain the heat rotary control assembly to the instrument panel top console. 6. Install the heat control knob at the instrument panel top console.

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7. Position the fuse panel cover to the right side of the instrument panel and install the four retaining screws. See Figure 28.

AIR CONDITIONING SWITCH REPLACEMENT 1. Remove the four screws that retain the fuse panel cover to the right side of the instrument panel and remove the cover to gain access to the underside of the instrument panel. See Figure 28. 2. Tag and disconnect the three electrical wires from the air conditioning switch. 3. Remove the air conditioning switch by pressing the two clips together and pushing the air conditioning switch from the inside to the outside. See Figure 29.


0100 YRM 1390 4. Install the new air conditioning switch by pushing the air conditioning switch from the outside to the inside until the two clips are latched. See Figure 29. 5. Connect the three wires to the air conditioning switch. 6. Position the fuse panel cover to the right side of the instrument panel and install the four retaining screws. See Figure 28.

INSTRUMENT PANEL ROCKER SWITCHES REPLACEMENT 1. Remove the four screws that retain the fuse panel cover to the right side of the instrument panel and remove the cover to gain access to the underside of the instrument panel. See Figure 28. NOTE: Most connectors are equipped with symbol labels for identification. 2. If necessary, tag the connector for identification. 3. Disconnect the connector from the rocker switch by pressing the clip at the connector. 4. Remove the rocker switch by pressing the two clips together and pushing the rocker switch from the inside to the outside. See Figure 29. 5. Install the new rocker switch by pushing the rocker switch from the outside to the inside until the two clips are latched. See Figure 29. 6. Connect the connector to the rocker switch. 7. Position the fuse panel cover to the right side of the instrument panel and install the four retaining screws. See Figure 28.

PARKING BRAKE SWITCH Remove 1. Remove the four screws that retain the parking brake switch cover to the instrument panel top console and remove the cover. See Figure 29. 2. Remove the tie wrap that connects the top and bottom rubber boots to each other, which together cover the electrical connector.

Instrument Panel 3. Remove the bottom rubber boot from the electrical connector to gain access to the electrical connector. 4. Disconnect the electrical connector by turning the clip to one side. 5. Remove the nut that retains the parking brake switch to the parking brake switch cover. 6. Remove the parking brake switch from the parking brake switch cover.

Install 1. Position the parking brake switch in the parking brake switch cover. 2. Install the nut to retain the parking brake switch to the parking brake switch cover. 3. Connect the electrical connector to the parking brake switch until the clip is securely latched. 4. Install the bottom rubber boot over the electrical connector. 5. Place the top rubber boot over the bottom rubber boot and tighten using a tie wrap. 6. Make sure the parking brake switch functions correctly. 7. Position the parking brake switch cover to the instrument panel top console and install the four retaining screws.

INDICATOR DISPLAY REPLACEMENT 1. Remove the four screws that retain the fuse panel cover to the right side of the instrument panel and remove the cover to gain access to the underside of the instrument panel. See Figure 28. 2. Disconnect the electrical connector from the indicator display at the inside of the instrument panel box. 3. Remove the indicator display by pressing the two clips together and pushing the indicator display from the inside to the outside. See Figure 30.

55


Instrument Panel

0100 YRM 1390 3. Remove the parking brake switch cover and parking brake switch. Refer to the section Parking Brake SwitchRemove. 4. Disconnect the electrical connector to the instrument panel inside the instrument panel box. 5. Remove the five screws that retain the instrument panel top console to the cab, and remove the instrument panel top console.

Install 1. INDICATOR DISPLAY CLIP Figure 30. Indicator Display Removal 4. Install the new indicator display by pushing the indicator display from the outside to the inside until the two clips are latched. 5. Connect the electrical connector to the indicator display at the inside of the instrument panel box. 6. Position the fuse panel cover to the right side of the instrument panel and install the four retaining screws. See Figure 28.

1. Position the instrument panel top console to the cab and install the five retaining screws. 2. Connect the electrical connector to the instrument panel inside the instrument panel box. 3. Install the parking brake switch and cover. Refer to the section Parking Brake SwitchInstall. 4. Install the heater switch cover and switches. Refer to the section Electric-Operated Heat Control and Air Recirculation Control (Airco Only)Install and the section Air Conditioning Switch Replacement.

INSTRUMENT PANEL TOP CONSOLE

5. Install the key switch and cover. Refer to the section Key SwitchInstall.

Remove

6. Make sure the switches function correctly.

1. Remove the key switch cover and key switch. Refer to the section Key SwitchRemove. 2. Remove the heater switch cover and switches. See Figure 29. Refer to the section Electric-Operated Heat Control and Air Recirculation Control (Airco Only)Remove and the section Air Conditioning Switch Replacement.

56


0100 YRM 1390

Steering Wheel and Column Assembly

Steering Wheel and Column Assembly STEERING WHEEL AND HORN Remove

CAUTION To prevent electrical arcs when removing the cover, disconnect the battery ground cable. 1. Disconnect the battery ground cable. 2. Remove the horn button from the steering wheel. See Figure 31. 3. Disconnect the electrical wire from the horn switch to the horn button. 4. Remove the large nut and remove the steering wheel from the steering column.

CAUTION Use caution when removing the steering control unit or damage may occur. 5. Remove the four capscrews that retain the steering control unit to the cab. See Figure 32. 6. Place the steering control unit with the hydraulic hoses attached in the engine compartment. 7. Remove the two capscrews and nuts that retain the steering column to the cab floor. See Figure 33. 8. Lower the cab until it is in the fully lowered and latched position. Refer to the section Raising and Lowering Cab.

Install

9. Remove the two capscrews that retain the steering column to the bracket. See Figure 33.

1. Install the steering wheel and the large nut onto the steering column. See Figure 31. Tighten the nut to 35 to 45 N•m (26 to 33 lbf ft).

10. Remove the steering column. Push the grommet out of the hole and slide the connector through the hole in the cab floor.

2. Connect the electrical wire from the horn switch to the horn button.

Install

3. Install the horn button onto the steering wheel.

1. Slide the connector through the hole in the cab floor and push the grommet into the hole.

4. Connect the battery ground cable.

STEERING COLUMN ASSEMBLY Remove 1. Turn the battery disconnect switch to the OFF position. 2. Remove the screws that retain the lower left-hand and right-hand steering column covers to the steering column. See Figure 31.

2. Position the steering column to the cab floor and Install the two capscrews to retain the steering column to the bracket. See Figure 33. 3. Tilt/raise the cab until it locks in the partially open position. Refer to the section Raising and Lowering Cab. 4. Install the two capscrews and nuts to retain the steering column to the cab floor.

CAUTION

3. Tilt/raise the cab until it locks in the partially open position. Refer to the section Raising and Lowering Cab.

DO NOT force the steering control unit onto the steering column shaft, as damage can occur.

4. Disconnect the steering column electrical connector located under the cab. See the Cab, Remove section of the model specific Frame manual.

5. Place the steering control unit in position under the cab while aligning the steering column shaft with the slot in the steering control unit.

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Yale f876 gdp90dc lift truck (europe) service repair manual  
Yale f876 gdp90dc lift truck (europe) service repair manual  
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