Yale E878 Maintenance Manual Download

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TABLE OF CONTENTS

Description ................................................................................................................................................................1
Proc_Cal_001: Service Password Entry ...................................................................................................................4

When to Perform .................................................................................................................................................. 4
Why Perform .........................................................................................................................................................4
How to Perform .....................................................................................................................................................4

Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed ....................................................................... 5

Proc_Cal_003: Save and Exit ...................................................................................................................................8

When to Perform .................................................................................................................................................. 8
Why Perform .........................................................................................................................................................8
How to Perform .....................................................................................................................................................8

Proc_Cal_004: Lift Valve Output Threshold ........................................................................................................... 10

Proc_Cal_005: Lower Valve Output Threshold ...................................................................................................... 13

Proc_Cal_006: Tilt Back Valve Output Threshold .................................................................................................. 16

Proc_Cal_007: Tilt Forward Valve Output Threshold ............................................................................................. 19

Proc_Cal_008: Aux 1 Dir A Valve Output Threshold .............................................................................................. 22

Proc_Cal_009: Aux 1 Dir B Valve Output Threshold .............................................................................................. 25

Proc_Cal_010: Aux 2 Dir A Valve Output Threshold .............................................................................................. 28

Proc_Cal_011: Aux 2 Dir B Valve Output Threshold .............................................................................................. 31

Table of Contents

Summary of Contents for E878

Page 1: ...GDP155VX C878 D878 E878 GLC GDC60VX GLC GDC70VX GC GLC GDC135VX GC GLC GDC155VX C879 D879 E879 F879 GLP GDP80VX GLP GDP80VX9 GLP GDP90VX GLP GDP170VX GLP GDP175VX36 GLP GDP190VX A909 B909 GLC030 035VX...

Page 2: ...dic 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 maki...

Page 3: ...3 Calibration Order 13 Why Perform 13 How to Perform 13 Proc_Cal_006 Tilt Back Valve Output Threshold 16 When to Perform 16 Calibration Order 16 Why Perform 16 How to Perform 16 Proc_Cal_007 Tilt Forw...

Page 4: ...rm 42 Proc_Cal_016 Transmission Valve Calibration 45 Applicable System Option 45 When to Perform 45 Calibration Order 45 Why Perform 45 How to Perform 45 Proc_Cal_016A Transmission Valve Calibration E...

Page 5: ...0VX GC GLC080 100VXBCS GC GLC120SVX GC GLC120VXPRS E818 F818 GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX GP GLP GDP080 090 100 110 120VX F813 G813 H813 J813 GLP GDP60VX GLP GDP70VX GP G...

Page 6: ......

Page 7: ...ulic Valves 4 Functions Electronic Hydraulic Valves 5 Functions Electronic Hydraulic Valves Mazda Engine w Electronic 1 Speed Transmission Units w Load Weight Display Electronic Transmission Basic L1...

Page 8: ...justment X 025 Hydraulic Valve Pressure Gage Installation X X X 026 Travel Speed Calibration X X Table 2 How to Read Calibration Procedure Proc_Cal_XXX Number and title of calibration procedure Calibr...

Page 9: ...FOR SERVICE PASSWORD ENTRY SEE PROC_CAL_001 Step 1 Press One Time You will see Passwords Enter Password Step 2 Press One Time You will see Enter Password Calibration steps Information Information to a...

Page 10: ...can cause seri ous injury Refer to Table 3 for the procedures on how to perform Pro_Cal_001 Service Password Entry Table 3 Proc_Cal_001 Service Password Entry A TYPICAL DISPLAY WITHOUT KEY WITH OPTIO...

Page 11: ...ature and that the air is bled out of the lift valve and cylinders prior to performing calibrations HOW TO PERFORM WARNING Keep yourself and all others clear of the lift mech anism Never allow anyone...

Page 12: ...DIRECTION A DIRECTION B 6 TILT FORWARD 7 SEAT ARMREST Perform Proc_Cal_025 Hydraulic Valve Pressure Gage Installation and Proc_Cal_001 Service Password Entry before proceeding Information First determ...

Page 13: ...until the lift function is operating smoothly and there is no mast movement upon engine start Step 2 Optional cylinder air bleed Cycle function completely two or three times repeat if necessary NOTE...

Page 14: ...or on the forks Never put hands arms head or legs through the mast or near the carriage or lift chains This warn ing applies not only to the operator but also the helper A helper must not be near the...

Page 15: ...you are working on Step Press or Until You See Save and Exit If you want to Save Step 1 Press One Time You Will See Save all changes and exit Menu Yes Step 2 Press One Time If you DO NOT want to Save...

Page 16: ...t mechanism while the operator is attempting to handle a load The lift mechanism has moving parts with close clearances that can cause seri ous injury Refer to Table 6 for the procedures on how to per...

Page 17: ...s or Until You See Main Menu Calibrations Step 2 Press One Time You Will See Calibrations Lift Valve Output Step 3 Press One Time You Will See Lift Valve Output Press at Creep A E HYD CONTROL LEVERS 1...

Page 18: ...STOP activating the Lift Control LOOK at the display Go to the calibration step below that matches your display If You See Result out of range Repeat Calibration Press One Time You Will See Lift Valve...

Page 19: ...rator but also the helper A helper must not be near the load or the lift mechanism while the operator is attempting to handle a load The lift mechanism has moving parts with close clearances that can...

Page 20: ...s Lift Valve Output Step 3 Press or Until You See Calibrations Lower Valve Output Step 4 Press One Time You Will See Lower Valve Output Press at Creep A E HYD CONTROL LEVERS 1 LIFT LOWER DIRECTION LIF...

Page 21: ...play If You See Result out of range Repeat Calibration Press One Time You Will See Lower Valve Output Press at Creep Return to Action 2 Perform Actions 2 through 4 again If You See Tilt Bk Valve Outpu...

Page 22: ...t mechanism while the operator is attempting to handle a load The lift mechanism has moving parts with close clearances that can cause seri ous injury Refer to Table 8 for the procedures on how to per...

Page 23: ...rds Step 1 Press or Until You See Main Menu Calibrations Step 2 Press One Time You Will See Calibrations Lift Valve Output Step 3 Press or Until You See Calibrations Tilt Bk Valve Output Step 4 Press...

Page 24: ...rol Action 6 STOP activating the Tilt Bk Control LOOK at the display Go to the Calibration Step below that matches your display If You See Result out of range Repeat Calibration Press One Time You Wil...

Page 25: ...ft mechanism while the operator is attempting to handle a load The lift mechanism has moving parts with close clearances that can cause seri ous injury Refer to Table 9 for the procedures on how to pe...

Page 26: ...ds Step 1 Press or Until You See Main Menu Calibrations Step 2 Press One Time You Will See Calibrations Lift Valve Output Step 3 Press or Until You See Calibrations Tilt Fw Valve Output Step 4 Press O...

Page 27: ...Action 6 STOP activating the Tilt Fw Control LOOK at the display Go to the Calibration Step below that matches your display If You See Result out of range Repeat Calibration Press One Time You Will Se...

Page 28: ...mechanism while the operator is attempting to handle a load The lift mechanism has moving parts with close clearances that can cause seri ous injury Refer to Table 10 for the procedures on how to per...

Page 29: ...ress or Until You See Main Menu Calibrations Step 2 Press One Time You Will See Calibrations Lift Valve Output Step 3 Press or Until You See Calibrations Aux 1 Valve Output Dir A Step 4 Press One Time...

Page 30: ...wly HOLD control steady and Press One Time while holding the control Action 4 STOP activating the Aux 1 Dir A Control LOOK at the display Go to the Calibration Step below that matches your display If...

Page 31: ...mechanism while the operator is attempting to handle a load The lift mechanism has moving parts with close clearances that can cause seri ous injury Refer to Table 11 for the procedures on how to per...

Page 32: ...p 1 Press or Until You See Main Menu Calibrations Step 2 Press One Time You Will See Calibrations Lift Valve Output Step 3 Press or Until You See Calibrations Aux 1 Output Dir B Step 4 Press One Time...

Page 33: ...wly HOLD control steady and Press One Time while holding the control Action 6 STOP activating the Aux 1 Dir B Control LOOK at the display Go to the Calibration Step below that matches your display If...

Page 34: ...mechanism while the operator is attempting to handle a load The lift mechanism has moving parts with close clearances that can cause seri ous injury Refer to Table 12 for the procedures on how to per...

Page 35: ...ress or Until You See Main Menu Calibrations Step 2 Press One Time You Will See Calibrations Lift Valve Output Step 3 Press or Until You See Calibrations Aux 2 Valve Output Dir A Step 4 Press One Time...

Page 36: ...wly HOLD control steady and Press One Time while holding the control Action 6 STOP activating the Aux 2 Dir A Control LOOK at the display Go to the Calibration Step below that matches your display If...

Page 37: ...mechanism while the operator is attempting to handle a load The lift mechanism has moving parts with close clearances that can cause seri ous injury Refer to Table 13 for the procedures on how to per...

Page 38: ...ep 1 Press or Until You See Main Menu Calibrations Step 2 Press One Time You Will See Calibrations Lift Valve Output Step 3 Press or Until You See Calibrations Aux 2 Output Dir B Step 4 Press One Time...

Page 39: ...wly HOLD control steady and Press One Time while holding the control Action 6 STOP activating the Aux 2 Dir B Control LOOK at the display Go to the Calibration Step below that matches your display If...

Page 40: ...mechanism while the operator is attempting to handle a load The lift mechanism has moving parts with close clearances that can cause seri ous injury Refer to Table 14 for the procedures on how to per...

Page 41: ...ep 1 Press or Until You See Main Menu Calibrations Step 2 Press One Time You Will See Calibrations Lift Valve Output Step 3 Press or Until You See Calibrations Aux 3 Output Dir A Step 4 Press One Time...

Page 42: ...wly HOLD control steady and Press One Time while holding the control Action 6 STOP activating the Aux 3 Dir A Control LOOK at the display Go to the Calibration Step below that matches your display If...

Page 43: ...mechanism while the operator is attempting to handle a load The lift mechanism has moving parts with close clearances that can cause seri ous injury Refer to Table 15 for the procedures on how to per...

Page 44: ...ep 1 Press or Until You See Main Menu Calibrations Step 2 Press One Time You Will See Calibrations Lift Valve Output Step 3 Press or Until You See Calibrations Aux 3 Output Dir B Step 4 Press One Time...

Page 45: ...ld control steady and Action 5 WATCH for Attachment Movement When it first starts to move slowly HOLD control steady and Press One Time while holding the control Action 6 STOP activating the Aux 3 Dir...

Page 46: ...rms head or legs through the mast or near the carriage or lift chains This warn ing applies not only to the operator but also the helper A helper must not be near the load or the lift mechanism while...

Page 47: ...CTION A DIRECTION B 3 LIFT 4 LOWER 5 AUX 2 DIRECTION A DIRECTION B 6 TILT FORWARD 7 SEAT ARMREST Step 1 Press or Until You See Main Menu Calibrations Step 2 Press One Time You Will See Calibrations Li...

Page 48: ...all others clear of the lift mech anism Never allow anyone under or on the forks Never put hands arms head or legs through the mast or near the carriage or lift chains This warn ing applies not only t...

Page 49: ...E WITH CLAMPING ATTACHMENT AUX 2 IS IN THE THIRD LEVER LOCATION 2 JOYSTICK 1 TILT BACK 2 AUX 1 DIRECTION A DIRECTION B 3 LIFT 4 LOWER 5 AUX 2 DIRECTION A DIRECTION B 6 TILT FORWARD 7 SEAT ARMREST Step...

Page 50: ...Present Not More Than Maximum Freelift Action 8 Lower Known Weight Load Approximately 51 mm 2 in Wait One Second Read The Load Weight Step 8 Press or Until You See The Weight Displayed One Second Afte...

Page 51: ...s sion pressure sensors CALIBRATION ORDER 1 Proc_Cal_001 NOTE Brakes must be properly adjusted and func tioning prior to performing this procedure 2 Proc_Cal_016 WHY PERFORM Performed to compensate fo...

Page 52: ...or Until You See Calibrations Calibrate Xsmn Valve Step 4 Press One Time You Will See Calibrate Xsmn Valve Press to Begin Action 1 APPLY Parking Brake and leave on throughout process Action 2 FULLY A...

Page 53: ...edures APPLICABLE SYSTEM OPTION Electronic Power Shift Transmission WHEN TO PERFORM Performed whenever disassembling or replacing the transmission the transmission valve or the transmis sion pressure...

Page 54: ...ss One Time You Will See Calibrate Xsmn Valve Press to Begin Action 1 APPLY Parking Brake and leave on throughout process Action 2 FULLY APPLY Service Brakes and HOLD during process Action 3 FULLY Dep...

Page 55: ...he following lift truck models covered in this YRM GLP GDP60VX GLP GDP70VX GP GLP GDP135VX GP GLP GDP155VX C878 D878 E878 GLC GDC60VX GLC GDC70VX GC GLC GDC135VX GC GLC GDC155VX C879 D879 E879 F879 GL...

Page 56: ...ss One Time You Will See Calibrations Lift Valve Output Step 3 Press or Until You See Calibrations Calibrate Xsmn Valve Step 4 Press One Time You Will See Calibrate Xsmn Valve Press to Begin Action 1...

Page 57: ...leted successfully You will see for approximately 5 minutes You Will See Calibrate Xmsn Valve Xmsn Calibration 1 Watch display When completed successfully You will see for approximately 5 minutes You...

Page 58: ...one under or on the forks Never put hands arms head or legs through the mast or near the carriage or lift chains This warn ing applies not only to the operator but also the helper A helper must not be...

Page 59: ...he value is above 27 percent remove the slack in the cable by adjust ing the same nuts If there is not enough adjustment verify that the bell crank to cowl clearance is correct When adjustment is comp...

Page 60: ...s through the mast or near the carriage or lift chains This warn ing applies not only to the operator but also the helper A helper must not be near the load or the lift mechanism while the operator is...

Page 61: ...free after the calibrations are completed and the gage is removed Preceding procedure is the same for lift trucks equipped with OPS solenoids Proc_Cal_026 Travel Speed Calibration WHEN TO PERFORM For...

Page 62: ...0 ft mark Be sure to drive straight as possible Travel speed will not have any affect on the outcome of the calibration Action 9 Press Action 10 The display should say Save and Exit if the calibration...

Page 63: ......

Page 64: ...8000 YRM 1134 12 14 4 14 3 13 9 12 7 12 1 12...

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