Yale Forklift A497 (FS030BF) Service Manual – PDF DOWNLOAD

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Yale Forklift A497 (FS030BF) Service Manual – PDF DOWNLOAD

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Yale Forklift A497 (FS030BF) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1078
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift A497 (FS030BF) Service Manual – PDF DOWNLOAD

520371764-2200YRM1230-(05-2017)-US-EN 1
General 5
Description 5
Guide Wire Physical Installation 7
Equipment 16
Specifications 18
Wire Slot and Expansion Loop Specifications 19
Material and General Specifications 20
System II Wire Guidance Specifications 22
Pre-Installation Information Form 24
520371765-2200YRM1229-(01-2012)-US-EN 29
toc 29
Wire Driver Manual 29
Safety Precautions Maintenance and Repair 30
General 33
Description 33
Installation Procedure 35
Checks and Adjustments 36
Checks 36
Adjustments 37
Troubleshooting 39
Wire Driver Troubleshooting 39
Guide Wire Troubleshooting 40
Guide Wire Repair 41
Short Circuit Repair 41
Open Circuit Repair 41
System II Wire Guidance Specifications 44
tables 29
Table 1 Wire Driver Troubleshooting 39
524150794-4000YRM0135-(03-2011)-US-EN 49
toc 49
Lift Cylinders 49
Safety Precautions Maintenance and Repair 50
Safety Procedures When Working Near Mast 53
General 57
Description 57
Lowering Control Valve 57
Cylinders (General) 60
Lift Cylinder Repair 60
Lift Cylinder Removal Without Removing Mast 60
Standard Masts With Main Lift Cylinder Fastened to Crossmember o 60
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to 61
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift 62
Disassemble 62
Assemble 62
Lift Cylinder Installation in Mast 64
Standard Masts With Main Lift Cylinder Fastened to Crossmember o 64
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to 64
Chevron-Style Packing 65
Chevron-Style Packing Installation on Piston 65
Chevron-Style Packing Installation in Packing Gland 67
Lift Cylinders for HI VIS® Masts 69
Description 69
Lowering Control Valve 69
Remove 71
Disassemble 72
Assemble 72
Install 74
Main Lift Cylinders 74
Free-Lift Cylinder 74
Lift System Leak Check 74
Specifications 75
Troubleshooting 76
tables 49
Table 1 Cylinder Retainer Torque Specifications and Weight Guid 75
524150797-8000YRM0231-(02-2023)-US-EN 81
General 87
Threaded Fasteners 87
Nomenclature, Threads 87
Strength Identification 88
Cotter (Split) Pins 89
Fastener Torque Tables 94
Conversion Table 96
524150797-8000YRM0231-(03-2020)-US-EN 103
General 107
Threaded Fasteners 107
Nomenclature, Threads 107
Strength Identification 108
Cotter (Split) Pins 109
Fastener Torque Tables 114
Conversion Table 116
524153907-1900YRM0097-(05-2012)-US-EN 123
toc 123
Hydraulic Gear Pumps 123
Safety Precautions Maintenance and Repair 124
Description 127
Operation 128
Flow Control Valve 128
Relief Valve 128
Hydraulic Gear Pump Repair 129
Remove 129
Disassemble 130
Clean 130
Inspect 131
Assemble 134
Install 136
Pump Output Check 136
Method No 1 136
Method No 2 137
Hydraulic System Air Check 138
Troubleshooting 139
524158040-2240YRM0001-(01-2023)-US-EN 145
General 151
Battery Type 151
Lead-Acid Batteries 151
Lithium-Ion Batteries 152
Specific Gravity 152
Chemical Reaction in a Cell 152
Electrical Terms 154
Battery Selection 155
Battery Voltage 156
Battery as a Counterweight 156
Battery Ratings 156
Kilowatt-Hours 156
Battery Maintenance 157
Safety Procedures 157
Maintenance Records 157
New Battery 157
Cleaning Battery 158
Adding Water to Battery 160
Hydrometer 160
Battery Temperature 161
Charging Battery 162
Types of Battery Charges 163
Methods of Charging 164
Troubleshooting Charger 165
Knowing When Battery Is Fully Charged 165
Where to Charge Batteries 165
Equipment Needed 165
Battery Connectors 166
Battery Care 166
Troubleshooting 168
524158040-2240YRM0001-(03-2020)-US-EN 173
General 177
Battery Type 177
Lead-Acid Batteries 177
Lithium-Ion Batteries 178
Specific Gravity 178
Chemical Reaction in a Cell 178
Electrical Terms 180
Battery Selection 180
Battery Voltage 181
Battery as a Counterweight 182
Battery Ratings 182
Kilowatt-Hours 182
Battery Maintenance 182
Safety Procedures 182
Maintenance Records 183
New Battery 183
Cleaning Battery 183
Adding Water to Battery 185
Hydrometer 186
Battery Temperature 187
Charging Battery 188
Types of Battery Charges 188
Methods of Charging 190
Troubleshooting Charger 190
Knowing When Battery Is Fully Charged 191
Where to Charge Batteries 191
Equipment Needed 191
Battery Connectors 192
Battery Care 192
Troubleshooting 194
524163979-0100YRM0760-(01-2012)-US-EN 199
toc 199
Frame 199
Safety Precautions Maintenance and Repair 200
General 203
Description 203
Frame Repair 204
Remove and Disassemble 204
Covers, Panels, and Plates 204
Caster and Caster Wheels 204
Description 204
Caster, Replace 205
Caster Wheels, Replace 205
Painting Instructions 206
Label Replacement 206
524164052-4000YRM0763-(01-2012)-US-EN 213
toc 213
MAST 213
Safety Precautions Maintenance and Repair 214
General 217
Mast Weldments 217
Operator Platform 219
Two-Stage Mast 220
Description 220
Load Rollers 222
Operation 222
Three-Stage Mast 222
Description 222
Operation 223
524164053-4000YRM0764-(05-2018)-US-EN 227
General 231
Forks 231
Replace 231
Safety Procedures When Working Near Mast 233
Operator Platform 235
Remove 235
Install 237
Two-Stage Mast 238
Remove 238
Disassemble 238
Clean and Inspect 240
Lift Cylinders 242
Assemble 242
Install 242
Three-Stage Mast 246
Remove 246
Disassemble 246
Clean and Inspect 248
Lift Cylinders 248
Assemble 248
Install 249
Load Wheels Replacement 249
Lift System Leak Check 250
Lift Chain Adjustment 250
Mast Adjustments 251
Operator Platform Adjustment 252
Troubleshooting 253
550032941-0630YRM1460-(03-2021)-US-EN 257
GK Master Drive Unit 261
General 261
Description 261
Maintenance 262
Changing the Oil 262
Traction Motor and Drive Unit Splines 262
Remove 262
Assemble 263
Mounting Electric Motor 263
Pivoted Connection 264
Disassemble 264
Install 264
Troubleshooting 265
550032942-0620YRM1461-(01-2012)-US-EN 267
toc 267
AC Motor Repair 267
Safety Precautions Maintenance and Repair 268
General 271
Special Precautions 271
Discharging the Capacitors 271
Traction Motor Repair 272
Remove 272
Disassemble 272
Inspect 273
Assemble 274
Drive End Bearing, Replace 275
Install 275
Hydraulic Motor Repair (OS/SS030BF) 276
Remove 276
Disassemble 276
Electrical Connector Repair or Replacement 278
Clean 278
Inspect 278
Assemble 279
Install 281
Troubleshooting 282
tables 267
Table 1 Speed Sensor Connector 278
Table 2 Thermal Sensor Connector 278
550032943-1600YRM1462-(01-2012)-US-EN 285
toc 285
Steering System 285
Safety Precautions Maintenance and Repair 286
General 289
Discharging The Capacitors 290
Checks, Calibrations, and Repairs 291
Electric Steering 291
Input Devices 291
Checks 291
Checks Prior to Powerup 291
Check Steering System for Correct Operation 292
Check High Lift Traction Speed Reduction and Shutoff 292
Calibrations 293
Auto-Center Steering Input Sensor Neutral 293
Drive Wheel Zero Angle Offset – Straight Travel Adjustment 294
Drive Wheel Angle (Multiturn Steering) 294
Initial Check 294
Adjustment 294
Drive Wheel Angle (Auto-Centering Steering) 294
Initial Check 294
Adjustment 295
Repairs 295
General 295
Steer Unit Assembly 295
Replace 295
Component Replacement 297
Steering Proximity Switch 298
Replace 298
Analog Input Sensor (Smart Steer) 299
Replace 299
Stepper Motor (Multiturn) 300
Replace 300
Troubleshooting 302
tables 285
Table 1 Platform Heights 292
550032944-1800YRM1463-(06-2016)-US-EN 305
General 309
Special Precautions 310
Description 311
Repair 312
Air Gap 312
Remove 313
Install 313
Operational Check 315
Troubleshooting 316
550032946-1900YRM1465-(05-2012)-US-EN 319
toc 319
Hydraulic System 319
Safety Precautions Maintenance and Repair 320
General 323
Discharging The Capacitors 323
Description 324
Hydraulic System (24/36 Volt DC Hoist) 324
Hydraulic System (36 Volt AC Hoist) 324
Control Handle 324
Control Valve 325
Description 325
Relief Valve 325
Manual Lowering Valve 325
Proportional Solenoid Valve 325
DC Hoist 325
AC Hoist 325
Solenoid Valve 325
Check and Adjust 325
Main Relief Valve 325
Lift Pump and Motor 327
Remove (DC Hoist) 327
Disassemble 328
Assemble 328
Install 328
Remove (AC Hoist) 329
Disassemble 330
Assemble 330
Install 331
Hydraulic Tank 332
Description 332
Remove and Disassemble 332
Assemble and Install 333
Troubleshooting 334
550032947-2200YRM1466-(02-2014)-US-EN 339
550032949-2200YRM1468-(01-2012)-US-EN 563
toc 563
Electrical System 563
Safety Precautions Maintenance and Repair 564
General 567
Discharging the Capacitors 568
Major Electrical System Features 569
Integrated System 569
CANbus Advantages 569
CANbus Communications 569
Electric Steering 569
Centering Proximity Sensor 569
Traction 569
CAN I/O 570
Input Devices 570
Output Devices 570
Encoder Integrity 571
Test Encoders 571
Proximity Switches 571
Key Switch 571
Multifunction Displays 571
BDI 571
Speed 571
Steer Angle 572
Truck Hours 572
Operational Mode 572
Setup 572
Setup Instructions 572
ACE0 Traction Control Unit 572
Normal Operation 572
Display 572
Password Access 572
Startup Checklist 572
Truck Operation Mode 573
Diagnostics 573
Power-On Self-Test 573
Interlocks 574
Setup Menu Diagnostics 574
Calibration 574
Traction Throttle 574
Lift/Lower Throttle 575
Proportional Valve 575
AC Traction Motor Controller 576
Controller Removal 577
Install 577
Low-Voltage Protection Function 577
AC Hoist Motor Controller 577
Controller Removal 578
Install 578
Low-Voltage Protection Function 578
Contactor and Electrical Panel Checks 578
Fuses 578
Contactors 579
General 579
Test 580
Tips 581
Disassemble and Assemble 581
Traction Throttle Sensor Removal and Installation 582
Instrument Panel Removal and Installation 584
Key Switch Removal and Installation 584
Remove 584
Install 584
Foot Switch Removal and Installation 585
Slack Chain Switch Removal and Installation 586
Limit Switch Removal and Installation 587
DC to DC Converter 587
tables 563
Table 1 Proximity Switches 571
Table 2 Coil Resistance 580
550032950-2200YRM1469-(12-2013)-US-EN 591
550032951-2200YRM1470-(12-2013)-US-EN 607
550032953-8000YRM1472-(03-2021)-US-EN 673
General 677
How to Move a Disabled Truck 677
How to Tow the Lift Truck 678
How to Put a Lift Truck on Blocks 678
How to Raise the Drive Tire 678
How to Raise the Load Wheels 679
Safety Procedures When Working Near Mast 680
Maintenance Schedule 682
Maintenance Procedures Every 8 Hours or Daily 693
How to Make Checks With Key Switch in the OFF Position 693
Hydraulic System 693
Battery 693
Safety Labels 694
Mast, Platform, Forks, Lift Chains, and Header Hoses 694
Inspection of Personal Fall Protection System (PFPS) 695
Pallet Clamp 695
Tire, Wheels, and Caster 695
How to Make Checks With Key Switch in the ON Position 696
Gauges, Lights, Horn, and Fuses 696
Fuses 696
Direction/Speed, Lift/Lower, and Horn Control 698
Lift System Operation 699
Parking Brake 699
Steering System 699
Maintenance Procedures Every 350 Hours or 2 Months 700
Hydraulics 700
Hydraulic Hoses 700
Hydraulic Tank Breather 700
How to Change Hydraulic Oil and Filter 700
Check for Leaks in Lift System 702
Check Lift Cylinders for Leaks 702
Electrical Inspection 703
Motor Brushes 703
Caster Wheel 704
Mast 704
Lift Chains 704
Electrical Cable Sheaves 705
Master Drive Unit 705
Maintenance Procedures Every 2000 Hours or Yearly 706
Electrical Inspection 706
Contactors 706
Master Drive Unit 706
Traction Motor and Input Pinion Splines 706
Wheels and Bearings 706
How to Change Hydraulic Oil and Filter 706
Inspection of Personal Fall Protection System (PFPS) and PFPS Tether Point 708
Battery Maintenance 709
How to Charge Battery 709
How to Change the Battery 710
General 710
Battery, Remove 710
Battery, Install 711
Wheels and Tires 713
How to Change Drive and Steer Tires 713
How to Replace Load Wheels 713
550032953-8000YRM1472-(09-2022)-US-EN 717
General 721
How to Move a Disabled Truck 721
How to Tow the Lift Truck 722
How to Put a Lift Truck on Blocks 722
How to Raise the Drive Tire 722
How to Raise the Load Wheels 723
Safety Procedures When Working Near Mast 724
Maintenance Schedule 726
Maintenance Procedures Every 8 Hours or Daily 738
How to Make Checks With Key Switch in the OFF Position 738
Hydraulic System 738
Battery 738
Safety Labels 739
Mast, Platform, Forks, Lift Chains, and Header Hoses 739
Inspection of Personal Fall Protection System (PFPS) 740
Pallet Clamp 740
Tire, Wheels, and Caster 740
How to Make Checks With Key Switch in the ON Position 741
Gauges, Lights, Horn, and Fuses 741
Fuses 741
Direction/Speed, Lift/Lower, and Horn Control 743
Lift System Operation 744
Parking Brake 744
Steering System 744
Maintenance Procedures Every 350 Hours or 2 Months 745
Hydraulics 745
Hydraulic Hoses 745
Hydraulic Tank Breather 745
How to Change Hydraulic Oil and Filter 745
Check for Leaks in Lift System 747
Check Lift Cylinders for Leaks 747
Electrical Inspection 748
Motor Brushes 748
Caster Wheel 749
Mast 749
Lift Chains 750
Electrical Cable Sheaves 751
Master Drive Unit 751
Maintenance Procedures Every 2000 Hours or Yearly 752
Electrical Inspection 752
Contactors 752
Wheels and Bearings 752
How to Change Hydraulic Oil and Filter 752
Inspection of Personal Fall Protection System (PFPS) and PFPS Tether Point 754
Battery Maintenance 755
How to Charge Battery 755
How to Change the Battery 756
General 756
Battery, Remove 756
Battery, Install 757
Wheels and Tires 759
How to Change Drive and Steer Tires 759
How to Replace Load Wheels 759
550032954-8000YRM1473-(03-2018)-US-EN 763
550032955-8000YRM1474-(10-2013)-US-EN 783
550073166-0620YRM1621-(12-2018)-US-EN 795
General 799
Special Precautions 799
Discharging the Capacitors 799
Traction Motor Repair 799
Remove 800
Disassemble 802
Clean/Inspect 806
Assemble 807
Install 808
Hydraulic Motor Repair 809
Disassemble 809
Inspect 811
Assemble 812
Special Tools 813
Tool Chart 813
Troubleshooting 814
550073167-0630YRM1609-(03-2021)-US-EN 819
Master Drive Unit 823
General 823
Description 823
Maintenance 824
Changing the Oil 824
Remove 824
Clean and Inspect 829
Install 832
Troubleshooting 833
550089217-2200YRM1650-(12-2013)-US-EN 837
550089220-2200YRM1651-(04-2020)-US-EN 853
General 861
Introduction 861
Description 861
Button Keypad 861
LED Indicator Lights 861
LCD Screen 861
Dash Display Menu Access 861
Menu Navigation 862
Dash Display Menu Operation 862
Nodes 862
Menu Structure 863
Service-Level Menu 864
Hour Meters 865
H1 Truck Hours 866
H2 Traction Hours 866
H3 Pump Hours 866
H4 Steer Hours 866
H5 Odometer Miles 866
H10 Display Hours 866
H30 Traction Node Hours 866
H40 Steer Node Hours 866
H50 Pump Node Hours 866
H70 Fwd Ant Node Hours 866
H71 Rev Ant Node Hours 866
H90 CAN I/O Hours 866
Performance 867
Performance Level 1 867
P1 1 Forward 868
P1 2 Reverse 868
P1 3 Acceleration 868
P1 4 Plug 868
P1 5 Coast 868
P1 6 Lift Speed 868
P1 7 Lower Speed 868
P1 8 Lift Accel 868
P1 9 Lift Decel 868
P1 10 Lower Accel 868
P1 11 Lower Decel 868
P1 33 Steer Ratio 869
Passwords 869
Add Password 869
Delete Password 869
Edit Password 870
Operator Password 870
Clear Log 870
Operator Logs 870
Operator 1-150 870
Information 870
I1 Series 871
I3 Serial Number 871
I5 Truck Voltage 871
Settings 871
S1 Metric 874
S2 User Performance 874
S3 Timeout 874
S4 Battery Type 874
S5 BDI Startup Full 874
S6 BDI Full 874
S7 BDI Empty 874
S8 BDI Reset 875
S9 Lift Interrupt 875
S10 Audible Warning 875
S12 Checklist 875
S13 Maint Reminder 875
S14 Restore Default 875
S15 Truck Lockout 876
S19 Lift Limit 876
S20 Lift Limit Enable 876
S21 Lower Limit 876
S22 Lower Limit Enable 876
S23 Set Steer 0 Positive 876
S25 Max CW Angle F 876
S27 Max CCW Angle F 876
S28 Wire Guidance 876
S29 Forward Antenna Freq 876
S30 Reverse Antenna Freq 876
S31 Wire Guidance Slow Set 876
S32 Wire Guidance Reverse Offset 876
S33 Forward Antenna Lag 876
S34 Forward Antenna Lead 876
S35 Forward Antenna ACQ Area 876
S36 Reverse Antenna Lag 877
S37 Reverse Antenna Lead 877
S38 Reverse Antenna ACQ Area 877
S39 Wire Depth Forward 877
S40 Wire Depth Reverse 877
S43 Simultaneity 877
S61 Extended Shift 877
S66 SWS Source 877
Software Version 878
Error Log 878
(E1) Error Log 1 879
Error 1 1 (E1 1) 879
Error 1 2 (E1 2) 879
Error 1 3 (E1 3) 879
Error 1 4 (E1 4) 879
Diagnostics 880
Diagnostics 880
D1 Status 880
D2 Input 880
D3 Output 880
D1 Status 881
D1 1 CAN 881
D1 2 Contactor 881
D1 3 Full Traction 881
D1 4 Limp Traction 881
D1 5 Steering 881
D1 6 Lift 881
D1 7 Lower 882
D2 Inputs 882
D2 10 Display 882
D2 10 1 Bus Error 883
D2 10 2 Bus Max Error 883
D2 10 30 Traction 883
D2 10 40 Steer 883
D2 10 50 Pump 883
D2 10 70 Forward Antenna 883
D2 10 71 Reverse Antenna 883
D2 10 90 CAN I/O 883
D2 30 Traction 884
D2 30 1 Target Speed 886
D2 30 2 Motor Speed 886
D2 30 3 Motor ENC 886
D2 30 5 Cont Temp 886
D2 30 6 Motor Temp 886
D2 30 7 Motor Curr 886
D2 30 8 Cap V 886
D2 30 9 Cap Max V 886
D2 30 10 Cap Min V 886
D2 30 11 Key V 886
D2 30 12 Key Max V 886
D2 30 13 Key Min V 886
D2 30 14 Brake Connect 886
D2 30 16 MC Connect 886
D2 30 19 Brake SW 886
D2 30 21 Service Key Switch 886
D2 30 22 Mast Proximity Switch 886
D2 30 26 Steer Status 887
D2 30 27 Load Hold Current 887
D2 30 28 Lift/Lower Valve Current 887
D2 30 31 Bank Out Current 887
D2 30 32 SOC 887
D2 40 Steer 887
D2 40 1 Target Speed 889
D2 40 2 Motor Speed 889
D2 40 3 Motor ENC 889
D2 40 5 Cont Temp 889
D2 40 7 Motor Curr 889
D2 40 8 Cap V 889
D2 40 9 Cap Max V 889
D2 40 10 Cap Min V 890
D2 40 11 Key V 890
D2 40 12 Key Max V 890
D2 40 13 Key Min V 890
D2 40 17 Center Prox SW 890
D2 40 18 Target Angle 890
D2 40 19 Steer Angle 890
D2 40 20 Wire Guidance Status 890
D2 40 21 APP Angle Forward 890
D2 40 22 APP Angle Reverse 890
D2 40 23 Side Error Forward 890
D2 40 24 Side Error Reverse 890
D2 40 25 Side Dist Forward 890
D2 40 26 Side Dist Reverse 890
D2 40 27 Frequency IN Range 890
D2 50 Pump 891
D2 50 1 Target Speed 892
D2 50 2 Motor Speed 892
D2 50 3 Motor ENC 892
D2 50 5 Cont Temp 892
D2 50 6 Motor Temp 892
D2 50 7 Motor Curr 892
D2 50 8 Cap V 892
D2 50 9 Cap Max V 892
D2 50 10 Cap Min V 892
D2 50 11 Key V 892
D2 50 12 Key Max V 892
D2 50 13 Key Min V 892
D2 70 Forward Antenna 893
D2 70 1 Line Frequency 893
D2 70 2 Field Strength 893
D2 70 3 Line Strength 893
D2 70 4 Path 893
D2 71 Reverse Antenna 894
D2 71 1 Line Frequency 894
D2 71 2 Field Strength 894
D2 71 3 Line Strength 894
D2 71 4 Path 894
D2 90 CAN I/O 895
D2 90 1 Height ENC 896
D2 90 2 Height ENC 896
D2 90 5 Gate Switch 897
D2 90 6 Lift Limit Switch 897
D2 90 7 Slack Chain Switch 897
D2 90 9 Brake Switch 897
D2 90 10 WG Switch 897
D2 90 14 Horn Switch 897
D2 90 15 Lift Switch 897
D2 90 16 Lower Switch 897
D2 90 17 Traction Input 897
D2 90 18 Hydraulic Input 897
D2 90 19 Auto CTR CW Sig 897
D2 90 20 Auto CTR CCW Sig 897
D2 90 21 MTS Q Line 897
D2 90 22 MTS D Line 897
D2 90 23 Steer Stat 897
D2 90 50 WG Light Connect 897
D3 Output 898
D3 10 Display 898
D3 10 10 Display Com 898
D3 10 30 Trac Comm 898
D3 10 40 Steer Com 898
D3 10 50 Pump Com 898
D3 10 70 Forward Antenna 899
D3 10 71 Reverse Antenna 899
D3 10 90 CAN I/O Com 899
D3 30 Traction 899
D3 30 1 U-V Line DC Curr 900
D3 30 2 U-W Line DC Curr 900
D3 30 3 V-W Line DC Curr 900
D3 30 4 Motor Open 900
D3 30 5 Motor Circuit 900
D3 30 6 Brake 900
D3 30 7 MC 900
D3 30 10 Lift/Lower 900
D3 30 11 Load Hold 900
D3 30 12 LH Valve Relay 900
D3 30 15 Horn 900
D3 30 17 Audible Alarm 900
D3 40 Steer 901
D3 40 1 U-V Line DC Curr 901
D3 40 2 U-W Line DC Curr 901
D3 40 3 V-W Line DC Curr 901
D3 40 4 Motor Open 901
D3 40 5 Motor Circuit 901
D3 40 6 Status Line 901
D3 50 Pump 902
D3 50 1 U-V Line DC Curr 902
D3 50 2 U-W Line DC Curr 902
D3 50 3 V-W Line DC Curr 902
D3 50 4 Motor Open 902
D3 50 5 Motor Circuit 902
D3 90 CAN I/O 903
D3 90 15 WG Light 903
D3 90 16 Sonalert 903
Calibration 903
550089223-9000YRM1648-(01-2015)-US-EN 907
550267564-0630YRM2448-(09-2022)-US-EN 1039
General 1045
General 1045
Description 1045
Discharging The Capacitors 1046
Master Drive Unit Repair 1050
Maintenance 1050
Draining the Oil 1050
Remove 1050
Disassemble 1052
Clean and Inspect 1053
Assemble 1053
Install 1054
Replace the Wheel Seal on Kordel Drive Units 1054
Tools required 1054
Truck setup 1054
Wheel shaft seal and protection ring removal (method 1) 1055
Wheel shaft seal and protection ring removal (method 2) 1055
Wheel shaft seal and protection ring installation 1057
Troubleshooting 1058
550289235-0800YRM5432-(05-2023)-US-EN 1061
Weight and Dimensions 1067
Safety and Precautions 1068
Safety Procedures For Working Near The Mast 1068
Before Starting Repairs To The Hydraulic System Always 1068
Preparing Truck For Assembly 1069
List of All Special Tools and Equipment Needed for the Assembly 1069
Preparing Mast and Platform for Initial Assembly 1069
Preparing Drive Frame for Assembly 1070
Truck Assembly 1071
Installing Mast and Platform to Drive Frame 1071
Connecting Hydraulic Hoses 1071
Connecting Electrical Connectors 1072
Installing Wire Guide Antenna 1076
Programing and Parameters 1076
Installing Drive Frame Cover 1076
General Checks After Assembly 1077
Plumbing Check 1077
Lubrication Check 1077
Functionality Check 1077
Cleaning 1077
Labels 1077

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