Yale Forklift D801 (OS030EF) Service Manual – PDF DOWNLOAD

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Yale Forklift D801 (OS030EF) Service Manual – PDF DOWNLOAD

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Yale Forklift D801 (OS030EF) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1142
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift D801 (OS030EF) 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
550032945-1900YRM1464-(08-2014)-US-EN 319
550032946-1900YRM1465-(05-2012)-US-EN 333
toc 333
Hydraulic System 333
Safety Precautions Maintenance and Repair 334
General 337
Discharging The Capacitors 337
Description 338
Hydraulic System (24/36 Volt DC Hoist) 338
Hydraulic System (36 Volt AC Hoist) 338
Control Handle 338
Control Valve 339
Description 339
Relief Valve 339
Manual Lowering Valve 339
Proportional Solenoid Valve 339
DC Hoist 339
AC Hoist 339
Solenoid Valve 339
Check and Adjust 339
Main Relief Valve 339
Lift Pump and Motor 341
Remove (DC Hoist) 341
Disassemble 342
Assemble 342
Install 342
Remove (AC Hoist) 343
Disassemble 344
Assemble 344
Install 345
Hydraulic Tank 346
Description 346
Remove and Disassemble 346
Assemble and Install 347
Troubleshooting 348
550032947-2200YRM1466-(02-2014)-US-EN 353
550032948-2200YRM1467-(08-2014)-US-EN 577
550032949-2200YRM1468-(01-2012)-US-EN 601
toc 601
Electrical System 601
Safety Precautions Maintenance and Repair 602
General 605
Discharging the Capacitors 606
Major Electrical System Features 607
Integrated System 607
CANbus Advantages 607
CANbus Communications 607
Electric Steering 607
Centering Proximity Sensor 607
Traction 607
CAN I/O 608
Input Devices 608
Output Devices 608
Encoder Integrity 609
Test Encoders 609
Proximity Switches 609
Key Switch 609
Multifunction Displays 609
BDI 609
Speed 609
Steer Angle 610
Truck Hours 610
Operational Mode 610
Setup 610
Setup Instructions 610
ACE0 Traction Control Unit 610
Normal Operation 610
Display 610
Password Access 610
Startup Checklist 610
Truck Operation Mode 611
Diagnostics 611
Power-On Self-Test 611
Interlocks 612
Setup Menu Diagnostics 612
Calibration 612
Traction Throttle 612
Lift/Lower Throttle 613
Proportional Valve 613
AC Traction Motor Controller 614
Controller Removal 615
Install 615
Low-Voltage Protection Function 615
AC Hoist Motor Controller 615
Controller Removal 616
Install 616
Low-Voltage Protection Function 616
Contactor and Electrical Panel Checks 616
Fuses 616
Contactors 617
General 617
Test 618
Tips 619
Disassemble and Assemble 619
Traction Throttle Sensor Removal and Installation 620
Instrument Panel Removal and Installation 622
Key Switch Removal and Installation 622
Remove 622
Install 622
Foot Switch Removal and Installation 623
Slack Chain Switch Removal and Installation 624
Limit Switch Removal and Installation 625
DC to DC Converter 625
tables 601
Table 1 Proximity Switches 609
Table 2 Coil Resistance 618
550032950-2200YRM1469-(12-2013)-US-EN 629
550032951-2200YRM1470-(12-2013)-US-EN 645
550032952-2200YRM1471-(08-2016)-US-EN 711
Introduction 715
Steering System and Wire Guidance Electric Components 716
EPS AC0 Module 716
Antenna Module 716
LED Operation 717
Alignment 717
Connection and Configuration 718
Stepper Motor (Multi-turn Steering) 719
Dual Hall Effect Sensor (Smart Steer) 719
Steering Motor Encoder 719
Centering Proximity Switch 719
Wire Guidance Parameters 720
EPS AC0 Module Parameters 720
Steer Settings 720

iSi SETTINGS PERFORMANCE Px 33 STEER RATIO
(MTS GAIN) 720

iSi SETTINGS S23
(SET STEER 0 POS) 720
Truck Settings 720

iSi SETTINGS S28 WIRE GUIDANCE
(WIRE GUIDANCE) 720
WG Config 720

iSi WG REV OFFSET S32
(WG REV OFFSET) 720
Antenna FWD and Antenna RR Module Parameters 720
WG Config 720

iSi SETTINGS S29 FWD ANT FREQ, S30 REV ANT FREQ
(LINE FREQUENCY) 720

iSi SETTINGS S34 FWD ANT LEAD, S37 REV ANT LEAD
(LEAD REGULATION) 720

iSi SETTINGS S33 FWD ANT LAG, S36 REV ANT LAG
(LAG REGULATION) 720

iSi SETTINGS S35 FWD ANT ACQ AREA, S38 REV ANT ACQ AREA
(ACQUISITION AREA) 721

iSi SETTINGS S39 WIRE DEPTH FWD, S40 WIRE DEPTH REV
(ANTENNA HEIGHT) 721
STRENGTH ACQ 721

iSi CALIBRATE C10 FREQUENCY CAL
(FREQUENCY ACQ) 721

iSi SETTINGS S31 WG SLOW SET
(WG SLOW SET) 721
Wire Guidance Setup 722
Set Frequency 722
Set Antenna Height 722
WG Antenna Calibration 722
WG Frequency Calibration 723
Set Steer 0 Position 723
Reverse Antenna Adjustment 723
Set WG REV OFFSET 724
Wire Guidance Operation 724
Wire Guidance Switch 725
Wire Acquisition 725
Steered Wheel Side 725
Load Wheel Side 726
Wire Guidance Adjustment 728
Signal Strength Setting Adjustment 728
Wire Guidance Installation 729
Forward Antenna 729
Reverse Antenna 729

OS030BF and OS030EF
730
SS030BF 732
Wire Guidance Troubleshooting 733
EPS AC0 Module Troubleshooting 733

iSi 10114, 10115 COM ERROR ANTENNA
(CODE 65516 NODE 6) 733
WG NOT CALIB 733
550032953-8000YRM1472-(03-2021)-US-EN 737
General 741
How to Move a Disabled Truck 741
How to Tow the Lift Truck 742
How to Put a Lift Truck on Blocks 742
How to Raise the Drive Tire 742
How to Raise the Load Wheels 743
Safety Procedures When Working Near Mast 744
Maintenance Schedule 746
Maintenance Procedures Every 8 Hours or Daily 757
How to Make Checks With Key Switch in the OFF Position 757
Hydraulic System 757
Battery 757
Safety Labels 758
Mast, Platform, Forks, Lift Chains, and Header Hoses 758
Inspection of Personal Fall Protection System (PFPS) 759
Pallet Clamp 759
Tire, Wheels, and Caster 759
How to Make Checks With Key Switch in the ON Position 760
Gauges, Lights, Horn, and Fuses 760
Fuses 760
Direction/Speed, Lift/Lower, and Horn Control 762
Lift System Operation 763
Parking Brake 763
Steering System 763
Maintenance Procedures Every 350 Hours or 2 Months 764
Hydraulics 764
Hydraulic Hoses 764
Hydraulic Tank Breather 764
How to Change Hydraulic Oil and Filter 764
Check for Leaks in Lift System 766
Check Lift Cylinders for Leaks 766
Electrical Inspection 767
Motor Brushes 767
Caster Wheel 768
Mast 768
Lift Chains 768
Electrical Cable Sheaves 769
Master Drive Unit 769
Maintenance Procedures Every 2000 Hours or Yearly 770
Electrical Inspection 770
Contactors 770
Master Drive Unit 770
Traction Motor and Input Pinion Splines 770
Wheels and Bearings 770
How to Change Hydraulic Oil and Filter 770
Inspection of Personal Fall Protection System (PFPS) and PFPS Tether Point 772
Battery Maintenance 773
How to Charge Battery 773
How to Change the Battery 774
General 774
Battery, Remove 774
Battery, Install 775
Wheels and Tires 777
How to Change Drive and Steer Tires 777
How to Replace Load Wheels 777
550032953-8000YRM1472-(09-2022)-US-EN 781
General 785
How to Move a Disabled Truck 785
How to Tow the Lift Truck 786
How to Put a Lift Truck on Blocks 786
How to Raise the Drive Tire 786
How to Raise the Load Wheels 787
Safety Procedures When Working Near Mast 788
Maintenance Schedule 790
Maintenance Procedures Every 8 Hours or Daily 802
How to Make Checks With Key Switch in the OFF Position 802
Hydraulic System 802
Battery 802
Safety Labels 803
Mast, Platform, Forks, Lift Chains, and Header Hoses 803
Inspection of Personal Fall Protection System (PFPS) 804
Pallet Clamp 804
Tire, Wheels, and Caster 804
How to Make Checks With Key Switch in the ON Position 805
Gauges, Lights, Horn, and Fuses 805
Fuses 805
Direction/Speed, Lift/Lower, and Horn Control 807
Lift System Operation 808
Parking Brake 808
Steering System 808
Maintenance Procedures Every 350 Hours or 2 Months 809
Hydraulics 809
Hydraulic Hoses 809
Hydraulic Tank Breather 809
How to Change Hydraulic Oil and Filter 809
Check for Leaks in Lift System 811
Check Lift Cylinders for Leaks 811
Electrical Inspection 812
Motor Brushes 812
Caster Wheel 813
Mast 813
Lift Chains 814
Electrical Cable Sheaves 815
Master Drive Unit 815
Maintenance Procedures Every 2000 Hours or Yearly 816
Electrical Inspection 816
Contactors 816
Wheels and Bearings 816
How to Change Hydraulic Oil and Filter 816
Inspection of Personal Fall Protection System (PFPS) and PFPS Tether Point 818
Battery Maintenance 819
How to Charge Battery 819
How to Change the Battery 820
General 820
Battery, Remove 820
Battery, Install 821
Wheels and Tires 823
How to Change Drive and Steer Tires 823
How to Replace Load Wheels 823
550032954-8000YRM1473-(03-2018)-US-EN 827
550032955-8000YRM1474-(10-2013)-US-EN 847
550073166-0620YRM1621-(12-2018)-US-EN 859
General 863
Special Precautions 863
Discharging the Capacitors 863
Traction Motor Repair 863
Remove 864
Disassemble 866
Clean/Inspect 870
Assemble 871
Install 872
Hydraulic Motor Repair 873
Disassemble 873
Inspect 875
Assemble 876
Special Tools 877
Tool Chart 877
Troubleshooting 878
550073167-0630YRM1609-(03-2021)-US-EN 883
Master Drive Unit 887
General 887
Description 887
Maintenance 888
Changing the Oil 888
Remove 888
Clean and Inspect 893
Install 896
Troubleshooting 897
550089217-2200YRM1650-(12-2013)-US-EN 901
550089220-2200YRM1651-(04-2020)-US-EN 917
General 925
Introduction 925
Description 925
Button Keypad 925
LED Indicator Lights 925
LCD Screen 925
Dash Display Menu Access 925
Menu Navigation 926
Dash Display Menu Operation 926
Nodes 926
Menu Structure 927
Service-Level Menu 928
Hour Meters 929
H1 Truck Hours 930
H2 Traction Hours 930
H3 Pump Hours 930
H4 Steer Hours 930
H5 Odometer Miles 930
H10 Display Hours 930
H30 Traction Node Hours 930
H40 Steer Node Hours 930
H50 Pump Node Hours 930
H70 Fwd Ant Node Hours 930
H71 Rev Ant Node Hours 930
H90 CAN I/O Hours 930
Performance 931
Performance Level 1 931
P1 1 Forward 932
P1 2 Reverse 932
P1 3 Acceleration 932
P1 4 Plug 932
P1 5 Coast 932
P1 6 Lift Speed 932
P1 7 Lower Speed 932
P1 8 Lift Accel 932
P1 9 Lift Decel 932
P1 10 Lower Accel 932
P1 11 Lower Decel 932
P1 33 Steer Ratio 933
Passwords 933
Add Password 933
Delete Password 933
Edit Password 934
Operator Password 934
Clear Log 934
Operator Logs 934
Operator 1-150 934
Information 934
I1 Series 935
I3 Serial Number 935
I5 Truck Voltage 935
Settings 935
S1 Metric 938
S2 User Performance 938
S3 Timeout 938
S4 Battery Type 938
S5 BDI Startup Full 938
S6 BDI Full 938
S7 BDI Empty 938
S8 BDI Reset 939
S9 Lift Interrupt 939
S10 Audible Warning 939
S12 Checklist 939
S13 Maint Reminder 939
S14 Restore Default 939
S15 Truck Lockout 940
S19 Lift Limit 940
S20 Lift Limit Enable 940
S21 Lower Limit 940
S22 Lower Limit Enable 940
S23 Set Steer 0 Positive 940
S25 Max CW Angle F 940
S27 Max CCW Angle F 940
S28 Wire Guidance 940
S29 Forward Antenna Freq 940
S30 Reverse Antenna Freq 940
S31 Wire Guidance Slow Set 940
S32 Wire Guidance Reverse Offset 940
S33 Forward Antenna Lag 940
S34 Forward Antenna Lead 940
S35 Forward Antenna ACQ Area 940
S36 Reverse Antenna Lag 941
S37 Reverse Antenna Lead 941
S38 Reverse Antenna ACQ Area 941
S39 Wire Depth Forward 941
S40 Wire Depth Reverse 941
S43 Simultaneity 941
S61 Extended Shift 941
S66 SWS Source 941
Software Version 942
Error Log 942
(E1) Error Log 1 943
Error 1 1 (E1 1) 943
Error 1 2 (E1 2) 943
Error 1 3 (E1 3) 943
Error 1 4 (E1 4) 943
Diagnostics 944
Diagnostics 944
D1 Status 944
D2 Input 944
D3 Output 944
D1 Status 945
D1 1 CAN 945
D1 2 Contactor 945
D1 3 Full Traction 945
D1 4 Limp Traction 945
D1 5 Steering 945
D1 6 Lift 945
D1 7 Lower 946
D2 Inputs 946
D2 10 Display 946
D2 10 1 Bus Error 947
D2 10 2 Bus Max Error 947
D2 10 30 Traction 947
D2 10 40 Steer 947
D2 10 50 Pump 947
D2 10 70 Forward Antenna 947
D2 10 71 Reverse Antenna 947
D2 10 90 CAN I/O 947
D2 30 Traction 948
D2 30 1 Target Speed 950
D2 30 2 Motor Speed 950
D2 30 3 Motor ENC 950
D2 30 5 Cont Temp 950
D2 30 6 Motor Temp 950
D2 30 7 Motor Curr 950
D2 30 8 Cap V 950
D2 30 9 Cap Max V 950
D2 30 10 Cap Min V 950
D2 30 11 Key V 950
D2 30 12 Key Max V 950
D2 30 13 Key Min V 950
D2 30 14 Brake Connect 950
D2 30 16 MC Connect 950
D2 30 19 Brake SW 950
D2 30 21 Service Key Switch 950
D2 30 22 Mast Proximity Switch 950
D2 30 26 Steer Status 951
D2 30 27 Load Hold Current 951
D2 30 28 Lift/Lower Valve Current 951
D2 30 31 Bank Out Current 951
D2 30 32 SOC 951
D2 40 Steer 951
D2 40 1 Target Speed 953
D2 40 2 Motor Speed 953
D2 40 3 Motor ENC 953
D2 40 5 Cont Temp 953
D2 40 7 Motor Curr 953
D2 40 8 Cap V 953
D2 40 9 Cap Max V 953
D2 40 10 Cap Min V 954
D2 40 11 Key V 954
D2 40 12 Key Max V 954
D2 40 13 Key Min V 954
D2 40 17 Center Prox SW 954
D2 40 18 Target Angle 954
D2 40 19 Steer Angle 954
D2 40 20 Wire Guidance Status 954
D2 40 21 APP Angle Forward 954
D2 40 22 APP Angle Reverse 954
D2 40 23 Side Error Forward 954
D2 40 24 Side Error Reverse 954
D2 40 25 Side Dist Forward 954
D2 40 26 Side Dist Reverse 954
D2 40 27 Frequency IN Range 954
D2 50 Pump 955
D2 50 1 Target Speed 956
D2 50 2 Motor Speed 956
D2 50 3 Motor ENC 956
D2 50 5 Cont Temp 956
D2 50 6 Motor Temp 956
D2 50 7 Motor Curr 956
D2 50 8 Cap V 956
D2 50 9 Cap Max V 956
D2 50 10 Cap Min V 956
D2 50 11 Key V 956
D2 50 12 Key Max V 956
D2 50 13 Key Min V 956
D2 70 Forward Antenna 957
D2 70 1 Line Frequency 957
D2 70 2 Field Strength 957
D2 70 3 Line Strength 957
D2 70 4 Path 957
D2 71 Reverse Antenna 958
D2 71 1 Line Frequency 958
D2 71 2 Field Strength 958
D2 71 3 Line Strength 958
D2 71 4 Path 958
D2 90 CAN I/O 959
D2 90 1 Height ENC 960
D2 90 2 Height ENC 960
D2 90 5 Gate Switch 961
D2 90 6 Lift Limit Switch 961
D2 90 7 Slack Chain Switch 961
D2 90 9 Brake Switch 961
D2 90 10 WG Switch 961
D2 90 14 Horn Switch 961
D2 90 15 Lift Switch 961
D2 90 16 Lower Switch 961
D2 90 17 Traction Input 961
D2 90 18 Hydraulic Input 961
D2 90 19 Auto CTR CW Sig 961
D2 90 20 Auto CTR CCW Sig 961
D2 90 21 MTS Q Line 961
D2 90 22 MTS D Line 961
D2 90 23 Steer Stat 961
D2 90 50 WG Light Connect 961
D3 Output 962
D3 10 Display 962
D3 10 10 Display Com 962
D3 10 30 Trac Comm 962
D3 10 40 Steer Com 962
D3 10 50 Pump Com 962
D3 10 70 Forward Antenna 963
D3 10 71 Reverse Antenna 963
D3 10 90 CAN I/O Com 963
D3 30 Traction 963
D3 30 1 U-V Line DC Curr 964
D3 30 2 U-W Line DC Curr 964
D3 30 3 V-W Line DC Curr 964
D3 30 4 Motor Open 964
D3 30 5 Motor Circuit 964
D3 30 6 Brake 964
D3 30 7 MC 964
D3 30 10 Lift/Lower 964
D3 30 11 Load Hold 964
D3 30 12 LH Valve Relay 964
D3 30 15 Horn 964
D3 30 17 Audible Alarm 964
D3 40 Steer 965
D3 40 1 U-V Line DC Curr 965
D3 40 2 U-W Line DC Curr 965
D3 40 3 V-W Line DC Curr 965
D3 40 4 Motor Open 965
D3 40 5 Motor Circuit 965
D3 40 6 Status Line 965
D3 50 Pump 966
D3 50 1 U-V Line DC Curr 966
D3 50 2 U-W Line DC Curr 966
D3 50 3 V-W Line DC Curr 966
D3 50 4 Motor Open 966
D3 50 5 Motor Circuit 966
D3 90 CAN I/O 967
D3 90 15 WG Light 967
D3 90 16 Sonalert 967
Calibration 967
550089223-9000YRM1648-(01-2015)-US-EN 971
550267564-0630YRM2448-(09-2022)-US-EN 1103
General 1109
General 1109
Description 1109
Discharging The Capacitors 1110
Master Drive Unit Repair 1114
Maintenance 1114
Draining the Oil 1114
Remove 1114
Disassemble 1116
Clean and Inspect 1117
Assemble 1117
Install 1118
Replace the Wheel Seal on Kordel Drive Units 1118
Tools required 1118
Truck setup 1118
Wheel shaft seal and protection ring removal (method 1) 1119
Wheel shaft seal and protection ring removal (method 2) 1119
Wheel shaft seal and protection ring installation 1121
Troubleshooting 1122
550289235-0800YRM5432-(05-2023)-US-EN 1125
Weight and Dimensions 1131
Safety and Precautions 1132
Safety Procedures For Working Near The Mast 1132
Before Starting Repairs To The Hydraulic System Always 1132
Preparing Truck For Assembly 1133
List of All Special Tools and Equipment Needed for the Assembly 1133
Preparing Mast and Platform for Initial Assembly 1133
Preparing Drive Frame for Assembly 1134
Truck Assembly 1135
Installing Mast and Platform to Drive Frame 1135
Connecting Hydraulic Hoses 1135
Connecting Electrical Connectors 1136
Installing Wire Guide Antenna 1140
Programing and Parameters 1140
Installing Drive Frame Cover 1140
General Checks After Assembly 1141
Plumbing Check 1141
Lubrication Check 1141
Functionality Check 1141
Cleaning 1141
Labels 1141

S.V 05/24