This is the Highly Detailed factory service repair manual for theYALE F876 GDP90DC LIFT TRUCK, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.YALE F876 GDP90DC LIFT TRUCK Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
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
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
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YALE F876 GDP90DC LIFT TRUCK (EUROPE) Service Repair Manual
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........................................................................................................ 550033400 0100 YRM 1390 11/13
CAB HEATER................................................................................................................. 550033398 0100 YRM 1459 08/12
FRAME............................................................................................................................ 550061801 0100 YRM 1594 08/12
CUMMINS ENGINE FAULT CODE GUIDE.................................................................... 524211827 0600 YRM 1101 07/14
COOLING SYSTEM........................................................................................................ 550061806 0700 YRM 1595 09/13
ZF TRANSMISSION OPERATION AND DIAGNOSTICS............................................... 550035502 1300 YRM 1455 09/13
TRANSMISSION REPAIR (ZF-WG161)......................................................................... 550035503 1300 YRM 1456 08/12
DIFFERENTIAL............................................................................................................... 524150779 1400 YRM 0046 08/12
PLANETARY DRIVE AXLE (WET SYSTEM)................................................................. 524150780 1400 YRM 0944 08/12
STEERING SYSTEM...................................................................................................... 550035504 1600 YRM 1479 08/12
BRAKE AND HYDRAULIC COOLING SYSTEM........................................................... 550035505 1800 YRM 1498 03/13
HYDRAULIC SYSTEM.................................................................................................... 550035506 1900 YRM 1478 11/14
HYDRAULIC CONTROL SYSTEM................................................................................. 550035498 2200 YRM 1481 08/12
ELECTRICAL SYSTEM.................................................................................................. 550061811 2200 YRM 1592 09/13
2-STAGE MAST.............................................................................................................. 550088524 4000 YRM 1647 05/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
ASSEMBLY GUIDE........................................................................................................ 524230692 8000 YRM 1181 12/14
DIAGRAMS..................................................................................................................... 550061816 8000 YRM 1591 10/13
PERIODIC MAINTENANCE............................................................................................ 550061821 8000 YRM 1593 07/12
CAPACITIES AND SPECIFICATIONS........................................................................... 550061826 8000 YRM 1596 07/13
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
PART NO. 550061831 (12/14)
2. 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 con-
tained 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 re-
move 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 man-
ual:
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 back-
ground. The CAUTION symbol and word are on yellow background.
4. 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
Table of Contents
ii
5. 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
Table of Contents
iii
6. 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
Table of Contents
iv
7. 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]
Table of Contents
v
8. 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.
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.
The remove and replace instructions for the cab as an
assembly are in the frame YRM specific to each
model lift truck.
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:
1. Place the lift truck on a solid, level surface.
2. Lower the mast completely and tilt forward.
3. Place the shift lever in NEUTRAL.
4. Apply the parking brake.
5. Shut down the engine.
0100 YRM 1390 General
1
9. 1. HEATER SECTION
2. INCHING PEDAL
3. BRAKE PEDAL
4. ACCELERATOR PEDAL
5. STEERING COLUMN
6. FRONT, REAR, AND TOP WINDOWS
7. 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
Description of Operation 0100 YRM 1390
2
10. Description of Operation
CAB STRUCTURE
The cab frame is a welded structure. The overhead
guard is an integral part of the cab frame. See Fig-
ure 1. In order to maintain maximum overhead protec-
tion, changes to the cab frame and integrated over-
head guard are not allowed. There are two cab op-
tions: 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 inte-
rior 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 po-
sition 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.
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 direc-
tional 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 op-
erated. See Raising and Lowering Cab, Raise Cab,
Figure 8.
NOTE: If the optional electrical cab tilt pump is inop-
erable, the cab can be raised or lowered by using the
manually operated cab tilt hand pump.
A. PULL DIRECTION OF THE TILT LATCH RE-
LEASE
1. CAB SUPPORT FRAME
2. CAB TILT HAND PUMP
3. CAB LATCH
4. CAB TILT CYLINDER
Figure 2. Cab Tilt System
A. LOWER
B. RAISE
1. PUMP LEVER CONNECTION
2. PUMP DIRECTIONAL VALVE
Figure 3. Cab Tilt Hand Pump
0100 YRM 1390 Description of Operation
3
11. 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, move-
ment 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 cylin-
der. 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 deter-
mined by a retaining ring in the cab tilt cylinder.
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 pres-
sure, the cylinder check valve will raise to allow the oil
at the piston side of the cylinder to return to the reser-
voir. The cylinder cannot lower when there is insuffi-
cient 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.
Description of Operation 0100 YRM 1390
4
12. 1. ROD AREA
2. CAB TILT CYLINDER
3. FREE FALL INTERCONNECTION
4. CHECK VALVE
5. PULL
6. ELECTRIC CAB TILT PUMP (OPTIONAL)
7. RESERVOIR
8. RELIEF VALVE
9. CAB TILT HAND PUMP
10. RESERVOIR CHECK VALVE
11. LOWER
12. PUMP DIRECTIONAL VALVE
13. RAISE
14. LATCH
15. PUSH
Figure 4. Cab Tilt System
0100 YRM 1390 Description of Operation
5
13. 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.
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 Lower-
ing Cab.
3. Place the pump lever connection in the fully down
position to create easy access to the fill cap. See
Figure 5.
1. FILL CAP
2. PUMP LEVER CONNECTION
Figure 5. Hand Pump
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 Mainte-
nance YRMfor the correct hydraulic oil specifica-
tion.
Figure 6. Cab Tilt Label
6. Install the fill cap. See Figure 5.
7. Tilt/raise the cab and make sure the maximum til-
ted/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 posi-
tion and completely latched. Refer to the section
Raising and Lowering Cab.
Oil Filling for Cab Tilt System 0100 YRM 1390
6
14. 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 parti-
ally open, is locked with the tilt latch, or serious
personal injury may occur.
CAUTION
Cab damage may occur if the mast is not com-
pletely tilted forward.
1. Tilt the mast fully forward.
2. Remove all unsecured items from the cab.
3. Close and securely latch the left-hand and right-
hand cab doors.
4. Clear all obstacles from the right-hand side of the
lift truck. Provide a minimum of 2 m (7 ft) clear-
ance 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 push-
button, 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.
A. LOWER B. RAISE
1. PUMP LEVER CONNECTION
2. PUMP DIRECTIONAL VALVE
Figure 7. Pump and Direction Valve
1. CAB
2. FRAME
3. TILT LATCH RELEASE KNOB
4. ELECTRIC CAB TILT PUSH-BUTTON (OP-
TIONAL)
5. PUMP LEVER
Figure 8. Pump Lever and Tilt Latch Release Knob
0100 YRM 1390 Raising and Lowering Cab
7
15. LOWER 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 parti-
ally open, is locked with the tilt latch, or serious
personal injury may occur.
CAUTION
Cab damage may occur if the mast is not com-
pletely tilted forward.
1. Make sure all foreign items/tools are removed
from under the cab.
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 push-
button, if equipped), until the cab locks in the par-
tially 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.
Cab Door Assembly
CAB DOOR
Remove
1. Open the sliding windows.
2. Attach a lift strap at the left-hand and right-hand
side of the sliding windows inside the sliding win-
dow frame. Place a cushion between the sliding
window frame and the lift straps (left-hand and
right-hand sides) to prevent damage.
3. Position the cab door at a 90° angle to the frame,
so the cab door can be lifted out the hinges.
CAUTION
Use caution when lifting the cab door to avoid
damage to the cab frame.
4. Lift the cab door out of the cab door hinges. See
Figure 9.
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.
2. Attach a lift strap to the left-hand and right-hand
side of the sliding windows inside the sliding win-
dow 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.
4. Slowly lower the cab door until the cab door is
seated on the hinges.
5. Remove the lift strap.
6. Make sure the cab door is opening, closing, and
moving properly on the hinges.
7. Make sure the locking system functions properly.
NOTE: Adjust one hinge at a time.
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.
9. Loosen the three capscrews and use a nylon
hammer to adjust the hinge. Retighten the cap-
screws.
10. If necessary, adjust the door striker pin. Refer to
the section Door Striker Pin Adjustment.
Cab Door Assembly 0100 YRM 1390
8
16. A. VIEW TURNED 90° COUNTERCLOCKWISE
1. DOOR HINGE
2. DOOR PUSH-BUTTON
3. DOOR RELEASE
4. DOOR LATCH
5. 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.
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.
1. DOOR HINGE
2. CAPSCREW
3. CAB FRAME
Figure 10. Door Hinge
0100 YRM 1390 Cab Door Assembly
9
17. 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 cap-
screws.
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 posi-
tioned correctly in the door opening of the cab.
5. Open the door with the release button still en-
gaged.
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 cor-
rectly seated against the door seals.
8. If necessary, repeat Step 1 through Step 7.
1. CAB FRAME
2. SECURING NUT
3. DOOR STRIKER PIN
Figure 11. Door Striker Pin
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 at-
tached 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.
1. CAPSCREW
2. WASHER
3. PLASTIC COVER
4. CAPSCREW
5. DOOR LATCH
6. CAB DOOR
7. CONNECTOR ROD
Figure 12. Door Latch
Cab Door Assembly 0100 YRM 1390
10
18. 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.
4. Remove the large nut and washer that retain the
door handle on the release button side of the door
handle.
5. Remove the door handle and two rubber cush-
ions.
Install
1. Position the door handle and two rubber cushions
on the door. See Figure 13.
2. Install the washer and large nut on the release
button side of the door handle.
1. WASHER
2. CAPSCREW
3. PLASTIC PLUG
4. CAB DOOR
5. RUBBER CUSHION (LARGE)
6. DOOR HANDLE
7. RUBBER CUSHION (SMALL)
Figure 13. Door Handle
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
1. Remove the door latch. Refer to the section Door
LatchRemove.
2. Remove the capscrew that retains the door re-
lease inside the bar located at the inside of the
door frame. See Figure 15.
3. Remove the connector rod and door release from
inside the bar.
1. CAPSCREW
2. DOOR RELEASE
3. CONNECTOR ROD
4. CAB DOOR
Figure 14. Door Release
0100 YRM 1390 Cab Door Assembly
11
19. 4. Disconnect the connector rod from the door re-
lease.
Install
1. Connect the connector rod to the door release.
See Figure 14.
2. Install the connector and door release inside the
bar, 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 loca-
ted 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.
2. Position the cab door in the locking system.
3. Tighten the three nuts.
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.
5. Install the three plastic caps to the nuts located at
the inside of the door frame.
1. CAB DOOR
2. WASHER
3. SEAL
4. DOOR HOLDER (PUSH BUTTON)
5. WASHER
6. NUT
7. 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 re-
tain the left-hand panel to the frame and remove
the left-hand panel.
4. Disconnect the electrical connector from the elec-
trical 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 electri-
cal tilt pump to the bracket.
Cab Tilt System 0100 YRM 1390
12
20. 9. Remove the electrical tilt pump from the bracket.
Install
1. Position the electrical tilt pump on the bracket.
2. Install the two capscrews that retain the electrical
tilt pump on the bracket.
3. Position the bracket with the electrical tilt pump on
the frame.
4. Install the two nuts that retain the bracket with the
electrical tilt pump to the frame.
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 in-
stall 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 po-
sition. 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
Remove
1. Tilt/raise the cab to the fully open position. Refer
to the section Raising and Lowering Cab.
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.
3. Remove the two capscrews and washers that re-
tain the left-hand panel to the frame and remove
the left-hand panel.
4. Remove the two capscrews and washers that re-
tain the hand pump to the frame. See Figure 16.
NOTE: Keep the hydraulic hose connection locations
from the hand pump facing upward to avoid spilling
hydraulic oil.
5. Tag and disconnect the three hydraulic hoses and
place plugs on the three hose ends. See Fig-
ure 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 in-
stall 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 Lower-
ing Cab, Raise Cab, Figure 8.
5. Lower the cab to the fully lowered and latched po-
sition. Refer to the section Raising and Lowering
Cab.
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.
7. Make sure the cab tilt system functions correctly.
0100 YRM 1390 Cab Tilt System
13
21. A. 180 DEGREES TURNED
1. FRAME
2. HAND PUMP
3. HYDRAULIC HOSE
4. WASHER
5. CAPSCREW
Figure 16. Hand Pump
Cab Tilt System 0100 YRM 1390
14
22. CAB TILT CYLINDER
Remove
1. Tilt/raise the cab until it locks in the partially open
position. Refer to the section Raising and Lower-
ing Cab.
2. Place wooden blocks between the frame and the
cab to prevent the cab from suddenly lowering.
3. Tag and disconnect the two hydraulic hoses from
the cab tilt cylinder and install caps on the hy-
draulic 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 re-
move 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 as-
sembly from the cylinder shell in a horizontal po-
sition.
7. Remove the piston rod assembly from the cylin-
der shell by pulling it out of the cylinder shell.
CAUTION
Be careful not to damage the grooves when re-
moving 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.
1. CAB TILT FRAME
2. SNAP RING
3. CAB TILT CYLINDER
4. PIN
5. FRAME
Figure 17. Cab Tilt Cylinder
0100 YRM 1390 Cab Tilt System
15
23. 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.
Figure 18. Cab Tilt Cylinder
Legend for Figure 18
1. FILTER
2. HYDRAULIC FITTINGS
3. SPACER
4. WIPER
5. GLAND RETAINING RING
6. U-CUP
7. O-RING
8. GLAND
9. END OF STROKE RING
10. SHAFT RETAINING RING
11. O-RING
12. O-RING
13. SLEEVE
14. PISTON
15. WASHER
16. O-RING
17. CHECK VALVE ASSEMBLY
18. PILOT PISTON ASSEMBLY
19. O-RING
15. Use a special tool to remove the check valve as-
sembly, located inside the cylinder shell.
16. Remove and discard the pilot piston assembly, lo-
cated 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 manufac-
turer’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.
Cab Tilt System 0100 YRM 1390
16
24. Assemble
NOTE: Make sure that all parts are clean before as-
sembly.
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 in-
side the cylinder shell.
2. Use a special tool to install the check valve as-
sembly 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 as-
sembly into the cylinder shell in a horizontal posi-
tion.
10. Lubricate the cylinder shell bore with clean hy-
draulic 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.
14. Install the wiper.
Install
1. Position the cab tilt cylinder inside the frame with
the hydraulic hose fittings positioned to the under-
side.
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 cylin-
der and hydraulic hoses and connect the two hy-
draulic 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 Lower-
ing 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.
0100 YRM 1390 Cab Tilt System
17
25. 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 Fig-
ure 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. FRONT LATCH
2. REAR LATCH
3. FRAME
4. HYDRAULIC HOSE
5. CAPSCREW
6. WASHER
7. NUT
8. T-ADAPTER
Figure 19. Latch
Cab Tilt System 0100 YRM 1390
18
26. 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 oper-
ation.
Brake and Inching Pedals
REMOVE
1. Remove the split pin and washer from the rod, lo-
cated behind the inching pedal.
2. Disconnect the rod from the inching pedal.
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.
5. Remove the inching and brake pedal assembly.
6. Separate the inching pedal from the brake pedal
and remove the three shims.
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.
8. Check if adjustments to the inching and brake
pedals are required, and adjust as needed. Refer
to the sections Brake Pedal Adjustment and In-
ching Pedal Adjustment.
BRAKE PEDAL ADJUSTMENT
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.
Wet Brake
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.
1. BRAKE PEDAL
2. INCHING PEDAL
3. ADJUSTMENT BOLT FOR BRAKE PEDAL AS-
SEMBLY
4. ADJUSTMENT BOLT FOR INCHING/BRAKE
PEDAL COUPLING
5. ADJUSTMENT BOLT FOR INCHING PEDAL AS-
SEMBLY
Figure 20. Brake Pedal System
0100 YRM 1390 Brake and Inching Pedals
19
27. INCHING PEDAL ADJUSTMENT
NOTE: Inching pedal adjustment influences inching
sensor adjustment and inching sensor calibration. Af-
ter the inching pedal has been adjusted, always cor-
rect inching sensor adjustment and inching sensor
calibration. Incorrect inching sensor calibration trig-
gers 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,Fig-
ure 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 ad-
ditional spring installed under the inching pedal al-
lows 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.
Figure 21. Brake Inching Pedal Adjustment
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, pro-
ceed as follows:
a. Tilt/raise the cab until the latch locks in the par-
tial 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) in-
ching pedal is between 600 and 700 mV.
1. SENSOR MOUNTING CAPSCREW
2. INCHING PEDAL SENSOR
Figure 22. Sensor Adjustment
Brake and Inching Pedals 0100 YRM 1390
20
28. d. Tighten the two sensor-mounting capscrews
and make sure the output voltage of the in-
ching pedal sensor is still between 600 and
700 mV, with the inching pedal in the up posi-
tion.
e. Lower the cab to the fully lowered and latched
position. Refer to the section Raising and Low-
ering Cab.
6. Turn the key switch to the OFF position.
7. Disconnect the laptop computer from the diagnos-
tic plug.
INCHING PEDAL SENSOR CALIBRATION
PROCEDURE USING DANA DASHBOARD
SOFTWARE
1. Make sure the pedals and inching sensor have
been correctly adjusted.
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.
5. Select the "Inching Pedal Calibration" mode of the
Dana Dashboard software and follow the instruc-
tions.
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 "In-
ching Pedal Calibration" process must be repea-
ted.
8. Turn the key switch to the OFF position.
9. Disconnect the laptop computer from the diagnos-
tic plug.
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 sec-
onds, the display will show:
2. Release the "S" button after 15 seconds when the
display shows:
3. Push the "M" button until the APC200 display
shows the analog input:
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 sen-
sor 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.
0100 YRM 1390 Brake and Inching Pedals
21
29. 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 in-
ching pedal sensor until the reading is within
specifications.
7. Turn the key switch to the OFF position to leave
the APC200 test function group.
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 sec-
onds, the display will show:
2. Release the "S" button after 15 seconds when the
display shows:
3. Push the "M" button several times until the
APC200 display shows:
4. Push the "S" button once to start the inching
pedal sensor calibration. The APC200 display will
show:
5. Push the "S" button while in the pedal up position.
The APC200 display will show:
6. Fully depress the inching pedal and push the "S"
button again.
7. When the calibration has been completed, the
APC200 display will show:
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 seg-
ments 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
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 in-
ching sensor is between 0.8-0.9V (800-900 mV).
4. If voltage is incorrect, proceed as follows:
a. Raise the Cab until the latch locks in the
partial open position.
b. Loosen the two mounting bolts of the in-
ching 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.
d. Tighten the two mounting bolts and verify
output voltage is still correct.
Brake and Inching Pedals 0100 YRM 1390
22
30. 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 cor-
rectly 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.
7. Turn the ignition key switch to the ON position but
DO NOT start the truck. The inch pedal calibration
mode is now active.
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 Trans-
mission 1300YRM1455, Description for rectifica-
tion.
11. After calibration is finished, switch OFF ignition
and turn the calibration switch OFF (flip the switch
to the up position).
Accelerator Pedal and Sensor
ACCELERATOR PEDAL
Remove
1. Remove the spring and capscrew on which the
pedal pivots. See 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
1. Maneuver the lower part of the pedal from the cab
interior through the hole in the floorplate.
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 Fig-
ure 23.
3. Fit the spring and check the adjustment of the ac-
celerator pedal sensor.
ACCELERATOR PEDAL SENSOR
Adjust
1. Start the engine and verify that idle speed will
raise after the pedal has been depressed be-
tween 6 and 10 mm (0.236 and 0.394 in.). See Di-
mension A in Figure 23.
2. If adjustment is incorrect, raise the cab until it
rests in the partially open position. Refer to the
section Raising and Lowering Cab.
3. Place a 5 mm (0.197 in.) spacer between the
pedal and the rubber pedal bumper.
4. Loosen the mounting screws of the pedal sensor
and turn the sensor until engine speed is about to
increase from idle.
5. Tighten the mounting screws and remove the
spacer between pedal and pedal bumper. Stop
the engine.
0100 YRM 1390 Accelerator Pedal and Sensor
23
31. Figure 23. Accelerator Arrangement
Legend for Figure 23
1. DIMENSION A
2. ACCELERATOR PEDAL
3. ACCELERATOR PEDAL ADJUSTMENT
4. ACCELERATOR PEDAL SENSOR
5. MOUNTING SCREW
6. CONNECTING ROD
7. CAB FLOOR PLATE
8. ACCELERATOR PEDAL STOP
9. COUNTERCLOCKWISE
10. SLOTTED HOLE
Seat Assembly
SEAT
Remove
NOTE: Use a lifting device for the removal of 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 me-
chanical seat. There are two electrical connectors on
the air suspension seat.
2. Disconnect the electrical connector(s).
3. Turn the electrical plug counterclockwise and dis-
connect the electrical plug located at the instru-
ment 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.
5. Remove the seat. See Figure 24.
Install
NOTE: Use a lifting device to install the seat.
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 lo-
cated above the sliding system that retain the
seat to the seat suspension.
3. Connect the electrical plug located at the instru-
ment panel side console.
NOTE: There is one electrical connector on the me-
chanical seat. There are two electrical connectors on
the air suspension seat.
4. Connect the connector(s).
NOTE: The ground cable is attached with the cap-
screw at the right rear corner of the suspension.
5. Connect the battery ground cable.
Seat Assembly 0100 YRM 1390
24
32. 1. SEAT CUSHION
2. BACK CUSHION
3. BOOT
4. 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.
3. Remove and discard the screw from the front right
side.
4. Remove and discard the three clips from the
cushion front.
5. Slide the seat fully backward.
6. Grip the seat cushion on the front right corner.
7. Lift the seat cushion until the guide block be-
comes 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 con-
nector block.
14. Remove and discard the seat cushion.
Install
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.
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 audi-
ble click.
8. Pull the cushion upward to make sure the cushion
is correctly locked into position.
9. Install three new clips to the cushion front.
10. Install a new screw to the front right side.
0100 YRM 1390 Seat Assembly
25
33. 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 cush-
ion to the back pan.
5. Remove the back cushion.
Install
1. Position the back cushion.
2. Install the two screws that retain the back cushion
to the back pan.
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 oper-
ating position.
SEAT SUSPENSION REPLACEMENT
Refer to Figure 24 for the following procedures.
1. Remove the seat. Refer to the section SeatRe-
move.
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 sus-
pension 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 SeatRe-
move.
2. Use a small pry bar to remove the 22 plastic plugs
that retain the boot to the seat suspension.
3. Remove the boot.
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.
Seat Assembly 0100 YRM 1390
26
34. 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 hous-
ing pivot shaft nut.
0100 YRM 1390 Seat Assembly
27
35. 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 hous-
ing while sliding the lower housing forward to disen-
gage the height adjustment rollers from the roller
channels of the lower housing.
Seat Assembly 0100 YRM 1390
28
36. 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 hous-
ing pivot shaft nut.
0100 YRM 1390 Seat Assembly
29
37. 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 suspen-
sion scissor forward to disengage the front suspen-
sion 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.
Seat Assembly 0100 YRM 1390
30
38. 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.
0100 YRM 1390 Seat Assembly
31
39. 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.
Seat Assembly 0100 YRM 1390
32
40. 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 push-
on 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.
0100 YRM 1390 Seat Assembly
33
41. STEP 6.
Install the rear bearing tubes to the suspension scis-
sor.
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.
Seat Assembly 0100 YRM 1390
34
42. STEP 9.
Install the weight indicator tension spring on the sus-
pension 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).
0100 YRM 1390 Seat Assembly
35
43. STEP 12.
For mechanical seats: Position the height adjust-
ment 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.
Seat Assembly 0100 YRM 1390
36
44. 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 posi-
tion the front suspension scissor rollers of the sus-
pension scissor into the roller channels of the lower
housing.
STEP 17.
Remove the wooden block and place the height ad-
justment 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.
0100 YRM 1390 Seat Assembly
37
45. 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.
Seat Assembly 0100 YRM 1390
38
46. 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.
0100 YRM 1390 Seat Assembly
39
47. STEP 6.
Using a 9/16" Allen wrench, remove the upper hous-
ing 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.
Seat Assembly 0100 YRM 1390
40
48. 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 pneu-
matic system.
STEP 11.
Remove the tie wrap that retains the air valve electri-
cal wire harness and tube to the suspension.
0100 YRM 1390 Seat Assembly
41
49. STEP 12.
Disconnect the orange electrical wire connector from
the air valve body.
STEP 13.
Disconnect the compressor black electrical wire con-
nector from the suspension harness at the rear of
the compressor assembly.
STEP 14.
Unscrew (counterclockwise) the plastic tube retain-
ing nut from the output port of the compressor. Re-
move the nut and O-ring from the tube and discard.
Seat Assembly 0100 YRM 1390
42
50. 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 sus-
pension.
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.
0100 YRM 1390 Seat Assembly
43
51. STEP 2.
Position the compressor and bracket into the sus-
pension 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.
Seat Assembly 0100 YRM 1390
44
52. 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 tighten-
ing 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 compres-
sor as shown.
0100 YRM 1390 Seat Assembly
45
53. STEP 7.
Connect the compressor black electrical wire con-
nector 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 har-
ness and tube to the suspension.
Seat Assembly 0100 YRM 1390
46
54. 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.
0100 YRM 1390 Seat Assembly
47
55. 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.
Seat Assembly 0100 YRM 1390
48
56. 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 ca-
ble to the armrest. See Figure 25.
3. Disconnect the cable from the armrest (1,Fig-
ure 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. LEVER
2. ROD END
3. LOCK NUT
4. MOUNTING CAPSCREW
5. ARMREST
6. CABLE
7. GAS SPRING
8. WASHER
9. ARMREST FRAME
10. NUT
Figure 25. Power Assist Armrest
0100 YRM 1390 Power Assist Armrest
49
