Yale GC030VX Guide

Maintenance
CALIBRATION
PROCEDURES
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809];
GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/
GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810];
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910, B910];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875, C875];
GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/
GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS)
[E818, F818];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX)
[F813, G813, H813, J813];
GLP/GDP60VX, GLP/GDP70VX; (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) [C878, D878, E878];
GLC/GDC60VX, GLC/GDC70VX; (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) [C879, D879, E879, F879];
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) [A909, B909];
GLC030-035VX, GLC040SVX [D809];
GLP/GDP16-18VX, GLP/GDP20SVX (GLP/GDP030-035VX, GLP/
GDP040SVX) [D810];
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [C910];
GLP/GDP20VX, GLP/GDP25VX, GLP/GDP30VX, GLP/GDP35VX
(GP/GLP/GDP040VX, GP/GLP/GDP050VX, GP/GLP/GDP060VX,
GP/GLP/GDP070VX) [D875]
This manual contains information that is confidential and/or proprietary to Yale Ma-
terials Handling Corporation, its subsidiaries and/or vendors. Copying or distribu-
tion of any sections of this manual marked "Confidential/Proprietary" is prohibited.
PART NO. 524223780 8000 YRM 1134

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.

©2014 Yale Materials Handling Corp.
TABLE OF CONTENTS
Description ................................................................................................................................................................1
Proc_Cal_001: Service Password Entry ...................................................................................................................4
When to Perform .................................................................................................................................................. 4
Why Perform .........................................................................................................................................................4
How to Perform .....................................................................................................................................................4
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed ....................................................................... 5
When to Perform .................................................................................................................................................. 5
Calibration Order .................................................................................................................................................. 5
Why Perform .........................................................................................................................................................5
How to Perform .....................................................................................................................................................5
Proc_Cal_003: Save and Exit ...................................................................................................................................8
When to Perform .................................................................................................................................................. 8
Why Perform .........................................................................................................................................................8
How to Perform .....................................................................................................................................................8
Proc_Cal_004: Lift Valve Output Threshold ........................................................................................................... 10
When to Perform ................................................................................................................................................ 10
Calibration Order ................................................................................................................................................ 10
Why Perform .......................................................................................................................................................10
How to Perform ...................................................................................................................................................10
Proc_Cal_005: Lower Valve Output Threshold ...................................................................................................... 13
When to Perform ................................................................................................................................................ 13
Calibration Order ................................................................................................................................................ 13
Why Perform .......................................................................................................................................................13
How to Perform ...................................................................................................................................................13
Proc_Cal_006: Tilt Back Valve Output Threshold .................................................................................................. 16
When to Perform ................................................................................................................................................ 16
Calibration Order ................................................................................................................................................ 16
Why Perform .......................................................................................................................................................16
How to Perform ...................................................................................................................................................16
Proc_Cal_007: Tilt Forward Valve Output Threshold ............................................................................................. 19
When to Perform ................................................................................................................................................ 19
Calibration Order ................................................................................................................................................ 19
Why Perform .......................................................................................................................................................19
How to Perform ...................................................................................................................................................19
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold .............................................................................................. 22
When to Perform ................................................................................................................................................ 22
Calibration Order ................................................................................................................................................ 22
Why Perform .......................................................................................................................................................22
How to Perform ...................................................................................................................................................22
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold .............................................................................................. 25
When to Perform ................................................................................................................................................ 25
Calibration Order ................................................................................................................................................ 25
Why Perform .......................................................................................................................................................25
How to Perform ...................................................................................................................................................25
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold .............................................................................................. 28
When to Perform ................................................................................................................................................ 28
Calibration Order ................................................................................................................................................ 28
Why Perform .......................................................................................................................................................28
How to Perform ...................................................................................................................................................28
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold .............................................................................................. 31
Table of Contents
i

TABLE OF CONTENTS (Continued)
When to Perform ................................................................................................................................................ 31
Calibration Order ................................................................................................................................................ 31
Why Perform .......................................................................................................................................................31
How to Perform ...................................................................................................................................................31
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold .............................................................................................. 34
When to Perform ................................................................................................................................................ 34
Calibration Order ................................................................................................................................................ 34
Why Perform .......................................................................................................................................................34
How to Perform ...................................................................................................................................................34
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold .............................................................................................. 37
When to Perform ................................................................................................................................................ 37
Calibration Order ................................................................................................................................................ 37
Why Perform .......................................................................................................................................................37
How to Perform ...................................................................................................................................................37
Proc_Cal_014: Load Weight Zero Point ................................................................................................................. 40
When to Perform ................................................................................................................................................ 40
Calibration Order ................................................................................................................................................ 40
Why Perform .......................................................................................................................................................40
How to Perform ...................................................................................................................................................40
Proc_Cal_015: Loaded Weight Calibration .............................................................................................................42
When to Perform ................................................................................................................................................ 42
Calibration Order ................................................................................................................................................ 42
Why Perform .......................................................................................................................................................42
How to Perform ...................................................................................................................................................42
Proc_Cal_016: Transmission Valve Calibration ..................................................................................................... 45
Applicable System/Option .................................................................................................................................. 45
When to Perform ................................................................................................................................................ 45
Calibration Order ................................................................................................................................................ 45
Why Perform .......................................................................................................................................................45
How to Perform ...................................................................................................................................................45
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function ................................................... 47
Applicable System/Option .................................................................................................................................. 47
When to Perform ................................................................................................................................................ 47
Calibration Order ................................................................................................................................................ 47
Why Perform .......................................................................................................................................................47
How to Perform ...................................................................................................................................................47
Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electronic Extended Function ...................................... 49
Applicable System/Option .................................................................................................................................. 49
When to Perform ................................................................................................................................................ 49
Calibration Order ................................................................................................................................................ 49
Why Perform .......................................................................................................................................................49
How to Perform ...................................................................................................................................................49
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment ........................................................................52
Required Tools ................................................................................................................................................... 52
When to Perform ................................................................................................................................................ 52
Calibration Order ................................................................................................................................................ 52
Why Perform .......................................................................................................................................................52
How to Perform ...................................................................................................................................................52
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation ...................................................................................54
When to Perform ................................................................................................................................................ 54
Table of Contents
ii

TABLE OF CONTENTS (Continued)
Why Perform .......................................................................................................................................................54
How to Perform ...................................................................................................................................................54
Proc_Cal_026: Travel Speed Calibration ............................................................................................................... 55
When to Perform ................................................................................................................................................ 55
Calibration Order ................................................................................................................................................ 55
Why Perform .......................................................................................................................................................55
How to Perform ...................................................................................................................................................55
This section is for the following models:
(GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX) [C809];
GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
GDP035VX, GP/GLP/GDP040SVX) [C810];
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910, B910];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875, C875];
GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) [E818, F818];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813, J813];
GLP/GDP60VX, GLP/GDP70VX; (GP/GLP/GDP135VX, GP/GLP/GDP155VX) [C878,
D878, E878];
GLC/GDC60VX, GLC/GDC70VX; (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
[C879, D879, E879, F879];
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) [A909, B909];
(GLC030-035VX, GLC040SVX ) [D809];
GLP/GDP16-18VX, GLP/GDP20SVX (GLP/GDP030-035VX, GLP/GDP040SVX)
[D810];
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [C910];
GLP/GDP20VX, GLP/GDP25VX, GLP/GDP30VX, GLP/GDP35VX (GP/GLP/
GDP040VX, GP/GLP/GDP050VX, GP/GLP/GDP060VX, GP/GLP/GDP070VX)
[D875]
Table of Contents
iii

Description
This section is written assuming no experience with
electronic controllers. The menu progressions indicate
how many key presses it will take to get to a given
screen, versus detailing out every screen you would
see. Refer to Table 1 for calibration procedures. Refer
to Table 2 for an example of how to read calibration
procedures.
NOTE: The calibration procedures described in this
YRM may have to be repeated when any on-board
controllers, sensors, or related components are
replaced.
Table 1. Calibration Procedures
When Procedure is Used:
Proc_Cal/Procedure All
Units
3
Functions
Electronic-
Hydraulic
Valves
4
Functions
Electronic-
Hydraulic
Valves
5
Functions
Electronic-
Hydraulic
Valves
Mazda Engine
w/Electronic 1-
Speed
Transmission
Units w/
Load
Weight
Display
Electronic
Transmission
(Basic & L1)
Electronic
Extended
Function
(L2)
001 Service Password
Entry
X
002 Hydraulic Valve
Calibration Warm Up and
Air Bleed
X X X
003 Save and Exit X
004 Lift Valve Output
Threshold
X X X
005 Lower Valve Output
Threshold
X X X
006 Tilt Back Valve Output
Threshold
X X X
007 Tilt Forward Valve
Output Threshold
X X X
008 Aux 1 Dir A Valve
Output Threshold
X X X
009 Aux 1 Dir B Valve
Output Threshold
X X X
010 Aux 2 Dir A Valve
Output Threshold
X X
011 Aux 2 Dir B Valve
Output Threshold
X X
012 Aux 3 Dir A Valve
Output Threshold
X
8000 YRM 1134 Description
Confidential/Proprietary - Do Not Copy or Duplicate 1

Table 1. Calibration Procedures (Continued)
When Procedure is Used:
Proc_Cal/Procedure All
Units
3
Functions
Electronic-
Hydraulic
Valves
4
Functions
Electronic-
Hydraulic
Valves
5
Functions
Electronic-
Hydraulic
Valves
Mazda Engine
w/Electronic 1-
Speed
Transmission
Units w/
Load
Weight
Display
Electronic
Transmission
(Basic & L1)
Electronic
Extended
Function
(L2)
013 Aux 3 Dir B Valve
Output Threshold
X
014 Load Weight Zero
Point
X
015 Loaded Weight
Calibration
X
016 Transmission Valve
Calibration (Basic & L1)
X
016A Transmission Valve
Calibration (L2)
X
016B Transmission Valve
Calibration (L1 & L2)
X X
019 Mazda LP and Gas
Acceleration Pedal
Adjustment
X
025 Hydraulic Valve
Pressure Gage Installation
X X X
026 Travel Speed
Calibration
X X
Table 2. How to Read Calibration Procedure
Proc_Cal_XXX Number and title of calibration procedure.
Calibration Order Calibration procedures that must be completed before this
procedure, if any.
When to Perform Performed either during initial manufacture or after component
changes.
Why Perform Description of why the procedure is performed.
Proc_Cal_001: Service Password Entry
Proc_Cal_002: Hydraulic Valve Calibration
Warm Up
Calibration procedures that must be completed before this
procedure, if any.
Action Actions to perform other than calibration steps. Numbered
when needed for clarification.
NOTE: Perform all actions and calibration steps in the order shown.
Description 8000 YRM 1134
2 Confidential/Proprietary - Do Not Copy or Duplicate

Table 2. How to Read Calibration Procedure (Continued)
A. TYPICAL DISPLAY WITHOUT KEY,
WITH OPTIONS
B. TYPICAL DISPLAY WITH KEY,
WITHOUT OPTIONS
1. SYMBOLS USED IN CALIBRATION
PROCEDURES
2. NUMBERS FOR SERVICE PASSWORD ENTRY -
SEE PROC_CAL_001
Step 1: Press * One Time
You will see:
Passwords
Enter Password
Step 2: Press * One Time
You will see:
Enter Password
Calibration steps.
Information Information to assist in completion of calibration procedure.
NOTE: Perform all actions and calibration steps in the order shown.
8000 YRM 1134 Description
Confidential/Proprietary - Do Not Copy or Duplicate 3

Proc_Cal_001: Service Password Entry
WHEN TO PERFORM
Performed when any service menu-related items must
be performed.
WHY PERFORM
Service-related items are protected from inadvertent
access. This procedure allows the service menus to
be accessed.
HOW TO PERFORM
WARNING
Keep yourself and all others clear of the lift mech-
anism. Never allow anyone under or on the forks.
Never put hands, arms, head, or legs through the
mast or near the carriage or lift chains. This warn-
ing applies not only to the operator but also the
helper. A helper must not be near the load or the
lift mechanism while the operator is attempting to
handle a load. The lift mechanism has moving
parts with close clearances that can cause seri-
ous injury.
Refer to Table 3 for the procedures on how to perform
Pro_Cal_001: Service Password Entry.
Table 3. Proc_Cal_001: Service Password Entry
A. TYPICAL DISPLAY WITHOUT KEY, WITH OPTIONS
B. TYPICAL DISPLAY WITH KEY, WITHOUT OPTIONS
NOTE: The password entry can only be done with the ignition ON and the engine OFF. If the engine is started,
and then turned OFF, the password will have to be re-entered.
Action: Ignition ON/EngineOFF
Step 1: Press * One Time. You Will See: Main Menu
Passwords
Step 2: Press * One Time. You Will See: Passwords
Enter Password
Step 3: Press * One Time. You Will See: Enter Password
Information: Refer to Number Location on Keypad and Enter Service Password (Default Service Password is
55555).
Step 4: Press * One Time. You Will See: Passwords or Main Menu
Enter Password
Proc_Cal_001: Service Password Entry 8000 YRM 1134
4 Confidential/Proprietary - Do Not Copy or Duplicate

Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air
Bleed
WHEN TO PERFORM
Performed when any hydraulic calibration items are
performed.
CALIBRATION ORDER
1. Proc_Cal_025
2. Proc_Cal_001
3. Proc_Cal_002
WHY PERFORM
Hydraulic calibrations are the process of setting the
hydraulic current levels that result in initial function
movement. Pressure and flow are directly related to
the hydraulic fluid viscosity which is a function of the
fluid temperature. Air, trapped within the lift valve as-
sembly, may produce slight mast movement at en-
gine start. This process ensures that the hydraulic
fluid achieves an optimum temperature, and that the
air is bled out of the lift valve and cylinders prior to
performing calibrations.
HOW TO PERFORM
WARNING
Keep yourself and all others clear of the lift mech-
anism. Never allow anyone under or on the forks.
Never put hands, arms, head, or legs through the
mast or near the carriage or lift chains. This warn-
ing applies not only to the operator but also the
helper. A helper must not be near the load or the
lift mechanism while the operator is attempting to
handle a load. The lift mechanism has moving
parts with close clearances that can cause seri-
ous injury.
Refer to Table 4 for the procedures on how to perform
Proc_Cal_002: Hydraulic Valve Calibration Warm Up
and Air Bleed.
8000 YRM 1134 Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed
Confidential/Proprietary - Do Not Copy or Duplicate 5

Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed
A. E-HYD CONTROL LEVERS
1. LIFT/LOWER
DIRECTION LIFT ↓
DIRECTION
LOWER ↑
2.TILT
DIRECTION BACK
↓
DIRECTION FWD
↑
3.*AUX 1 OR AUX
2
DIRECTION A ↑
DIRECTION B ↓
4.*AUX 2 OR AUX
3
DIRECTION A ↑
DIRECTION B ↓
5.*FOURTH
LEVER
6.*THIRD LEVER
7.SEAT ARMREST
*AUX 2 IS IN THE FOURTH LEVER LOCATION EXCEPT AS FOLLOWS: WITH 5 FUNCTION VALVE WITH CLAMPING ATTACHMENT,
AUX 2 IS IN THE THIRD LEVER LOCATION.
2. JOYSTICK
1. TILT BACK 2. AUX 1
DIRECTION A ↑
DIRECTION B ↓
3. LIFT ↓
4. ↑ LOWER
5. AUX 2
DIRECTION A ↑
DIRECTION B ↓
6. TILT FORWARD
7. SEAT ARMREST
Perform Proc_Cal_025: Hydraulic Valve Pressure Gage Installation and Proc_Cal_001: Service Password
Entry before proceeding.
Information: First determine if it is necessary to bleed the air out of the lift valve and cylinders. The hoist valve
air bleed procedure is necessary if the carriage moves slightly (approximately 1/4 inch) when the engine is
started, without activation of the lift control. The cylinder air bleed procedure is necessary if the cylinders have
not been previously cycled, or if the left function is not operating smoothly.
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 8000 YRM 1134
6 Confidential/Proprietary - Do Not Copy or Duplicate

Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed (Continued)
NOTE: Optional for initial manufacture.
Information: To ensure that the oil temperature is optimal, warm up the hydraulic fluid until it is within a range of
50 to 65°C (122 to 149°F).
Action:
•Ignition: ON
•Engine: High Idle
•Transmission: Neutral
•Park Brake: ON
Step 1: (Optional hoist valve air bleed): Activate Lift Control from neutral to full lift and back to neutral at a
rate of one or two times per second. Repeat until the lift function is operating smoothly and there is no
mast movement upon engine start.
Step 2: (Optional cylinder air bleed): Cycle function completely two or three times; repeat if necessary.
NOTE: Optional for initial manufacture.
Step 3: (Required warm up for service): Activate tilt at relief pressure until the hydraulic fluid temperature
is within the optimum range 50 to 65°C (12 to 149°F).
Step 4: Proceed to calibrate desired electro-hydraulic functions.
Information: You do not need to START or turn OFF the vehicle if you are performing other procedures.
8000 YRM 1134 Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed
Confidential/Proprietary - Do Not Copy or Duplicate 7

Proc_Cal_003: Save and Exit
WHEN TO PERFORM
Must be performed after any calibration except Proce-
dure 016, Transmission Valve Calibration.
WHY PERFORM
Calibration processes do not automatically save their
results until this routine is run.
HOW TO PERFORM
WARNING
Keep yourself and all others clear of the lift mech-
anism. Never allow anyone under or on the forks.
Never put hands, arms, head, or legs through the
mast or near the carriage or lift chains. This warn-
ing applies not only to the operator but also the
helper. A helper must not be near the load or the
lift mechanism while the operator is attempting to
handle a load. The lift mechanism has moving
parts with close clearances that can cause seri-
ous injury.
Refer to Table 5 for the procedures on how to perform
Proc_Cal_003: Save and Exit.
Proc_Cal_003: Save and Exit 8000 YRM 1134
8 Confidential/Proprietary - Do Not Copy or Duplicate

Table 5. Proc_Cal_003: Save and Exit
A. TYPICAL DISPLAY WITHOUT KEY, WITH OPTIONS
B. TYPICAL DISPLAY WITH KEY, WITHOUT OPTIONS
Information: You can enter this process from any of the sub menu levels. As such, you will be asked to press
the up or down arrow until you get to the Save and Exit Screen for the item you are working on.
Step:
Press or
Until You See: Save and Exit
If you want to Save...
Step 1: Press * One Time You Will See: Save all changes
and exit Menu - Yes
Step 2: Press * One Time
If you DO NOT want to Save...
Step 1: Press * One Time You Will See: Save all changes
and exit Menu - Yes
Step 2: Press One Time You Will See: Cancel Save
Return to Menu
Step 3: Press * One Time
You will return to the menu level where you last were.
8000 YRM 1134 Proc_Cal_003: Save and Exit
Confidential/Proprietary - Do Not Copy or Duplicate 9

Proc_Cal_004: Lift Valve Output Threshold
WHEN TO PERFORM
Performed when troubleshooting procedures indicate,
when lift valve components have been serviced, or
when the lift valve is replaced.
CALIBRATION ORDER
1. Proc_Cal_025
2. Proc_Cal_001
3. Proc_Cal_002
4. Proc_Cal_004
WHY PERFORM
All electro-hydraulic valves have different operating
characteristics. One of the key characteristics is the
point at which hydraulic flow begins for a given com-
mand current. This cracking’ current is determined by
this process.
HOW TO PERFORM
WARNING
Keep yourself and all others clear of the lift mech-
anism. Never allow anyone under or on the forks.
Never put hands, arms, head, or legs through the
mast or near the carriage or lift chains. This warn-
ing applies not only to the operator but also the
helper. A helper must not be near the load or the
lift mechanism while the operator is attempting to
handle a load. The lift mechanism has moving
parts with close clearances that can cause seri-
ous injury.
Refer to Table 6 for the procedures on how to perform
Proc_Cal_004: Lift Valve Output Threshold.
Table 6. Proc_Cal_004: Lift Valve Output Threshold
A. TYPICAL DISPLAY WITHOUT KEY, WITH OPTIONS
B. TYPICAL DISPLAY WITH KEY, WITHOUT OPTIONS
Perform Proc_Cal_025: Hydraulic Valve Pressure Gage Installation, Proc_Cal_001: Service Password En-
try, and Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed before proceeding.
Information: "Creep" is defined as the threshold when a function first starts to move very slowly (barely percepti-
ble motion). The identification of this motion is defined as the "visual method." The method that provides more
consistent calibration is by monitoring the change in pressure when the function is activated; this is defined as
the "pressure method."
Proc_Cal_004: Lift Valve Output Threshold 8000 YRM 1134
10 Confidential/Proprietary - Do Not Copy or Duplicate

Table 6. Proc_Cal_004: Lift Valve Output Threshold (Continued)
Information: Pressure Method: Perform actions 1, 2, 3, 4, and 6.
Visual Method: Perform actions 2, 3, 5, and 6.
Information: Leave truck running at idle after performing Proc_Cal_002.
Action 1: With the truck running, note the pressure reading (standby pressure).
Action 2: Activate Lift Control to Position Attachment 0.6 m (2 ft) up
with no load on the forks/attachment.
You Will See: Main Menu
Passwords
Step 1: Press or Until You See: Main Menu
Calibrations
Step 2: Press * One Time You Will See: Calibrations
Lift Valve Output
Step 3: Press * One Time You Will See: Lift Valve Output
Press * at Creep
A. E-HYD CONTROL LEVERS
1. LIFT/LOWER
DIRECTION LIFT ↓
DIRECTION
LOWER ↑
2.TILT
DIRECTION BACK
↓
DIRECTION FWD
↑
3.*AUX 1 OR AUX
2
DIRECTION A ↑
DIRECTION B ↓
4.*AUX 2 OR AUX
3
DIRECTION A ↑
DIRECTION B ↓
5.*FOURTH
LEVER
6.*THIRD LEVER
7.SEAT ARMREST
*AUX 2 IS IN THE FOURTH LEVER LOCATION EXCEPT AS FOLLOWS: WITH 5 FUNCTION VALVE WITH CLAMPING ATTACHMENT,
AUX 2 IS IN THE THIRD LEVER LOCATION.
8000 YRM 1134 Proc_Cal_004: Lift Valve Output Threshold
Confidential/Proprietary - Do Not Copy or Duplicate 11

Table 6. Proc_Cal_004: Lift Valve Output Threshold (Continued)
2. JOYSTICK
1. TILT BACK 2. AUX 1
DIRECTION A ↑
DIRECTION B ↓
3. LIFT ↓
4. ↑ LOWER
5. AUX 2
DIRECTION A ↑
DIRECTION B ↓
6. TILT FORWARD
7. SEAT ARMREST
Action 3: SLOWLY Activate (Feather) Lift Control.....
Action 4: Until the pressure is 0.7 MPa (100 psi) above the standby pressure. Note that the pressure reading
may oscillate. Hold control steady and.....
Action 5: WATCH for Attachment Movement. When it first starts to move slowly, HOLD control steady and.....
Press * One Time while holding control.
Action 6: STOP activating the Lift Control. LOOK at the display.
Go to the calibration step below that matches your display.
If You See..... Result out of range
Repeat Calibration
Press * One Time You Will See: Lift Valve Output
Press * at Creep
Return to Action 3.
Pressure Method: Perform Actions 3, 4, and 6 again.
Visual Method: Perform Actions 3, 5, and 6 again.
If You See..... Lower Valve Output
Press * at Creep
To Continue with Calibrations.....
Go to Action 2 of Proc_Cal_005.
To Quit and Save....
Step 1: Press or Until You See: Lower Valve Output
Back 1 Level
Step 2: Press * One Time You Will See: Calibrations
Back 1 Level
Perform Proc_Cal_003: Save and Exit.
Proc_Cal_004: Lift Valve Output Threshold 8000 YRM 1134
12 Confidential/Proprietary - Do Not Copy or Duplicate

Proc_Cal_005: Lower Valve Output Threshold
WHEN TO PERFORM
Performed when troubleshooting procedures indicate,
when lower valve components have been serviced, or
when the lower valve is replaced.
CALIBRATION ORDER
1. Proc_Cal_001
2. Proc_Cal_002
3. Proc_Cal_005
WHY PERFORM
All electro-hydraulic valves have different operating
characteristics. One of the key characteristics is the
point at which hydraulic flow begins for a given com-
mand current. This cracking' current is determined by
this process.
HOW TO PERFORM
WARNING
Keep yourself and all others clear of the lift mech-
anism. Never allow anyone under or on the forks.
Never put hands, arms, head, or legs through the
mast or near the carriage or lift chains. This warn-
ing applies not only to the operator but also the
helper. A helper must not be near the load or the
lift mechanism while the operator is attempting to
handle a load. The lift mechanism has moving
parts with close clearances that can cause seri-
ous injury.
Refer to Table 7 for the procedures on how to perform
Pro_Cal_005: Lower Valve Output Threshold.
Table 7. Proc_Cal_005: Lower Valve Output Threshold
A. TYPICAL DISPLAY WITHOUT KEY, WITH OPTIONS
B. TYPICAL DISPLAY WITH KEY, WITHOUT OPTIONS
Perform Proc_Cal_001: Service Password Entry and Proc_Cal_002: Hydraulic Valve Calibration Warm Up
and Air Bleed before proceeding.
Information: "Creep" is defined as the threshold when a function first starts to move very slowly (barely percepti-
ble motion). The identification of this motion is defined as the "visual method." This procedure cannot be per-
formed by using the pressure method.
8000 YRM 1134 Proc_Cal_005: Lower Valve Output Threshold
Confidential/Proprietary - Do Not Copy or Duplicate 13

Table 7. Proc_Cal_005: Lower Valve Output Threshold (Continued)
Information: Leave truck running at idle after performing Proc_Cal_002.
Action 1: Activate Lift Control to Position Attachment 0.6 m (2 ft) up
with no load on the forks/attachment. If the forks/attachment are/is
not installed, ensure that the attachment will lower when the control
is activated. It may be necessary to apply a load (approximately
90 kg (200 lb) to the attachment.
You Will See: Main Menu
Passwords
Step 1: Press or Until You See: Main Menu
Calibrations
Step 2: Press * One Time You Will See: Calibrations
Lift Valve Output
Step 3: Press or Until You See: Calibrations
Lower Valve Output
Step 4: Press * One Time You Will See: Lower Valve Output
Press * at Creep
A. E-HYD CONTROL LEVERS
1. LIFT/LOWER
DIRECTION LIFT ↓
DIRECTION
LOWER ↑
2.TILT
DIRECTION BACK
↓
DIRECTION FWD
↑
3.*AUX 1 OR AUX
2
DIRECTION A ↑
DIRECTION B ↓
4.*AUX 2 OR AUX
3
DIRECTION A ↑
DIRECTION B ↓
5.*FOURTH
LEVER
6.*THIRD LEVER
7.SEAT ARMREST
*AUX 2 IS IN THE FOURTH LEVER LOCATION EXCEPT AS FOLLOWS: WITH 5 FUNCTION VALVE WITH CLAMPING ATTACHMENT,
AUX 2 IS IN THE THIRD LEVER LOCATION.
2. JOYSTICK
1. TILT BACK 2. AUX 1
DIRECTION A ↑
DIRECTION B ↓
3. LIFT ↓
4. ↑ LOWER
5. AUX 2
DIRECTION A ↑
DIRECTION B ↓
6. TILT FORWARD
7. SEAT ARMREST
Proc_Cal_005: Lower Valve Output Threshold 8000 YRM 1134
14 Confidential/Proprietary - Do Not Copy or Duplicate