Maintenance

HYDRAULIC SYSTEM
GDP/GLP80-120DB
(GP/GDP/GLP170-280DB)
[B876, C876, D876];
GDP/GLP130-160EB
(GP/GDP/GLP300-360EB)
[B877, C877, D877]

PART NO. 524150787 1900 YRM 938

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, 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 remove 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 manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Hydraulic System Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description and Operation................................................................................................................................... 1
Hydraulic Tank................................................................................................................................................. 1
Hydraulic Pump............................................................................................................................................... 2
Steering Priority Flow Valve ............................................................................................................................ 2
Pilot Valve........................................................................................................................................................ 3
Main Control Valve .......................................................................................................................................... 5
Unloader Valve ................................................................................................................................................ 6
Hydraulic Operation ........................................................................................................................................ 7
Checks And Adjustments .................................................................................................................................... 10
Quick Disconnect Fittings................................................................................................................................ 10
Steering Priority Flow Valve ............................................................................................................................ 10
Steering Relief Pressure ................................................................................................................................. 10
Modulator Valve............................................................................................................................................... 11
Pilot Valve and Pressure Reducing Valve ....................................................................................................... 11
Accumulator .................................................................................................................................................... 12
Filter ................................................................................................................................................................ 12
Main Control Valve .......................................................................................................................................... 12
Relief Pressure Check ................................................................................................................................ 12
Check Valves................................................................................................................................................... 13
Unloader Valve ................................................................................................................................................ 13
Hydraulic Pump Repair........................................................................................................................................ 14
Remove ........................................................................................................................................................... 14
Disassemble.................................................................................................................................................... 14
Clean and Inspect ........................................................................................................................................... 14
Assemble ........................................................................................................................................................ 15
Install............................................................................................................................................................... 16
Pilot Accumulator Replacement ......................................................................................................................... 16
Remove ........................................................................................................................................................... 16
Install............................................................................................................................................................... 16
Pilot Valve Repair ................................................................................................................................................ 16
Remove ........................................................................................................................................................... 16
Disassemble.................................................................................................................................................... 17
Clean and Inspect ........................................................................................................................................... 17
Assemble ........................................................................................................................................................ 17
Install............................................................................................................................................................... 18
Control Levers and Joystick Repair ..................................................................................................................... 19
Remove ........................................................................................................................................................... 19
Install............................................................................................................................................................... 19
Calibration and Diagnostics................................................................................................................................. 20
General ........................................................................................................................................................... 20
Description ...................................................................................................................................................... 20
Lever and Joystick Calibration .................................................................................................................... 20
Flow Adjustment ......................................................................................................................................... 20
Dead Band Value Setting............................................................................................................................ 21
Lowering Delay ........................................................................................................................................... 22
PWM and I/O Module Readouts ................................................................................................................. 22
Function Disable ......................................................................................................................................... 23
General Startup............................................................................................................................................... 23
Minimum system requirements ................................................................................................................... 23
Install the Hydraulic Controls Program ....................................................................................................... 23

©2007 Yale Materials Handling Corp. i

Table of Contents Hydraulic System

TABLE OF CONTENTS (Continued)

DelayTimeFile (Reset) ................................................................................................................................ 23
Select the Processor Speed ....................................................................................................................... 24
Hydraulic Controls Program ............................................................................................................................ 24
Calibration ....................................................................................................................................................... 25
Joystick/Lever Calibration ........................................................................................................................... 25
Levers ..................................................................................................................................................... 25
Joystick ................................................................................................................................................... 26
Valve Flow Adjustment .................................................................................................................................... 26
Diagnostics...................................................................................................................................................... 27
Calibration System Shutdown ......................................................................................................................... 27
LED Diagnostics .................................................................................................................................................. 28
Electrical Connections ......................................................................................................................................... 30
Specifications ...................................................................................................................................................... 34
Diagrams, Schematics, or Arrangements ............................................................................................................ 34

This section is for the following models:

GDP/GLP80-120DB (GP/GDP/GLP170-280DB) [B876, C876, D876];

GDP/GLP130-160EB (GP/GDP/GLP300-360EB) [B877, C877, D877]

ii
1900 YRM 938 Description and Operation

General
This section describes the operation of the hydraulic Steering System 1600 YRM 936
system and its main components. Hydraulic systems of Main Control Valve 2000 YRM 943
sub components are separately described in following
publications:

Description and Operation

The hydraulic system includes the circuits for lift, steer- is not required by the steering system, is directed from
ing, tilt, and auxiliary functions. See Figure 1. the steering priority valve to the main control valve.

The main control valve is operated by a hydraulic pilot

system. Oil supply for the pilot system is controlled by
the pilot valve.

The electric solenoids are operated by a separate elec-

tronic system that also allows for setting and diagnos-
tics of the main control valve.

HYDRAULIC TANK
The hydraulic tank is located at the left hand side of the
frame. The hydraulic tank stores oil for the main hy-
draulic system, steering, and wet brakes system. See
Figure 2.

Oil level is indicated by a sight glass. Topping up oc-

curs by removing a plug above the hydraulic return filter,
which is installed inside the tank. Draining is by remov-
ing a plug at the bottom of the tank.

Hydraulic oil demand causes oil volume to change. The

resulting air flow entering and escaping from the tank is
filtered by the tank breather.

The hydraulic system and the wet brake system have

separate suction and return lines. The return filter for
1. PUMP the wet brake system is outside the hydraulic tank.
2. STEERING PRIORITY VALVE
3. STEERING SYSTEM The return filter for the hydraulic system incorporates
4. PILOT VALVE a relief valve. A spring between the filter and the filter
5. MAIN CONTROL VALVE cover keeps the filter seated.
6. LIFT, TILT, AND AUXILIARY FUNCTIONS
7. TANK For trucks with air brakes, the suction and return con-
Figure 1. Hydraulic System Diagram nections for the wet brakes system have been blocked
off with a plug.
A pump supplies oil from the tank to the main control
valve and to the steering priority valve. Oil supply, that

1
Description and Operation 1900 YRM 938

The large section of the pump supplies oil to the lift sec-
tion of the main valve. The small section of the pump
supplies oil to the steering priority flow valve.

STEERING PRIORITY FLOW VALVE

The steering priority flow valve provides priority oil flow
to the steering system and directs the remainder of the
oil supply to the pilot system and the main control valve.

Oil flow is controlled by a modulating flow divider, which

receives pressure signals from the steering system
(port P) and the modulator valve (port LS1 and port
A2). Depending on these pressure signals, the flow
divider allows more or less flow to the main control
valve (port EF). See Figure 3 and Table 1.

1. BREATHER
2. HYDRAULIC SYSTEM RETURN
3. BRAKE SYSTEM RETURN
4. INSPECTION COVER
5. DRAIN PLUG
6. SIGHT GLASS
7. FILTER ELEMENT 1. MODULATOR VALVE
8. SPRING 2. PILOT SYSTEM PRESSURE (A2)
9. FLANGE 3. PILOT VALVE SUPPLY LINE (A1)
10. FILL PLUG 4. STEERING SYSTEM SUPPLY LINE (P)
5. TO MAIN CONTROL VALVE (EF)
6. MODULATOR FLOW DIVIDER
Figure 2. Hydraulic Tank 7. STEERING PRIORITY FLOW VALVE SUPPLY
LINE (S)
HYDRAULIC PUMP 8. TANK (T)
9. STEERING LOAD SENSE LINE (LS1)
The hydraulic pump is a tandem gear-type pump. The
two sections have a common inlet and separate outlets. Figure 3. Steering Priority Flow Valve Schematic

2
1900 YRM 938 Description and Operation

Table 1. Main Control Valve Port Settings

More Flow to Ports P and A1 More Flow to Port EF

Steering Activated P low P high No steering
Steering Activated LS1 high LS1 low No steering
Low Pilot Pressure A2 low A2 high High pilot pressure

The resulting oil pressure at port A1, that leads to the
pilot valve, depends on the position of the flow divider
and the actual flow through ports P and A1. Pressure
may vary 20 to 165 bar (290 to 2393 psi). Pressure will
raise when the flow divider sends more oil to ports P
and port A1 while oil flow is restricted.
to 29 bar (218 to 421 psi), it will result in more oil flow
from the steering priority flow valve to the pilot valve.
When pilot pressure is getting higher, 35 to 38 bar (493
to 551 psi), it will result in a reduction of oil flow to the
pilot valve. See Figure 4 and Figure 5.

The force of a spring in the flow divider causes a certain

minimum pressure to be reached at port P, before the
connection to port EF is opened.

If port EF is opened at too low of an oil pressure, it will

result in a low oil supply for the steering system. This
will result in difficulty in turn the steering wheel quickly.
If port EF is opened at too high of an oil pressure, this
will result in heat generation at the pressure reducer in
the pilot valve.

The pressure level at which port EF will open can be

adjusted by turning a screw at the modulator valve. See
Checks And Adjustments.

Restrictors in the steering priority flow valve assist in

the smooth operation of the modulating flow divider, to
prevent pressure shocks for the hydraulic pump and the
pump drive.

The 185 bar (2683 psi) relief valve has no particular

function, because the relief valve in the steering hand
pump determines the maximum pressure of 165 bar
(2393 psi) for line LS1.

PILOT VALVE 1. CHECK VALVE

2. FROM STEERING PRIORITY VALVE
The function of the pilot valve is to create a constant 3. FROM HOIST CYLINDER
level of oil pressure for the pilot circuit of the main con- 4. MANUAL VALVE
trol valve. 5. TANK BYPASS VALVE
6. FILTER
Port A1 of the steering priority flow valve sends fluctu- 7. ACCUMULATOR
ating oil pressure to port P1 of the pilot valve. The pres- 8. PILOT PRESSURE
9. FILTER BYPASS VALVE
sure reducing valve in the pilot valve limits pilot system 10. PRESSURE REDUCING VALVE
oil pressure to 45 to 50 bar (653 to 725 psi). Excess oil
pressure is returned to the tank. Figure 4. Pilot Valve Schematic
Pilot system pressure is also connected with the mod-
ulator valve. When pilot pressure is low, between 15

3
Description and Operation 1900 YRM 938

When the steering system requires more oil flow, it will

result in elevated pressures both at port P and at port
A1 of the steering priority flow valve. Despite a pressure
of 45 to 50 bar (580 to 725 psi) in the pilot system, and
modulator valve, the pressure in port A1 will continue to
raise and will exceed 50 bar (725 psi).

An accumulator compensates for differences in oil sup-

ply and oil demand for the pilot system. The accumu-
lator starts using oil volume at pressures higher than
16 bar (232 psi). With increasing pressure the addi-
tional volume of used oil reduces. When the pressure
in the accumulator is 27 bar (392 psi), the used volume
allows operating the control valve at a minimum of 5
times. When the pressure in the accumulator is higher,
the used volume will allow operating the control valve
more than five times. See Checks And Adjustments to
inspect the accumulator for proper functioning.

Oil flow to the pilot lines and to the accumulator has to

pass through a filter, that is protected by a bypass valve.
The 10 micron filter can be replaced by removing the
plug at the bottom of the block. The filter bypass valve
is located on top of the valve block.

The bypass valve that maintains pressure in the pilot

system is incorporated in the cartridge of the pressure
reducing valve. The excess flow leading to the tank
leaves the valve at port T.

The pilot valve also has a manual valve, that allows low-
ering the hoist cylinders when there is insufficient pi-
lot pressure to operate the hoist spool. By opening the
1. ACCUMULATOR manual valve the hoist cylinders will drain to the tank.
2. SEAL
3. TANK BYPASS VALVE
4. SETSCREW
5. FILTER
6. PLUG
7. MANUAL VALVE
8. PRESSURE REDUCING VALVE
9. FILTER BYPASS VALVE

Figure 5. Pilot Valve

4
1900 YRM 938 Description and Operation

MAIN CONTROL VALVE
The main control valve collects oil supply from the tan-
dem pump, distributes oil to the lift, tilt, and auxiliary
functions, and collects returning oil and leads it back to
the tank. See Figure 6 and Figure 7.
The hydraulic functions are divided over two sections
of the main control valve. One section contains the tilt
and auxiliary functions. Flanged at one side is the in-
let that receives oil from the steering priority flow valve.
A primary relief valve limits pressure for this section to
193 bar (2799 psi). Spools direct the oil to the related
functions when actuated. When the tilt or the auxiliary
functions are not being used, the excess oil flows either
to the tank through the unloader valve, or to the lift sec-
tion of the control valve. See Unloader Valve for the
description of the unloader valve.
The lift section has an inlet section, the lift/lower control
valve, and an outlet section. The inlet section receives
oil from the large pump and under certain conditions
from the auxiliary section. A primary relief valve limits
pressure to 210 bar (3046 psi). When the spool for the
lift function is moved, then oil is supplied to the hoist
cylinders. When the lift function is not used, or when the
lowering function is applied, then oil supply is drained
to the tank port.

1. INLET SECTION 9. PARALLEL PASSAGE

2. TILT SECTION 10. CHECK VALVE
3. AUXILIARY SECTION 11. UNLOADER VALVE
4. CENTER SECTION 12. PILOT SUPPLY
5. LIFT SECTION 13. SUPPLY CAVITY
6. OUTLET SECTION 14. DRAIN CAVITY
7. DRAIN PASSAGE 15. PILOT DRAIN LINE
8. OPEN-CENTER PASSAGE

Figure 6. Main Control Valve Schematic

5
Description and Operation 1900 YRM 938

UNLOADER VALVE
Oil that is not used for the tilt or the auxiliary functions,
flows to the lift section of the control valve, or to the tank
through the unloader valve. See Figure 8 and Figure 13.

1. FROM LIFT PUMP

2. TO LIFT SECTION
3. CHECK VALVE
4. UNLOADER PISTON
1. INLET SECTION 5. FROM SMALL PUMP
2. TILT SECTION 6. TO TANK
3. AUXILIARY SECTION 7. 140 bar (2031 psi) RELIEF VALVE
4. CENTER SECTION 8. 56 bar (812 psi) CHARGE VALVE
5. LIFT SECTION
6. OUTLET SECTION Figure 8. Unloader Valve
7. PILOT DRAIN LINE
8. TO RIGHT HAND HOIST CYLINDER Oil passes the check valve to the lift section when the
9. LARGE PUMP INLET
10. OUTLET PORT pressure of the small pump is higher than the pressure
11. STEERING RETURN (T) of the large lift pump. The pressure of the small pump is
12. TO LEFT HAND HOIST CYLINDER higher when the lift function is not applied or when the
13. AUXILIARY PISTON SIDE lift function is beginning to be applied.
14. TILT FORWARD
15. FROM PILOT VALVE (T) When the lift function is not applied, oil supply drains
16. PILOT PRESSURE (X) directly to the tank through the central passage of he lift
17. FROM STEERING PRIORITY VALVE
18. TILT BACKWARD section.
19. AUXILIARY ROD SIDE

Figure 7. Main Control Valve

6
1900 YRM 938
When the lift function is beginning to be applied, the
small pump will assist with delivering oil until pressure
has reached 140 bar (2031 psi). The additional supply
below 140 bar (2031 psi) allows quicker hoist speeds
when the load weighs less than 2/3 of the truck ca-
pacity. When supply from the small pump has reached
140 bar (2031 psi), the relief valve in the unloader valve
will open. The resulting pressure drop will open the un-
loader piston, causing the supply from the small pump
to drain to the tank. Because of the very weak return
spring, the unloader piston will remain in the drain posi-
tion. Once the 140 bar (2031 psi) relief valve is opened,
the 56 bar (812 psi) charge valve will keep the relief
valve in the opened position, until the pressure from the
lift pump has dropped below 56 bar (812 psi). Below
56 bar (812 psi) bar the relief valve will close. The un-
loader piston will close when the relief valve is closed
and when the check valve to the lift section is open
again. The check valve to the lift section will reopen
when lift pump pressure has returned to near zero.
HYDRAULIC OPERATION
The operation of the tilt, auxiliary, and hoist spool sec-
tions is similar. An electric current activates a solenoid,
Description and Operation
which causes a pressure reducing cartridge to open.
Oil from the pilot line enters the cavity of the spool and
moves the spool against the spring force. See Figure 6
for the schematic and Figure 9 and Figure 10 for cross
sections. The movement of the spool relates to the
pressure admitted to the cavity. The pressure in the
cavity relates to the current through the solenoid. For a
detailed description and setting of the solenoid signals,
see Calibration and Diagnostics. When the solenoid is
deactivated, the cartridge shuts off pilot oil pressure and
opens a connection with the external tank return line. A
spring at the opposite side of the activated solenoid re-
turns the spool to its neutral position and moves pilot oil
into the external return line to the tank.
When a spool is moved, it shuts off the connection with
the outlet port of the control valve, and it opens the
connection between the supply cavity and the selected
function. Because the outlet has been shut off, inlet oil
will flow to the parallel passage and pass a check valve
that leads to the supply cavity of the selected function.
The check valve prevents oil from flowing in the incor-
rect direction.
7
Description and Operation 1900 YRM 938

A. SPOOL SELECTED TO EXTEND CYLINDER C. SPOOL SELECTED TO RETRACT CYLINDER

B. NEUTRAL
1. COMPRESSED SPRING 6. PRESSURED CAVITY
2. DRAIN CAVITY 7. CARTRIDGE
3. PORT TO CYLINDER 8. ACTIVATED SOLENOID
4. CHECK VALVE 9. PARALLEL PASSAGE
5. SPOOL 10. OPEN-CENTER PASSAGE

Figure 9. Tilt and Auxiliary

8
1900 YRM 938 Description and Operation

A. SPOOL SELECTED TO RAISE B. NEUTRAL C. SPOOL SELECTED TO

LOAD LOWER LOAD
1. COMPRESSED SPRING 5. PRESSURED CAVITY 9. SUPPLY CAVITY
2. DRAIN CAVITY 6. CARTRIDGE 10. PARALLEL PASSAGE
3. PORT TO LIFT CYLINDER 7. ACTIVATED SOLENOID 11. CHECK VALVE
4. OPEN-CENTER PASSAGE 8. SPOOL

Figure 10. Lifting and Lowering

9
Checks And Adjustments 1900 YRM 938

Checks And Adjustments

QUICK DISCONNECT FITTINGS
These trucks use quick disconnect test fittings for hy-
draulics, transmissions, and air systems. The test ports
are course thread. The recommended hose and adap-
tor fittings, for testing these trucks, are shown on Fig-
ure 11 and Figure 12.
to inspect for debris that may cause the problem.
Screen filters are behind port S and behind the car-
tridge for the charge valve adjustment. Only the cut
in and cut out pressure of the modulator valve can be
adjusted. See Figure 13.

A. LENGTH = 800 mm (31.5 in.)

B. M16 X 2.0 THREAD

Figure 11. Flexible Hose

1. CHARGE VALVE ADJUSTMENT

Figure 13. Steering Priority Valve Ports

STEERING RELIEF PRESSURE

NOTE: The relief valve for the steering system is in the
steering control unit. The relief pressure is set at the
factory.

1. Connect a 0 to 20 MPa (0 to 2900 psi) gauge to test

port.

2. Start engine. Operate hydraulic system until tem-

perature of hydraulic oil is 55 to 65 C (130 to 150 F).
A. 1/4-18 NPT
B. 19 MM Run engine at approximately 2300 RPM (turbo) or
C. M16 X 2.0 2200 RPM (nonturbo) when checking pressure.
D. 56.4 mm (2.22 in.)
3. Steer in one direction until wheels will not turn
Figure 12. Gauge Adaptor further. Keep steering wheel fully turned and
read gauge. Correct relief pressure is 16.5 MPa
STEERING PRIORITY FLOW VALVE (2400 psi).

The steering priority flow valve cannot be repaired. In

case of malfunction, plugs and fittings may be removed

10
1900 YRM 938
WARNING
The adjustment screw compresses a spring. Use
caution and wear eye protection when adjusting re-
lief valve.
4. If relief pressure is not correct, remove plug and
adjust pressure by turning adjustment screw. See
Figure 14.
NOTE: If you cannot correctly adjust relief pressure, re-
place parts of relief valve.
5. When checks are complete, remove gauge and in-
stall cap on fitting.
1. STEERING RELIEF VALVE PLUG
2. MANIFOLD
Figure 14. Manifold, Steering Control Unit
MODULATOR VALVE
NOTE: After warming up the engine, keep the engine
at idle speed.
1. Warm up the hydraulic system by operating for two
minutes the tilt relief valve in 10 second on/off in-
tervals. The oil temperature should be near 60 C
(140 F).
2. Connect a 70 bar (1015 psi) pressure gauge at port
X2 of the pilot valve. See Figure 4.
NOTE: Record the pressure setting when the gauge
stops declining.
3. Operate the lowering function until the pressure at
the gauge stops declining.
Checks And Adjustments
4. At the recorded pressure in Step 3 (cut in setting),
the pressure will start rising until the pilot pressure
reaches the cut out setting. Record this pressure
reading.
5. Verify if the recorded pressures are within specifi-
cation. Cut in should be between 25 to 29 bar (363
to 421 psi). Cut out should be between 34 to 38 bar
(493 to 551 psi).
6. If the pressure are not within the specified range
in Step 5, remove the plug from the charge valve
adjustment cartridge and proceed Step 7.
7. Loosen the lock nut two turns with a 10 mm socket
head wrench.
8. Insert a 3 mm socket head wrench and adjust the
cut in and cut out pressures as required. Turning
the socket head wrench clockwise increases (both)
the cut in and the cut out pressure, turning anti-
clockwise decreases (both) pressures. It may be
necessary to repeat Step 3, Step 4, and Step 5 until
the correct pressures are achieved.
9. Tighten the lock nut.
10. Reinstall the plug with silicon sealant, and discon-
nect the test hose from port X2.
PILOT VALVE AND PRESSURE REDUCING
VALVE
The pressure reducing valve cannot be adjusted and
must be replaced if malfunctioning. For the location of
the pressure reducing valve, see Figure 5. Proper op-
eration of the pressure reducing valve can be indicated
by connecting pressure gauges at the quick disconnect
fittings at port P1 and port X2 of the pilot valve, see
Figure 15. When pressure at port P1 is above 60 bar
(870 psi), pressure reading at port X2 should be be-
tween 45 to 50 bar (653 to 725 psi). Supply pressure
at port P1 will be at least 25 bar (363 psi) when the
engine is idling. When using the steering system, pres-
sure at P1 will raise above 60 bar (870 psi). Maximum
pressure is obtained, when the pressure relief valve of
the tilt/auxiliary section reaches its maximum value of
193 bar (2799 psi).
11
Checks And Adjustments
Figure 15. Pilot Valve Pressure Check Ports
ACCUMULATOR
NOTE: Check the accumulator pre-charge pressure ev-
ery 6 months.
The pre-charge pressure of the accumulator should be
16 bar (232 psi). To check the pre-charge pressure,
connect a pressure gauge at port X2 of the pilot valve.
See Figure 15. Run the engine until the gauge reads
a minimum of 27 bar (392 psi). Stop the engine and
turn the key switch to ON. Gently operate one of the hy-
draulic functions. Pressure reading at port X2 will drop
gradually each time a hydraulic lever is moved. At a
value close to 16 bar (232 psi), the pressure will sud-
denly drop quickly. The pressure reading just before the
pressure started dropping quickly is the accumulator
12
1900 YRM 938
pre-charge pressure. Replace the accumulator if the
pre-charge pressure is below 12 bar (174 psi).
An indication of insufficient pre-charge pressure is the
reduced number of times the control valve can be oper-
ated while the engine is not running. When starting with
a pressure of 27 bar (392 psi) at port X2, it should still
be possible to lower the mast five times after the engine
has stopped. To check this, the mast has to be raised
halfway first, to allow observing the actual lowering.
FILTER
NOTE: Replace the filter every year.
If the filter is clogged, the filter bypass valve causes a
pressure drop of about 3 bar (44 psi). An indication for
a clogged filter can only be obtained by observing the
pressure differences between port P1 and port X2 of the
pilot valve. A pressure increase at port P1 will result in
a delayed pressure increase at port X2. When the filter
is not clogged, there will be a simultaneous pressure
increase at ports P1 and X2.
MAIN CONTROL VALVE
Relief Pressure Check
The main control valve has two quick disconnect fittings.
See Figure 16. To check the relief pressures, the hy-
draulic oil must be between 55 to 65 C (131 to 149 F).
Run the engine at maximum rpm when making pres-
sure checks.
Check the relief pressure in the lift section by raising the
mast until it stops.
Check the relief pressure in the tilt/auxiliary section by
tilting the mast fully forward.
To change the setting, release the jam nut. Tighten the
adjustment cap to increase pressure, loosen the adjust-
ment cap to lower pressure. Retighten the jam nut to 55
to 67 N•m (41 to 49 lbf ft).
1900 YRM 938
1. 193 bar (2799 psi) CHECK PORT
2. 193 bar (2799 psi) RELIEF VALVE
3. CHECK VALVE
4. 210 bar (3046 psi) RELIEF VALVE
Figure 16. Main Control Valve Check Ports
CHECK VALVES
To check proper functioning of the check valves, the
related cylinder(s) must be under load. Operate the
hydraulic lever until the cylinders move. Hold the lever
and let the engine run at idle speed. If the cylinders
return in the opposite direction, the check valve leaks.
Replace a leaking check valve.
Checks And Adjustments
5. 210 bar (3046 psi) CHECK PORT
6. UNLOADER CARTRIDGE
7. UNLOADER PISTON
UNLOADER VALVE
NOTE: When lifting a capacity load, pressure reading
at the tilt check port will remain zero. Pressure reading
at the lift check port will be near 210 bar (3046 psi).
Attach a pressure gauge at the 193 bar (2799 psi) and
210 bar (3046 psi) pressure check ports. When lifting a
light load, pressure readings at these ports will be sim-
ilar. When the lift cylinders have reached the extended
position, pressure at the tilt check port will drop to zero
and pressure at the lift check port will raise to 210 bar
(3046 psi). When lowering, pressure at the lift check
port will drop to zero.
13
Hydraulic Pump Repair 1900 YRM 938

Hydraulic Pump Repair

See other sections of the Service Manual for making DISASSEMBLE
repairs to components within the hydraulic system. See
the section Main Control Valve 2000 YRM 943, Lift CAUTION
Cylinders for your lift truck, Masts 4000 YRM 445 or
If pump is held in a vise for disassembly, verify that
Masts and Carriages, Starting 2003 4000 YRM 1062,
vise does not hold pump too tightly and cause dam-
Steering System 1600 YRM 936, and Tilt Cylinders
age to pump body.
2100 YRM 103 for your lift truck.
NOTE: Take careful notes of locations of parts and
NOTE: Worn or damaged seals are the most common
seals during disassembly. Some parts are similar but
cause of hydraulic pump repair. The seals can be re-
not exactly the same. Use a punch to make alignment
placed in the hydraulic pump. The pump thrust plates,
marks on parts of housing.
bearings, gears, and shafts also wear. Replace a worn
or damaged hydraulic pump. 1. Remove four studs from end housing. See Fig-
ure 17. Carefully separate housing pieces.
REMOVE
2. Remove thrust plates and seals from end housing.
WARNING
3. Remove nuts from studs in center section of pump.
Tilt mast forward and lower carriage completely be- Carefully separate center housing from end hous-
fore disconnecting any parts of hydraulic system. ing and remove connection shaft.
Mast can lower suddenly and cause injury if mast
and carriage are not lowered. 4. Separate center housing from shaft end housing.
Remove thrust plates and seals from center hous-
1. Tilt cab. See the section Operator’s Cab for your ing.
lift truck.
5. Remove seal for shaft end from housing.
2. Turn key OFF and shut down engine.

3. Get a plug that will fit suction hose. Disconnect

suction hose at pump and quickly raise end of hose.
Install plug in hose.
4. Disconnect high-pressure line at outlet port on side
of pump. Keep end of line above hydraulic tank until
a plug is installed in line.
5. Disconnect second pump supply line at fitting in end
of pump. Install plug in line.
WARNING
The pump weighs approximately 45 kg (100 lb) and
can cause injury or damage if it falls. Verify that the
pump has support before removing capscrews.
6. Remove four capscrews in pump flange and re-
move pump from torque converter housing.
CLEAN AND INSPECT
WARNING
Cleaning solvents are flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety procedures. Wear protective
goggles or a face shield to prevent eye injuries.
Clean all parts of pump with solvent. Use compressed
air to dry parts. Do not use a cloth to dry parts. Pieces
of cloth can cause restrictions in hydraulic system.
Inspect gear assemblies and housing parts for wear
and damage. Replace a damaged or worn hydraulic
pump. If gears are replaced, they must be replaced as
matched sets.

14
1900 YRM 938 Hydraulic Pump Repair

NOTE: Some pump bodies will show gear marks where
the gears rotate because of the small clearances be-
tween parts. These gear marks do not indicate a worn
or damaged pump unless the pump will not supply the
volume and pressure shown in Specifications.
ASSEMBLE
NOTE: Use new seals during assembly.
1. Verify internal parts of pump are clean. Lubricate
parts with hydraulic oil as parts are installed. See
Figure 17.

1. HOUSING, GEAR 6. THRUST PLATE 11. SEAL

2. GEAR, SHAFT SET 7. THRUST PLATE 12. SEAL
3. HOUSING 8. SEAL 13. SEAL
4. GEAR SET 9. SEAL
5. SEAL 10. SEAL

Figure 17. Hydraulic Pump

15
Pilot Valve Repair
2. Install seal in shaft end housing.
3. Verify alignment pins are in shaft end housing. In-
stall seals, thrust plates, and center housing on
shaft end housing.
4. Install connection shaft. Tighten nuts in a cross
pattern.
5. Verify that alignment pins are in center housing. In-
stall thrust plates and gear housing in center hous-
ing. Verify that seals for housing and thrust plate
are installed.
6. Verify that alignment pins and seals are installed.
Install end housing with studs, nuts, and washers.
Tighten nuts to 271 N•m (200 lbf ft).
Pilot Accumulator Replacement
REMOVE
WARNING
The accumulator has a pressure charge and can
cause an injury if the pressure is released too fast.
Follow the manufacturer’s instructions during re-
moval and installation.
Before disconnecting the pilot accumulator, release
pressure from the hydraulic circuit as follows:
• Shut off engine and completely lower the mast. Install
blocks at wheels to prevent truck from moving.
• Operate the levers until no pressure is left in the hy-
draulic system (at least 20 times).
1. Slowly disconnect the pilot accumulator from the pi-
lot valve by unscrewing the accumulator. Remove
the pilot accumulator and put a cap on the pilot
valve connection.
Pilot Valve Repair
REMOVE
WARNING
Tilt mast forward and lower carriage completely be-
fore disconnecting any parts of hydraulic system.
Mast can lower suddenly and cause injury if mast
and carriage are not lowered.
1. Shut down engine.
2. Turn key switch to ON position.
16
1900 YRM 938
INSTALL
1. Clean flange of pump and mounting surface on
torque converter housing.
2. Install pump on torque converter housing. Use a
sealant (Yale Part No. 520042831) on flange of
pump. Tighten capscrews to 77 N•m (57 lbf ft).
3. Connect hydraulic line(s) to pump. Tighten cap-
screws for flange of high-pressure hose to 50 N•m
(37 lbf ft). If necessary, tighten capscrews for flange
of suction hose to 77 N•m (57 lbf ft).
INSTALL
NOTE: Follow the manufacturer’s instructions during in-
stallation of the new pilot accumulator.
1. Operate the system and check for leaks.
2. Check if the pilot accumulator pressure charge is
between 2.7 to 3.6 MPa (391 to 522 psi). See the
section Periodic Maintenance, Perkins Tier 2
Emission Engine 8000 YRM 1066 for B876 and
B877 trucks Periodic Maintenance 8000 YRM
1099 for C876 and C877 trucks, and Periodic
Maintenance 8000 YRM 1347 for D876 and D877
trucks, for the correct pressure charge check.
3. Shift all hydraulic control levers together, back and
forth, a minimum of 20 repetitions to ensure all pres-
sure has been removed from hydraulic system.
4. Tilt cab. See the section Operator’s Cab for your
lift truck.
5. Disconnect hydraulic lines at valve. Put tags for
identification on lines. Put caps on open lines.
6. Remove nuts and bolts that hold valve to mounting
plate. See Figure 18. Remove pilot valve.
1900 YRM 938 Pilot Valve Repair

1. PILOT VALVE 4. NUT

2. BOLT 5. PILOT BLOCK MANUAL TAP
3. WASHER

Figure 18. Pilot Valve Mounting

DISASSEMBLE solvents, always follow the solvent manufacturer’s

CAUTION
If pilot valve is held in vise for disassembly, verify
that vise does not hold valve too tightly and cause
damage to valve body.
NOTE: Take careful notes of locations of parts and
seals during disassembly. Some parts are similar but
not exactly the same.
1. Remove parts as necessary to replace defective or
worn components. See Figure 19.
CLEAN AND INSPECT
WARNING
Cleaning solvents are flammable and toxic and
can cause skin irritation. When using cleaning
recommended safety procedures. Wear protective
goggles or a face shield to prevent eye injuries.
Clean all parts of valve with solvent. Use compressed
air to dry parts. Do not use a cloth to dry parts. Pieces
of cloth can cause restrictions in hydraulic system.
ASSEMBLE
NOTE: Use new seals during assembly.
1. Verify internal parts of valve are clean. See Fig-
ure 19. Lubricate parts with hydraulic oil as they
are installed.
2. Replace defective or worn components as neces-
sary.

17
Pilot Valve Repair 1900 YRM 938

INSTALL
1. Tilt cab. See the section Operator’s Cab for your
lift truck.

2. Put valve on mounting plate. See Figure 18. Install

nuts and bolts that hold valve to mounting plate.

3. Connect hydraulic lines at valve. Verify connections

are correct and tight.

4. Operate system and check for leaks.

5. Lower cab until latched.

1. BLOCK 9. PLUG
2. ACCUMULATOR 10. FILTER
3. PROTECTING CAP 11. PILOT BLOCK
4. BOLT MANUAL TAP
5. SEAL 12. CHECK VALVE
6. NUT 13. SEAL KIT
7. VALVE 14. O-RING
8. SEAL

Figure 19. Pilot Valve

18
1900 YRM 938 Control Levers and Joystick Repair

Control Levers and Joystick Repair

REMOVE
WARNING
Tilt mast forward and lower carriage completely be-
fore disconnecting any parts of hydraulic system.
Mast can lower suddenly and cause injury if mast
and carriage are not lowered.
1. Shut down engine.
2. Turn key switch to ON position.
4. Attach bottom cover plate to armrest with six
screws.
5. Calibrate new control levers. See Calibration and
Diagnostics.
NOTE: The joystick is removed and installed using the
same procedures as noted for control levers except that
four screws are used to fasten the joystick to mounting
plate rather than two screws, as used for control levers.

3. Shift all hydraulic control levers together, back and

forth, a minimum of 20 repetitions to ensure all pres-
sure has been removed from hydraulic system.

4. Remove six screws from cover/mounting plate on

bottom side of armrest and remove plate. See Fig-
ure 20.

5. Disconnect electrical connector.

6. Remove two screws and washers that attach con-

trol lever to mounting plate.

7. Remove defective control lever.

1. ELECTRICAL CONNECTOR
INSTALL 2. SCREW
3. WASHER
1. Place new control lever in mounting plate. See Fig- 4. COVER/MOUNTING PLATE
5. CONTROL LEVER
ure 20.
Figure 20. Control Levers
2. Fasten two screws and washers that hold control
lever into mounting plate.

3. Connect electrical connector.

19
Calibration and Diagnostics 1900 YRM 938

Calibration and Diagnostics

GENERAL
By moving hydraulic levers, electrical signals are sent to
the PWM (Pulse Width Modulation) module and to the
I/O (Input/Output) modules when installed. The PWM
module communicates with the I/O module by use of the
CAN bus wires. The PWM and I/O module translates
the signal received into a current that is connected with
the solenoids on the main control valve, causing the
selected function to operate.

The CAN bus wires also lead to a connector that can be

linked to a PC. When a related software program has
been installed, the PC allows setting and diagnostics of
the hydraulic system.

To verify proper functioning without a PC, the PWM and

I/O module have LED’s, that flash a code that relates to
either proper functioning or a specific error.

DESCRIPTION
Lever and Joystick Calibration
The PWM module (Pulse Width Modulation) and I/O A. FORWARD LEVER POSITION
module (Input/Output) generate a base signal to the po- B. BACKWARD LEVER POSITION
C. NEUTRAL LEVER POSITION
tentiometers (potmeters) in the hydraulic levers. De- D. SIGNAL VOLTAGE TO PWM
pending on the lever position, the lever returns a sig- E. LEVER BIT POSITION
nal voltage to the PWM module. In positions close to F. SIGNALS GENERATING ERROR CODE
the neutral position, the lever signal remains at a fixed
value. See Figure 21. The signal voltages assigned to Figure 21. Lever Signal
the neutral position, and to the extreme positions are
essential for proper functioning. Signal voltages lower Flow Adjustment
than 0.5 Volt or higher than 4.5 volt are considered false,
NOTE: Flow adjustment is only possible for the auxiliary
and will generate an error code. The neutral position
function. If two auxiliary functions are operated at the
provides a signal voltage of 2.5 volt, causing the control
same time, then the highest output signal determines
valve to NOT be activated by the control valve. Signal
the flow of the control valve.
voltages between 0.5 Volt 2.5 volt and 2.5 volt and 4.5
volt will activate the control valve. To adjust the response of the control valve, the valve
flow adjustment program allows entering the lowest
A random replacement lever will send different signal
and highest PWM output signal to the control valve.
voltages to the PWM module. These different signal
The PWM output signal results in an electrical current
voltages may generate error codes, or activate the con-
through the solenoid of the control valve. The direct
trol valve, although the lever is in the neutral position.
relation between output signal (in bit) and current (in
By calibrating a lever, the PWM module is programed to
mAmps) is shown on the horizontal axis in Figure 22.
know which signal voltages belong to the lever positions
neutral, fully forward, and fully backward. To prevent un- The electric current activates a solenoid, which causes
justified error codes, verify the lever has fully reached a pressure reducing cartridge to move. Depending on
these positions during calibration. the electric current, the cartridge takes a certain posi-

20
1900 YRM 938
tion and provides a related pilot oil pressure to the cavity
of the control valve spools. The relation between cur-
rent and admitted pilot pressure is shown in Figure 22.
A minimum of 320 mAmp (20 bit) is required to start car-
tridge movement. At 1100 mAmp (69 bit) the cartridge
is at its maximum stroke. A further increase in current
does not result in a further increase of the admitted pilot
oil pressure.
The purpose of the pilot pressure is to move the spool
of the control valve. It takes a minimum pilot pressure
of 5 bar (73 psi), before the spool of the control valve
moves and the activated function will start operating. To
obtain 5 bar (73 psi) pilot pressure at the spool cavity
requires a PWM output of 0.51 Amp (32 bit). Maximum
movement of the control valve spool is achieved when
pilot pressure is 24 bar (348 psi), at a PWM output of
1.10 Amp (69 bit). It is suggested to adjust the function
flow settings between 30 and 70.
A. PILOT PRESSURE
B. VALVE FLOW ADJUSTMENT LEVEL
C. PWM OUTPUT SIGNAL IN MILLIAMPERE’S
D. START SPOOL STROKE
E. FULL SPOOL STROKE
Figure 22. Pilot Pressure
Dead Band Value Setting
NOTE: The dead band value entered will be applied to
all levers. It is not possible to select different dead band
values for each individual lever.
Calibration and Diagnostics
Selection of an auxiliary function causes the solenoid
of the selected function to open and to operate the aux-
iliary spool of the main control valve. When releasing
the auxiliary function, these two valves close simulta-
neously. This results in trapped pressured oil between
the auxiliary spool and the selected solenoid, affecting
service life of hoses and valves. By releasing the auxil-
iary spool earlier than the solenoid of the selected func-
tion, remaining pressure in the hose between these two
valves is limited. Timing of the earlier release of the
auxiliary spool is achieved by widening the dead band.
When the dead band is widened, it will also take longer
until the PWM module will start sending output currents.
Therefore the dead band must be set as low (narrow) as
possible, but as high (wide) as necessary to avoid trap-
ping pressured oil. A small dead band value provides
immediate lever response. A wider dead band value
requires a longer lever stroke before the PWM module
activates the selected solenoid. See Figure 23.
A. B-SIDE SOLENOID
B. A-SIDE SOLENOID
C. DEAD BAND
D. PWM BIT OUTPUT
E. LEVER SIGNAL VOLTAGE
Figure 23. Dead Band
21
Calibration and Diagnostics 1900 YRM 938

Lowering Delay
A capacity load will induce quick lowering movements
when applying the lowering lever. To facilitate a smooth
start of the lowering movement, the signal increase as
provided by the actual lever movement is delayed with
a maximum of 150 milli-seconds. Setting the lowering
delay at a maximum value of 150, provides a delayed
response. A setting at a lower value provides a quicker
response. See Figure 24.

Figure 25. PV3 Readouts Screen

A. PWM BIT OUTPUT

B. TIME IN MILLI-SECONDS
C. LEVER MOVEMENT
D. DELAYED PWM OUTPUT

Figure 24. Lowering Delay

PWM and I/O Module Readouts

This function indicates the position of the function lever, Figure 26. I/O Readouts Screen
the programmed output current that belongs to that
lever position, and the actual solenoid coil current. See
Figure 25 and Figure 26.

For the PWM Readout, current A refers to hoist, tilt for-

ward, and auxiliary out. Current B refers to lowering, tilt
backward, and auxiliary in. For the I/O Board Readouts
the pin numbers 9 through 12 refer to the 12-pole plug
(C3) just below the LED’s on the I/O board. See Fig-
ure 27.

1. LED ROWS 2. MODULE

Figure 27. Module Connectors

22
1900 YRM 938 Calibration and Diagnostics

Function Disable a default number that corresponds to the processor

speed will be listed (Example: 85555). Replace this
NOTE: When re-enabling these functions, recalibration number by highlighting and entering the value as
is necessary. For description see Hydraulic Controls described in step 6.
Program. 5. From Table 2, chose the number that corresponds
to the processor speed. If the actual processor
It is possible to disable the 3rd and the 4th proportional
speed is not listed, select the next lowest value. Do
function and the sideshift function. In case you want to
not select a speed that is greater than the actual
disable or re-enable, select the following programs in
processor speed.
the Hydraulic Controls Program:
6. Highlight and replace the number in the "delay-
• Lever Calibration, for 3rd and 4th Proportional Func-
Timefile.dat" file as discussed in step 4. Replace
tion.
the number with one from Table 2. Save the new
• Joystick Calibration, for Sideshift.
number by opening "file" in the toolbar and select-
ing "Save". Exit the file. Reboot the PC before
GENERAL STARTUP
using the Hydraulic Controls Program.
Minimum system requirements Table 2. Processor Speed Settings
• IBM compatible laptop computer with minimum Pen-
tium 133 MHz processor Number Processor Speed
• Windows 98, Windows NT, Windows 2000, or Win- 33333 150 MHz
dows XP
• CD reader 44444 250 MHz
• An open PC serial communication port: Communica- 55555 350 MHz
tion port 1 or 2.
65535 450 MHz
• Communication cable (Yale Part Number 580024119)
• Hydraulic Controls Program (Yale Part Number 75555 550 MHz
524151041)
85555 600 MHz
Install the Hydraulic Controls Program 140000 775 MHz

Install the Hydraulic Controls Program on the PC ac- 198000 950 MHz
cording to the directions received with the software. 255000 1.1 GHz (1100 MHz)

DelayTimeFile (Reset) 312000 1.3 GHz (1300 MHz)

369000 1.5 GHz (1500 MHz)
By default, the synchronization speed of older User-In-
terface programs is set at 600 MHz. Laptops with higher 426000 1.8 GHz (1800 MHz)
processor speeds can experience communication syn-
483000 2.0 GHz (2000 MHz)
chronization issues, that show up after opening the pro-
gram and selecting "PWM". Typical error messages in- 540000 2.2 GHz (2200 MHz)
clude: "Run time error 13", "Run time error 6", and "No
597000 2.4 GHz (2400 MHz)
Communication with PV3". Starting with User-Interface
program V3.3, this issue can be resolved as follows: 654000 2.5 GHz (2500 MHz)
1. Install the Hydraulic User-Interface program V3.3.
711000 2.71 GHz (2700 MHz)
2. Go to "Start", "Control Panel" and "System Prop-
erties" on the computer and record the processor 768000 2.9 GHz (2900 MHz)
speed. 825000 3.0 GHz (3000 MHz)
3. Open Microsoft Explorer (File Manager) and go to
directory "c:\program files\node_syst".
4. Double click on file "delayTimeFile.dat" and open it
with "Notepad" or "Wordpad". When the file opens,

23
Calibration and Diagnostics 1900 YRM 938

Select the Processor Speed

For correct operation of the software, the processor
speed in the Hydraulic Controls Program must be
selected. Select setup, the processor speed screen
will be displayed. See Figure 28. Select the processor
speed of your computer. Quit the program. Reboot the
computer.

1. PLUG
Figure 28. Processor Speed Screen
Figure 29. Electronic Diagnostic Plug Location
HYDRAULIC CONTROLS PROGRAM NOTE: The first time this diagnostic test is performed,
the Hydraulic Controls Program will have to be installed
CAUTION on computer according to directions received with soft-
Do not start engine while performing diagnostic ware.
test. Engine should not be running at any time
6. Select Start, Programs, then Hydraulic Controls
during test.
Program. Click to start program. The first program
menu will be displayed. See Figure 30.
CAUTION
Irreparable damage may occur to the PWM board
and/or the I/O board if the calibration system shut-
down procedure is not precisely followed.

1. Remove cover to gain access to electronic control

compartment.

2. Remove plug from electronic diagnostic port. See

Figure 29.

3. Connect communication interface cable between Figure 30. Board Connection Screen
laptop computer and hydraulic diagnostic port.
7. Select PWM.
4. Turn ignition key to ON position.
8. The Hydraulic Controls Interface screen will be
5. Turn on laptop computer. displayed. See Figure 31 and Figure 32. Select
number of I/O devices.

24
1900 YRM 938
Figure 31. Hydraulic Controls Program Interface
Screen, Altering Supply and Return
Figure 32. Hydraulic Controls Program Interface
Screen, Fixed Supply
NOTE: (E)CH is not a valid option for C876, C877,
D876, and D877 trucks. When selecting an incorrect
attachment option, the system will perform incorrect
calibration, adjustment, setting, diagnostic, and read-
outs.
9. Attachment select. Select altering supply and re-
turn or fixed supply. Altering or fixed supply de-
pends on the hydraulic system configuration. After
selection, the appropriate screen will be displayed.
See Figure 31 and Figure 32.
10. Select clamp options. Clamp options for these 3rd
or 4th proportional functions can be recognized by
Calibration and Diagnostics
the operating lever, that must be pushed in before
lever movement is possible. If the lever must be
pushed in, select 3rd or 4th Proportional Function.
11. Select language.
NOTE: The following step is only available with the al-
tering supply.
12. Select PWM number listed on the PWM label, i.e.,
8507741. Otherwise, select other.
CALIBRATION
Joystick/Lever Calibration
Select Joystick/Lever Calibration. The Calibration
screen will be displayed. See Figure 33.
Figure 33. Lever Calibration Screen
Levers
1. For calibration of levers, select Lever.
2. Select function to be calibrated: Lift, Tilt, 3rd Pro-
portional Function, or 4th Proportional Function.
3. Move lever BACKWARD and hold. Click on Lever
Backward. Allow value to be saved, then release
lever.
4. Move lever to NEUTRAL position. Click on Lever
Centered. Allow value to be saved, then release
lever.
5. Move lever FORWARD and hold. Click on Lever
Forward. Allow value to be saved, then release
lever.
25
Calibration and Diagnostics 1900 YRM 938

6. Select next function to be calibrated and repeat
Step 3, Step 4, and Step 5.
NOTE: It is possible to select a deadband value for
levers. With lever centered, select required deadband
value and save by clicking on deadband. Saved dead-
band value is for all levers; individual setting is not pos-
sible. It is also possible to disable a lever. Click on
3rd Proportional Function or 4th Proportional Function
to activate the disable function. After the problem has
been cured, recalibration of the function is required.
5. Move joystick or rotate wheel in direction dependant
upon function selected and hold. Click on appropri-
ate button. Allow value to be saved, then release
joystick/wheel.
6. Select next function to be calibrated and repeat
Step 3, Step 4, and Step 5.
7. After calibration of levers or joystick/wheel, click on
Go Back. Main menu will be displayed. See Fig-
ure 31 and Figure 32.

Joystick VALVE FLOW ADJUSTMENT

NOTE: It is possible to select a deadband value for 1. Click on Valve Flow Adjustment. Flow Adjustment
joystick/wheel. With joystick/wheel centered, select re- screen will be displayed. See Figure 35.
quired deadband value, and save by clicking on Dead-
band. Saved deadband value is for all joystick; individ-
ual setting is not possible. It is also possible to disable
the function sideshift. Click on Sideshift to activate the
disable function. After the problem has been cured, re-
calibration of the re-enabled function is required.

1. For calibration of joystick, select Joystick. See Fig-

ure 34.

Figure 35. Flow Adjustment Screen

2. Select function to be adjusted, Step 1 on the adjust-

ment screen.

NOTE: The following procedure is for lowering only.

3. Adjust lower flow delay.

Figure 34. Joystick Calibration Screen
4. Adjust function flow settings, Step 2 on the adjust-
2. Select function to be calibrated: Lift, Tilt, 3rd Pro- ment screen.
portional Function, or 4th Proportional Function.
5. Click on Save, Step 3 on the adjustment screen.
3. Move joystick or rotate wheel in direction dependant
upon function selected and hold. Click on appropri- 6. Repeat procedure for next function.
ate button. Allow value to be saved, then release
7. Click on Go Back and main menu will be displayed.
joystick/wheel.
See Figure 31 and Figure 32.
4. Move joystick or rotate wheel to NEUTRAL po-
sition. Click on Joystick/wheel Centered to save
value.

26
1900 YRM 938 Calibration and Diagnostics

DIAGNOSTICS 2. View Diagnostic screen for possible error codes.

1. Click on Diagnostics. Diagnostics screen will be 3. Click on Go Back. Main menu screen be displayed.
displayed. See Figure 36. See Figure 31 and Figure 32.

CALIBRATION SYSTEM SHUTDOWN

1. Click on Quit to close the Hydraulic Controls Pro-
gram.

2. Turn off laptop computer.

3. Turn ignition key to OFF position.

4. Disconnect communication cable.

5. Install plug for diagnostic port.

6. Install cover.

Figure 36. Diagnostics Screen

27
LED Diagnostics 1900 YRM 938

LED Diagnostics
Within the system, there is always a PWM Driver mod-
ule. The PWM module has an advanced microproces-
sor with 32K of memory.
When the truck is switched on, LED row A1 to A4 are
tested. See Figure 27. First A4 blinks, then A3, then
A2, and then A1. After this test sequence, LED row A1
blinks one time per second to indicate that no system
errors are present.
When a system error occurs, LED row A indicates error
conditions. See Table 3.
In addition to the PWM module, an I/O module might be
present. This I/O module has a less advanced micro-
processor with 2K of memory. The module is used to
process operator commands and generate appropriate
output signals. LED rows A and B indicate the status of
the input and output commands. See Table 4, Table 5,
and Table 6.

Table 3. PWM Board LED Error Codes

Error Code
No. of
1=LED "ON" Fault Description
Flashes
0=LED "OFF"
A1 A2 A3 A4
0 1 0 0 1 CAN communication error with I/O 1
0 1 0 0 2 CAN communication error with I/O 2
0 1 0 0 6 Over current on valve 1 (Lift)
0 1 0 0 7 Over current on valve 2 (Tilt)
0 1 0 0 8 Over current on valve 3
0 1 0 0 9 Supply voltage greater than 32 volts
0 1 0 0 10 Supply voltage less than 9 volts
0 1 0 0 11 5-volt supply too low
1 1 0 0 1 I/O module 1, output 1 over current
1 1 0 0 2 I/O module 1, output 2 over current
1 1 0 0 3 I/O module 1, output 3 over current
1 1 0 0 4 I/O module 1, output 4 over current
1 1 0 0 5 I/O module 1, voltage greater than 32 volts
1 1 0 0 6 I/O module 1, voltage less than 9 volts
1 1 0 0 7 I/O module 1, 5-volt supply failure
1 1 0 0 8 I/O module 1, 4-volt supply failure
1 1 0 0 9 I/O module 1, 1-volt supply failure
0 1 1 0 1 I/O module 2, output 1 over current
0 1 1 0 2 I/O module 2, output 2 over current
0 1 1 0 3 I/O module 2, output 3 over current
0 1 1 0 4 I/O module 2, output 4 over current
0 1 1 0 5 I/O module 2, voltage greater than 32 volts
0 1 1 0 6 I/O module 2, voltage less than 9 volts

28
1900 YRM 938 LED Diagnostics

Table 3. PWM Board LED Error Codes (Continued)

Error Code
No. of
1=LED "ON" Fault Description
Flashes
0=LED "OFF"
A1 A2 A3 A4
0 1 1 0 7 I/O module 2, 5-volt supply failure
0 1 1 0 8 I/O module 2, 4-volt supply failure
0 1 1 0 9 I/O module 2, 1-volt supply failure
0 0 1 1 1 Joystick 1 error (Lift)
0 0 1 1 2 Joystick 2 error (Tilt)
0 0 1 1 3 Joystick 3 error (Sideshift)
0 0 1 1 4 Joystick 4 error (Aux/clamp)

Table 4. Altering PT I/O Board LED’s (Old Logic)

Input Signal Output Signal

Command Remark
Indication Indication
Standby A1 A1 will blink if CAN communication error occurs
Aux 2 switch input A1 On B1 On
Aux 3 switch input A2 On B2 On
Inhibit switch on the Inhibit switch enables fourth lever solenoids
A3 On
fourth lever
Fourth lever A4 On B1 and B2 On
Third lever B3 and B4 On

Table 5. Altering PT I/O Board LED’s (New Logic)

Input Signal Output Signal

Command Remark
Indication Indication
Standby A1 A1 will blink if CAN communication error occurs
Auxiliary 2 switch A1 On B1 On
Auxiliary 3 switch A2 On B2 On
Inhibit switch on the Inhibit switch enables fourth lever solenoids
A3 On
fourth lever
Fourth lever A4 On B4 On
Third lever B3 On

29
Electrical Connections 1900 YRM 938

Table 6. Fixed PT Logic I/O Boards LED’s

Input Signal Output Signal

Command Remark
Indication Indication
Standby A1 A1 will blink if CAN communication error occurs
I/O 1
Auxiliary 2 switch A1 On
Auxiliary 3 switch A2 On
Inhibit switch on the Inhibit switch enables fourth lever solenoids on
A3 On
fourth lever I/O 1
Fourth lever A4 On B3 or B4 On Depending on direction of lever and inhibit switch
Third lever B1 or B2 On Depending on direction of lever and inhibit switch
I/O 2
Inhibit switch on the Inhibit switch enables third lever solenoids on I/O
A3 On
third lever 1
Fourth lever B3 or B4 On Depending on direction of lever and inhibit switch
Third lever B1 or B2 On Depending on direction of lever and inhibit switch

Electrical Connections
The PWM and I/O modules have three connectors; C1, Input and output signals are received and sent at plug
C2, and C3. See Figure 27. C3. Connector references are C290, C320, and C350.

Electric supply for the PWM and I/O modules is at mod-
ule connector C1 through wires 112 and 621, 622, and
623. See Figure 37. The connector references for the
side console harness are C300, C330, and C360.
CAN bus communication is at C2 through wires 453 and
454. Connector references for the harness are C280,
C310, and C340.
The standard electrical schematic does not show all op-
tional wiring connections. In addition, the PWM and I/O
module have an internal logic that cannot be made visi-
ble on the electrical schematic. Tables Table 7, Table 8,
and Table 9 assist with the verification of electrical cir-
cuits.
Table 10 and Table 11 shows the interaction of the mod-
ules depending on the input signals received.

Figure 37. Connector Reference

30
1900 YRM 938 Electrical Connections

Table 7. PWM Driver Module

Before February Starting February Starting February

2003 2003 2003
PIN WIRE Alternating A/B Alternating A/B Fixed PT
1 408 Lift Joystick Input Lift Potentiometer Lift Potentiometer
Input Input
2 409 Tilt Joystick Input Tilt Potentiometer Tilt Potentiometer
Input Input
3 410 Aux Joystick Input Aux 0 Potentiometer Aux 0 Potentiometer
Input Input
4 405 5V Joystick Supply 5V Potentiometer 5V Potentiometer
Supply Supply
5 406 Digital Ground Digital Ground Digital Ground
6 Not Used Not Used Not Used
7 425 Aux Valve Output B Aux Valve Output B Aux Valve Output B
8 424 Aux Valve Output A Aux Valve Output A Not Used
9 423 Tilt Valve Output B Tilt Valve Output B Tilt Valve Output B
10 422 Tilt Valve Output A Tilt Valve Output A Tilt Valve Output A
11 468 Lift Valve Output B Lift Valve Output B Lift Valve Output B
12 457 Lift Valve Output A Lift Valve Output A Lift Valve Output A

Table 8. Input/Output Module 1

Before February Starting February Starting February

2003 2003 2003
PIN WIRE Alternating A/B Alternating A/B Fixed PT
1 411 Clamp Joystick Input Aux 1 Potentiometer Aux 1 Potentiometer
Input Input
2 413 Aux 2 Switch Input Aux 2 Switch Input Aux 2 Switch Input
3 414 Aux 3 Switch Input Aux 3 Switch Input Aux 3 Switch Input
4 412 Deadman Switch Inhibit 1 Switch Input Inhibit 1 Switch Input
Input
5 405 5V Joystick Supply 5V Potentiometer 5V Potentiometer
Supply Supply
6 406 Digital Ground Digital Ground Digital Ground
7 404 4V Switch Supply 4V Switch Supply 4V Switch Supply
8 407 1V Switch Supply 1V Switch Supply 1V Switch Supply
9 429 Sideshift Output Aux 1 Output Aux 0 Output
10 428 Sideshift Output Aux 0 Output Aux 0 Output

31
Electrical Connections 1900 YRM 938

Table 8. Input/Output Module 1 (Continued)

Before February Starting February Starting February

2003 2003 2003
PIN WIRE Alternating A/B Alternating A/B Fixed PT
11 427 Clamp/Aux 3 Output Aux 3 Output Aux 1 Output
12 426 Clamp/Aux 2 Output Aux 2 Output Aux 1 Output

Table 9. Input/Output Module 2

Before February Starting February Starting February

2003 2003 2003
PIN WIRE Alternating A/B Alternating A/B Fixed PT
1 Aux 4 Switch Input Aux 4 Switch Input Aux 4 Switch Input
2 Aux 5 Switch Input Aux 5 Switch Input Aux 5 Switch Input
3 Aux 6 Switch Input Unused Analog Aux 6 Switch Input
Input
4 470 Unused Analog Inhibit 0 Switch Input Inhibit 0 Switch Input
Input
5 405 5V Supply 5V Supply 5V Supply
6 406 Digital Ground Digital Ground Digital Ground
7 404 4V Switch Supply 4V Switch Supply 4V Switch Supply
8 407 1V Switch Supply 1V Switch Supply 1V Switch Supply
9 Unused Output Aux 1 Output Aux 0 Output
10 Aux 6 Output Aux 0 Output Aux 0 Output
11 Aux 5 Output Aux 5 Output Aux 1 Output
12 Aux 4 Output Aux 4 Output Aux 1 Output

32
1900 YRM 938 Electrical Connections

Table 10. Altering PT

Input Output
Without Inhibit Switch With Inhibit Switch
C290 1 C290 11/12 C290 11/12
C290 2 C290 9/10 C290 9/10
C290 3 C290 7/8 + C320 10 C290 7/8 + C350 10
C350 4 + C290 3 N/A C290 7/8 + C320 10
C320 1 C290 7/8 + C320 9 C290 7/8 + C350 9
C320 4 + C320 1 N/A C290 7/8 + C320 9
C320 2 C290 7/8 + C320 12 C290 7/8 + C320 12
C320 3 C290 7/8 + C320 11 C290 7/8 + C320 11
C350 1 C290 7/8 + C350 12 C290 7/8 + C350 12
C350 2 C290 7/8 + C350 11 C290 7/8 + C350 11

Table 11. Fixed PT

Input Output
Without Inhibit Switch With Inhibit Switch
C290 1 C290 11/12 C290 11/12
C290 2 C290 9/10 C290 9/10
C290 3 C290 7 + C320 9/10 C290 7 + C350 9/10
C350 4 + C290 3 N/A C290 7 + C320 9/10
C320 1 C290 7 + C320 11/12 C290 7 + C350 11/12
C320 4 + C320 1 N/A C290 7 + C320 11/12
C320 2 C290 7 C290 7
C320 3 C290 7 C290 7
C350 1 C290 7 C290 7
C350 2 C290 7 C290 7
C350 3 C290 7 C290 7

33
Diagrams, Schematics, or Arrangements 1900 YRM 938

Specifications
Item Specification
Hydraulic Pump Capacity* Turbo Engine
Large Section 192.0 liter/min (51 gal/min) at 21.0 MPa (3045 psi)
Small Section 93.0 liter/min (24.6 gal/min) at 19.3 MPa (2800 psi)
Relief Pressures*
Main Control Valve
Lift Circuit 21.0 MPa (3045 psi)
Tilt and Sideshift Circuits 19.3 MPa (2800 psi)
Steering Circuit 16.5 MPa (2400 psi)
Hydraulic Tank Capacity
Dipstick FULL mark 109 liter (27.8 gal)
Hydraulic System Capacity 139 liter (36.7 gal)
*Oil temperature 60 C (140 F) and engine speed at 2300 RPM.

NOTE: For all hydraulic schematics, see Diagrams 8000 YRM 1103 for C876 and C877 trucks, and Dia-
8000 YRM 941 for B876 and B877 trucks, Diagrams grams 8000 YRM 1346 for D876 and D877 trucks.

34
 Yale Europe Materials Handling Limited
Flagship House, Reading Road North, Fleet, Hampshire GU138 HR United Kingdom

1900 YRM 938 3/07

(2/06)(12/05)(6/05)(9/03)(5/03)(3/03)(11/02)(4/02)(2/02)(8/01) Printed in the United Kingdom