Yale C910 (GC_GLC040VX, GC_GLC050VX, GC_GLC055SVX, GC_GLC60VX, GC_GLC070VX) Service Manual PDF
$40.95
Yale Forklift C910 (GC_GLC040VX, GC_GLC050VX, GC_GLC055SVX, GC_GLC60VX, GC_GLC070VX) Service Manual – PDF DOWNLOAD
Description
Yale Forklift C910 (GC_GLC040VX, GC_GLC050VX, GC_GLC055SVX, GC_GLC60VX, GC_GLC070VX) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Yale Forklift C910 (GC_GLC040VX, GC_GLC050VX, GC_GLC055SVX, GC_GLC60VX, GC_GLC070VX) Service Manual – PDF DOWNLOAD
Language : English
Pages : 5014
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Yale Forklift C910 (GC_GLC040VX, GC_GLC050VX, GC_GLC055SVX, GC_GLC60VX, GC_GLC070VX) Service Manual – PDF DOWNLOAD
524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524221866-9000YRM1112-(10-2020)-US-EN 43
SECTION 9010 Operational Diagnostic Procedures 59
Group 05 – Operational Checkout 61
SECTION 9020 Engine 79
Group 10 – Principles of Operation 89
Group 30 – Observed Symptoms 287
Group 40 – Tests and Adjustments 389
SECTION 9030 Electrical System 421
Group 03 – General Maintenance and Diagnostic Data 445
Group 10 – Principles of Operation 539
Group 20 – Diagnostic Trouble Codes 563
Group 30 – Observed Symptoms 1535
SECTION 9040 Drive Train 1591
Group 10 – Principles of Operation 1595
Group 30 – Observed Symptoms 1651
Group 40 – Tests and Adjustments 1701
SECTION 9050 Hydraulic Systems 1711
Group 10 – Principles of Operation 1715
Group 30 – Observed Symptoms 1773
Group 33 – Observed Symptoms-Gear Pump 1775
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1863
Group 40 – Tests and Adjustments 1907
Group 43 – Tests and Adjustments-Gear Pump 1909
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1933
SECTION 9060 Operators Station 1951
Group 10 – Principles of Operation 1953
SECTION 9070 Front End (Mast) and Chassis 1989
Group 10 – Principles of Operation 1991
Group 30 – Observed Symptoms 2013
SECTION 9080 Supplementary Data 2071
Group 50 – Abbreviations and Acronyms 2073
Group 60 – Special Tools List 2081
Group 70 – Fault Mode Indicator Reference 2091
Group 80 – Supplier Specification Data 2093
524223769-2200YRM1128-(01-2023)-US-EN 2097
Series Code / Model Designation Reference Table 2105
General 2107
Deutsch Crimping Tool 2108
How to Strip a Wire for Use With Deutsch Crimping Tool 2108
How to Crimp With the Deutsch Crimping Tool 2109
Calibration Test for the Deutsch Crimping Tool 2111
Deutsch Connectors 2113
DT, DTM, and DTP Series Connectors 2113
HD Series Connectors 2156
Metri-Pack Connectors 2178
Remove and Install 2178
Micro-Pack Connectors 2181
Weather-Pack Connectors 2182
AMPSEAL Crimping Tools 2184
AMP Hand Crimping Tool With Certi-Crimp 2184
Description 2184
Stripping Wire for Use with AMP Hand Crimping Tool 2185
Insulation Crimp Adjustment 2186
Maintenance and Inspection for AMP Hand Crimping Tool 2186
AMP Hand Crimping Tool 2186
Crimp Height Inspection 2186
How to use AMP Hand Crimping Tool 2187
AMP Pro-Crimper II Tool 2187
Description 2187
Remove and Install Die Set and Locator Assembly 2188
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2188
Contact Support Adjustment 2189
Crimp Height Adjustment 2190
Maintenance and Inspection Procedures 2190
PRO-CRIMPER II Tool 2190
Crimp Height Inspection 2190
How to Use AMP PRO-CRIMPER II Tool 2191
AMPSEAL Connector Assemblies 2192
Description for Plug Connector Assembly 2192
Seal Plug 2193
Contact Crimping 2193
Description for Plug Connector and Header Assembly 2198
Voltage Reading 2201
Seal Plug 2201
Contact Crimping 2201
AMP Superseal 1 5 Crimping Tools 2208
Mini Mic Receptacle and Tab Contacts 2208
Description 2208
Crimping Conditions and Measurements 2208
Insertion of Rubber Seal on Cable 2210
AMP Hand Application Tool 2215
Description 2215
Maintenance and Inspection 2215
Crimp Height Inspection 2215
Crimp Height Adjustment 2216
How to Use AMP Hand Application Tool 2216
AMP Pro-Crimper II Tool 2217
Description 2217
Remove and Install Die Set and Locator Assembly 2217
Adjustments 2218
Contact Support 2218
Crimp Height 2219
Inspections and Maintenance 2220
Crimp Height Inspection 2220
Visual Inspection 2220
Maintenance 2221
How to Use Pro-Crimper II Tool 2221
AMP Superseal 1 5 Connector Assemblies 2222
Description 2222
Repair and Maintenance 2229
Panel Mount Option 2229
AMP Fastin-Faston Hand Tools 2230
Description – AMP Double Action Hand Tool 2230
Maintenance and Inspection Procedures 2230
Daily Maintenance 2230
Periodic Tool Inspection 2231
Lubrication 2231
Visual Inspection 2231
Crimp Height Inspection 2231
Certi-Crimp Ratchet Inspection 2232
How to Use AMP Double Action Hand Tool 2233
Description – AMP Extraction Tool 2234
Maintenance and Inspection 2235
How to Use AMP Extraction Tool 2235
AMP Fastin-Faston Receptacles and Housings 2237
Description 2237
Wire Repair 2245
Wire Splicing Requirements 2245
Deutsch Jiffy Splice 2246
Twisted/Shielded Cable and Leads Repair 2252
Special Tools 2254
524223769-2200YRM1128-(07-2020)-US-EN 2263
Series Code / Model Designation Reference Table 2269
General 2272
Deutsch Crimping Tool 2272
How to Strip a Wire for Use With Deutsch Crimping Tool 2272
How to Crimp With the Deutsch Crimping Tool 2273
Calibration Test for the Deutsch Crimping Tool 2275
Deutsch Connectors 2277
DT, DTM, and DTP Series Connectors 2277
HD Series Connectors 2319
Metri-Pack Connectors 2342
Remove and Install 2342
Micro-Pack Connectors 2344
Weather-Pack Connectors 2345
AMPSEAL Crimping Tools 2347
AMP Hand Crimping Tool With Certi-Crimp 2347
Description 2347
Stripping Wire for Use with AMP Hand Crimping Tool 2347
Insulation Crimp Adjustment 2348
Maintenance and Inspection for AMP Hand Crimping Tool 2348
AMP Hand Crimping Tool 2348
Crimp Height Inspection 2348
How to use AMP Hand Crimping Tool 2349
AMP Pro-Crimper II Tool 2349
Description 2349
Remove and Install Die Set and Locator Assembly 2350
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2351
Contact Support Adjustment 2351
Crimp Height Adjustment 2352
Maintenance and Inspection Procedures 2352
PRO-CRIMPER II Tool 2352
Crimp Height Inspection 2352
How to Use AMP PRO-CRIMPER II Tool 2353
AMPSEAL Connector Assemblies 2354
Description for Plug Connector Assembly 2354
Seal Plug 2355
Contact Crimping 2355
Description for Plug Connector and Header Assembly 2360
Voltage Reading 2362
Seal Plug 2362
Contact Crimping 2362
AMP Superseal 1 5 Crimping Tools 2369
Mini Mic Receptacle and Tab Contacts 2369
Description 2369
Crimping Conditions and Measurements 2369
Insertion of Rubber Seal on Cable 2371
AMP Hand Application Tool 2376
Description 2376
Maintenance and Inspection 2376
Crimp Height Inspection 2376
Crimp Height Adjustment 2377
How to Use AMP Hand Application Tool 2377
AMP Pro-Crimper II Tool 2378
Description 2378
Remove and Install Die Set and Locator Assembly 2379
Adjustments 2379
Contact Support 2379
Crimp Height 2380
Inspections and Maintenance 2381
Crimp Height Inspection 2381
Visual Inspection 2381
Maintenance 2382
How to Use Pro-Crimper II Tool 2382
AMP Superseal 1 5 Connector Assemblies 2383
Description 2383
Repair and Maintenance 2390
Panel Mount Option 2390
AMP Fastin-Faston Hand Tools 2391
Description – AMP Double Action Hand Tool 2391
Maintenance and Inspection Procedures 2391
Daily Maintenance 2391
Periodic Tool Inspection 2392
Lubrication 2392
Visual Inspection 2392
Crimp Height Inspection 2392
Certi-Crimp Ratchet Inspection 2393
How to Use AMP Double Action Hand Tool 2394
Description – AMP Extraction Tool 2395
Maintenance and Inspection 2395
How to Use AMP Extraction Tool 2396
AMP Fastin-Faston Receptacles and Housings 2397
Description 2397
Wire Repair 2404
Wire Splicing Requirements 2404
Deutsch Jiffy Splice 2405
Twisted/Shielded Cable and Leads Repair 2410
Special Tools 2413
524223770-2200YRM1130-(03-2020)-US-EN 2421
General 2425
Description 2425
Dash Display Menu Access 2425
Menu Navigation 2426
Standard Display 2426
Main Menu 2426
Passwords Menu 2427
Password Administration 2427
Add Password 2427
Delete Password 2428
Edit Password 2428
Other Password Functions 2429
Operator Passwords – Enable/Disable 2429
Password Time-Out Delay 2429
Passwords – Number Wrong to Disable 2430
Lockout Reset Password 2430
View Password Log 2431
View Versions 2432
VSM Versions 2432
Dash Display Versions 2433
Engine Controller Version 2434
Transmission (Xmsn) Controller Version 2435
Truck Serial Number 2436
Diagnostics 2437
View Fault Log 2437
Set Travel and Braking 2438
Speed Limit 2438
Acceleration Rate 2439
Auto-Deceleration Rate 2439
Set Power Reversal Rate 2440
Set Inching/Brake Overlap 2441
Setup Display Menu 2442
Set Operator Language 2442
Set Units 2443
Set Time Format (12/24 Hour) 2443
Set Daylight Saving Time 2443
Set Time 2446
Set Date Format 2447
Set Date 2447
Setup Hydraulics 2448
Return to Set Tilt Delay/On/Off 2448
Setup General Items 2449
Light Shutdown Time-Out 2449
Impact Sensor – Enable/Disable 2450
Impact Sensor – Soft Impact Settings 2451
Impact Sensor – Hard Impact Settings 2452
Adjust Impact Sensor Settings 2452
Initial Adjustment of Soft and Hard Impact Settings 2454
Readjustment of Soft and Hard Impact Settings 2454
Impact Sensor – Impact Alarm/Shutdown Reset 2455
Impact Sensor – Alarm Time Duration and Deactivation 2456
Impact Sensor – View Impact Event Log 2457
Engine Mode Indicator 2458
Generation 1 (ECO-eLo ONLY) 2458
Generation 2 2459
Operator Checklist 2460
Operator Checklist Off-On Mode 2460
Edit Operator Checklist 2460
Set Operator Checklist Expiration 2461
View Checklist Log 2461
Clear Operator Checklist Log 2462
Clear Operator Checklist Fault 2462
Calibrations 2463
Set Tilt Stop Point 2463
Calibrate Loaded Weight 2463
524223770-2200YRM1130-(05-2021)-US-EN 2465
General 2469
Description 2469
Dash Display Menu Access 2469
Menu Navigation 2470
Standard Display 2470
Main Menu 2470
Passwords Menu 2471
Password Administration 2471
Add Password 2471
Delete Password 2471
Edit Password 2472
Other Password Functions 2473
Operator Passwords – Enable/Disable 2473
Password Time-Out Delay 2473
Passwords – Number Wrong to Disable 2473
Lockout Reset Password 2474
View Password Log 2474
View Versions 2475
VSM Versions 2475
Dash Display Versions 2476
Engine Controller Version 2477
Transmission (Xmsn) Controller Version 2478
Truck Serial Number 2479
Diagnostics 2480
View Fault Log 2480
Set Travel and Braking 2481
Speed Limit 2481
Acceleration Rate 2482
Auto-Deceleration Rate 2482
Set Power Reversal Rate 2483
Set Inching/Brake Overlap 2484
Setup Display Menu 2485
Set Operator Language 2485
Set Units 2486
Set Time Format (12/24 Hour) 2486
Set Daylight Saving Time 2487
Set Time 2490
Set Date Format 2490
Set Date 2491
Setup Hydraulics 2492
Return to Set Tilt Delay/On/Off 2492
Setup General Items 2493
Light Shutdown Time-Out 2493
Impact Sensor – Enable/Disable 2494
Impact Sensor – Soft Impact Settings 2495
Impact Sensor – Hard Impact Settings 2495
Adjust Impact Sensor Settings 2496
Initial Adjustment of Soft and Hard Impact Settings 2498
Readjustment of Soft and Hard Impact Settings 2498
Impact Sensor – Impact Alarm/Shutdown Reset 2499
Impact Sensor – Alarm Time Duration and Deactivation 2500
Impact Sensor – View Impact Event Log 2501
Engine Mode Indicator 2501
Generation 1 (ECO-eLo ONLY) 2501
Generation 2 2502
Operator Checklist 2503
Operator Checklist Off-On Mode 2503
Edit Operator Checklist 2503
Set Operator Checklist Expiration 2503
View Checklist Log 2504
Clear Operator Checklist Log 2505
Clear Operator Checklist Fault 2505
Calibrations 2506
Set Tilt Stop Point 2506
Calibrate Loaded Weight 2506
524223771-2200YRM1131-(03-2020)-US-EN 2509
Series Code / Model Designation Reference Table 2515
General 2517
Description 2517
Dash Display Menu Access 2517
Menu Navigation 2518
Main Menu 2518
Passwords 2519
Adding Passwords 2519
Hourmeters 2521
View Versions 2522
VSM Versions 2522
Dash Display Versions 2523
Engine Controller Version 2524
Transmission (Xmsn) Controller Version 2525
Truck Serial Number 2526
Truck Configuration 2527
Diagnostics 2528
Clear Fault Log 2528
View Fault Log 2529
No-Run Data Display 2530
Engine Accelerator and Throttle Data Display 2530
Engine Speeds and Governor Data Display 2531
Engine Fuel and Emissions Data Display 2532
Engine General Data Display 2534
XMSN/Brake Data Display 2535
Hydraulic Data Display 2538
General Truck Data Display 2540
Set Travel and Braking 2541
Speed Limit 2541
Acceleration Rate 2542
Auto-Deceleration Rate 2543
Set Power Reversal Rate 2543
Set Inching/Brake Overlap 2544
Setup Hydraulics 2544
Lift Maximum Speed 2545
Lower Maximum Speed 2545
Tilt Maximum Speed 2546
Auxiliary Function One, Direction A, Maximum Speed 2548
Auxiliary Function One, Direction B, Maximum Speed 2550
Auxiliary Function Two, Direction A, Maximum Speed 2550
Auxiliary Function Two, Direction B, Maximum Speed 2551
Auxiliary Function Three, Direction A, Maximum Speed 2552
Auxiliary Function Three, Direction B, Maximum Speed 2552
Lift/Lower Ramp Rate 2553
Hydraulic Auxiliary Ramp Rate 2553
Return to Set Tilt Delay/On/Off 2554
Hydraulic Input Device 2555
Auxiliary Solenoid 2555
Dual Function 2556
Setup Display 2557
Set Service Language 2557
Setup General Items 2557
Motion Alarm Activation Type 2558
Light Shutdown Time-Out 2559
Restore Default Settings 2559
Restore Engine Controller Default Calibration 2560
Impact Sensor – Enable/Disable 2560
Impact Sensor – Soft Impact Settings 2561
Impact Sensor – Hard Impact Settings 2562
Adjust Impact Sensor Settings 2563
Initial Adjustment of Soft and Hard Impact Settings 2565
Readjustment of Soft and Hard Impact Settings 2565
Impact Sensor – Impact Alarm/Shutdown Reset 2566
Impact Sensor – Alarm Time Duration and Deactivation 2567
Impact Sensor – View Impact Event Log 2568
Engine Mode Indicator 2568
Generation 1 (ECO-eLo ONLY) 2568
Generation 2 2569
Diesel Particulate Filter (DPF) Display 2570
General Description 2570
Passive Regeneration Only 2570
Regeneration Level 0 2570
Auto/Active Regeneration Inhibited 2571
Auto/Active Regeneration 2571
Regeneration Level 1 2571
Parked Regeneration Request 2572
Regeneration Level 2 2572
Warning Level 2572
Regeneration Level 3 2572
Service Level 2573
Regeneration Level 4 2573
Display, Diesel Particulate Filter (DPF), Revised 2573
Operator Interface 2573
Refer to Operator Manual 2573
CAN Communication Lost 2574
Passive Regeneration Only 2574
Regeneration Level 0 2574
Auto/Active Regeneration Inhibited 2574
Auto/Active Regeneration 2575
Regeneration Level 1 2575
Idle-up Auto/Active Regeneration 2575
Parked Regeneration Request 2575
Regeneration Level 2 2575
Warning Level 2577
Regeneration Level 3 2577
Service Level 2577
Regeneration Level 4 2577
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2577
Display, Diesel Particulate Filter (DPF), Stage V Engine 2577
Operator Interface 2578
Refer to Operator Manual 2578
CAN Communication Lost 2578
Passive Regeneration Only 2578
Regeneration Level 0 2578
Auto/Active Regeneration Inhibited 2579
Auto/Active Regeneration 2579
Regeneration Level 1 2579
Idle-up Auto/Active Regeneration 2580
Parked Regeneration Request 2580
Regeneration Level 2 2580
Warning Level 2581
Regeneration Level 3 2581
Service Level 2582
Regeneration Level 4 2582
Stage V Content 2582
Emissions System Malfunction 2582
Ash Load 2582
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2583
Operator Interface 2583
Refer to Operator Manual 2583
CAN Communication Lost 2584
Passive Regeneration Only 2584
Regeneration Level 0 2584
Auto/Active Regeneration Inhibited 2584
Auto/Active Regeneration 2585
Regeneration Level 1 2585
Idle-up Auto/Active Regeneration 2585
Parked Regeneration Request 2585
Regeneration Level 2 2585
Warning Level 2587
Regeneration Level 3 2587
Service Level 2587
Regeneration Level 4 2587
Calibrations 2588
Calibrate Transmission Valve 2590
Set Tilt Stop Point 2590
Calibrate Loaded Weight 2590
Calibrate Travel Speed Sensor 2591
Calibrate Mazda LP and Gas Accelerator Pedal 2591
524223771-2200YRM1131-(05-2021)-US-EN 2593
Series Code / Model Designation Reference Table 2599
General 2601
Description 2601
Dash Display Menu Access 2601
Menu Navigation 2602
Main Menu 2603
Passwords 2603
Adding Passwords 2603
Hourmeters 2605
View Versions 2606
VSM Versions 2606
Dash Display Versions 2607
Engine Controller Version 2608
Transmission (Xmsn) Controller Version 2609
Truck Serial Number 2610
Truck Configuration 2611
Diagnostics 2612
Clear Fault Log 2612
View Fault Log 2613
No-Run Data Display 2614
Engine Accelerator and Throttle Data Display 2615
Engine Speeds and Governor Data Display 2617
Engine Fuel and Emissions Data Display 2618
Engine General Data Display 2620
XMSN/Brake Data Display 2621
Hydraulic Data Display 2623
General Truck Data Display 2626
Set Travel and Braking 2628
Speed Limit 2628
Acceleration Rate 2629
Auto-Deceleration Rate 2629
Set Power Reversal Rate 2630
Set Inching/Brake Overlap 2630
Setup Hydraulics 2631
Lift Maximum Speed 2631
Lower Maximum Speed 2632
Tilt Maximum Speed 2632
Auxiliary Function One, Direction A, Maximum Speed 2634
Auxiliary Function One, Direction B, Maximum Speed 2637
Auxiliary Function Two, Direction A, Maximum Speed 2637
Auxiliary Function Two, Direction B, Maximum Speed 2638
Auxiliary Function Three, Direction A, Maximum Speed 2639
Auxiliary Function Three, Direction B, Maximum Speed 2639
Lift/Lower Ramp Rate 2640
Hydraulic Auxiliary Ramp Rate 2640
Return to Set Tilt Delay/On/Off 2641
Hydraulic Input Device 2642
Auxiliary Solenoid 2642
Dual Function 2643
Setup Display 2644
Set Service Language 2644
Setup General Items 2644
Motion Alarm Activation Type 2645
Light Shutdown Time-Out 2646
Restore Default Settings 2646
Restore Engine Controller Default Calibration 2647
Impact Sensor – Enable/Disable 2647
Impact Sensor – Soft Impact Settings 2648
Impact Sensor – Hard Impact Settings 2648
Adjust Impact Sensor Settings 2649
Initial Adjustment of Soft and Hard Impact Settings 2651
Readjustment of Soft and Hard Impact Settings 2651
Impact Sensor – Impact Alarm/Shutdown Reset 2652
Impact Sensor – Alarm Time Duration and Deactivation 2653
Impact Sensor – View Impact Event Log 2654
Engine Mode Indicator 2654
Generation 1 (ECO-eLo ONLY) 2654
Generation 2 2655
Diesel Particulate Filter (DPF) Display 2656
General Description 2656
Passive Regeneration Only 2656
Regeneration Level 0 2656
Auto/Active Regeneration Inhibited 2657
Auto/Active Regeneration 2657
Regeneration Level 1 2657
Parked Regeneration Request 2658
Regeneration Level 2 2658
Warning Level 2659
Regeneration Level 3 2659
Service Level 2659
Regeneration Level 4 2659
Display, Diesel Particulate Filter (DPF), Revised 2659
Operator Interface 2660
Refer to Operator Manual 2660
CAN Communication Lost 2660
Passive Regeneration Only 2660
Regeneration Level 0 2660
Auto/Active Regeneration Inhibited 2661
Auto/Active Regeneration 2661
Regeneration Level 1 2661
Idle-up Auto/Active Regeneration 2661
Parked Regeneration Request 2662
Regeneration Level 2 2662
Warning Level 2663
Regeneration Level 3 2663
Service Level 2663
Regeneration Level 4 2663
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2664
Display, Diesel Particulate Filter (DPF), Stage V Engine 2664
Operator Interface 2664
Refer to Operator Manual 2664
CAN Communication Lost 2665
Passive Regeneration Only 2665
Regeneration Level 0 2665
Auto/Active Regeneration Inhibited 2665
Auto/Active Regeneration 2666
Regeneration Level 1 2666
Idle-up Auto/Active Regeneration 2666
Parked Regeneration Request 2666
Regeneration Level 2 2666
Warning Level 2668
Regeneration Level 3 2668
Service Level 2668
Regeneration Level 4 2668
Stage V Content 2668
Emissions System Malfunction 2668
Ash Load 2669
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2670
Operator Interface 2670
Refer to Operator Manual 2670
CAN Communication Lost 2671
Passive Regeneration Only 2671
Regeneration Level 0 2671
Auto/Active Regeneration Inhibited 2671
Auto/Active Regeneration 2672
Regeneration Level 1 2672
Idle-up Auto/Active Regeneration 2672
Parked Regeneration Request 2672
Regeneration Level 2 2672
Warning Level 2674
Regeneration Level 3 2674
Service Level 2674
Regeneration Level 4 2674
Calibrations 2675
Calibrate Transmission Valve 2677
Set Tilt Stop Point 2677
Calibrate Loaded Weight 2678
Calibrate Travel Speed Sensor 2678
Calibrate Mazda LP and Gas Accelerator Pedal 2679
524223780-8000YRM1134-(03-2020)-US-EN 2681
Series Code / Model Designation Reference Table 2687
Description 2689
Proc_Cal_001: Service Password Entry 2691
When to Perform 2691
Why Perform 2691
How to Perform 2691
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2692
When to Perform 2692
Calibration Order 2692
Why Perform 2692
How to Perform 2693
Proc_Cal_003: Save and Exit 2694
When to Perform 2694
Why Perform 2694
How to Perform 2694
Proc_Cal_004: Lift Valve Output Threshold 2695
When to Perform 2695
Calibration Order 2695
Why Perform 2695
How to Perform 2696
Proc_Cal_005: Lower Valve Output Threshold 2698
When to Perform 2698
Calibration Order 2698
Why Perform 2698
How to Perform 2698
Proc_Cal_006: Tilt Back Valve Output Threshold 2701
When to Perform 2701
Calibration Order 2701
Why Perform 2701
How to Perform 2701
Proc_Cal_007: Tilt Forward Valve Output Threshold 2704
When to Perform 2704
Calibration Order 2704
Why Perform 2704
How to Perform 2704
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2707
When to Perform 2707
Calibration Order 2707
Why Perform 2707
How to Perform 2707
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2710
When to Perform 2710
Calibration Order 2710
Why Perform 2710
How to Perform 2710
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2713
When to Perform 2713
Calibration Order 2713
Why Perform 2713
How to Perform 2713
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2716
When to Perform 2716
Calibration Order 2716
Why Perform 2716
How to Perform 2716
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2719
When to Perform 2719
Calibration Order 2719
Why Perform 2719
How to Perform 2719
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2722
When to Perform 2722
Calibration Order 2722
Why Perform 2722
How to Perform 2722
Proc_Cal_014: Load Weight Zero Point 2726
When to Perform 2726
Calibration Order 2726
Why Perform 2726
How to Perform 2726
Proc_Cal_015: Loaded Weight Calibration 2728
When to Perform 2728
Calibration Order 2728
Why Perform 2728
How to Perform 2728
Proc_Cal_016: Transmission Valve Calibration 2731
Applicable System/Option 2731
When to Perform 2731
Calibration Order 2731
Why Perform 2731
How to Perform 2731
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2733
Applicable System/Option 2733
When to Perform 2733
Calibration Order 2733
Why Perform 2733
How to Perform 2733
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2735
Applicable System/Option 2735
When to Perform 2735
Calibration Order 2735
Why Perform 2735
How to Perform 2736
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2737
Required Tools 2737
When to Perform 2737
Calibration Order 2737
Why Perform 2738
How to Perform 2738
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2739
When to Perform 2739
Why Perform 2739
How to Perform 2739
Proc_Cal_026: Travel Speed Calibration 2741
When to Perform 2741
Calibration Order 2741
Why Perform 2741
How to Perform 2741
524223780-8000YRM1134-(05-2022)-US-EN 2745
Series Code / Model Designation Reference Table 2751
Description 2754
Proc_Cal_001: Service Password Entry 2756
When to Perform 2756
Why Perform 2756
How to Perform 2756
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2757
When to Perform 2757
Calibration Order 2757
Why Perform 2757
How to Perform 2757
Proc_Cal_003: Save and Exit 2759
When to Perform 2759
Why Perform 2759
How to Perform 2759
Proc_Cal_004: Lift Valve Output Threshold 2760
When to Perform 2760
Calibration Order 2760
Why Perform 2760
How to Perform 2760
Proc_Cal_005: Lower Valve Output Threshold 2763
When to Perform 2763
Calibration Order 2763
Why Perform 2763
How to Perform 2763
Proc_Cal_006: Tilt Back Valve Output Threshold 2766
When to Perform 2766
Calibration Order 2766
Why Perform 2766
How to Perform 2766
Proc_Cal_007: Tilt Forward Valve Output Threshold 2769
When to Perform 2769
Calibration Order 2769
Why Perform 2769
How to Perform 2769
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2772
When to Perform 2772
Calibration Order 2772
Why Perform 2772
How to Perform 2772
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2775
When to Perform 2775
Calibration Order 2775
Why Perform 2775
How to Perform 2775
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2778
When to Perform 2778
Calibration Order 2778
Why Perform 2778
How to Perform 2778
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2781
When to Perform 2781
Calibration Order 2781
Why Perform 2781
How to Perform 2781
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2784
When to Perform 2784
Calibration Order 2784
Why Perform 2784
How to Perform 2784
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2787
When to Perform 2787
Calibration Order 2787
Why Perform 2787
How to Perform 2787
Proc_Cal_014: Load Weight Zero Point 2790
When to Perform 2790
Calibration Order 2790
Why Perform 2790
How to Perform 2790
Proc_Cal_015: Loaded Weight Calibration 2792
When to Perform 2792
Calibration Order 2792
Why Perform 2792
How to Perform 2792
Proc_Cal_016: Transmission Valve Calibration 2795
Applicable System/Option 2795
When to Perform 2795
Calibration Order 2795
Why Perform 2795
How to Perform 2795
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2797
Applicable System/Option 2797
When to Perform 2797
Calibration Order 2797
Why Perform 2797
How to Perform 2797
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2800
Applicable System/Option 2800
When to Perform 2800
Calibration Order 2800
Why Perform 2800
How to Perform 2800
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2803
Required Tools 2803
When to Perform 2803
Calibration Order 2803
Why Perform 2803
How to Perform 2803
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2805
When to Perform 2805
Why Perform 2805
How to Perform 2805
Proc_Cal_026: Travel Speed Calibration 2807
When to Perform 2807
Calibration Order 2807
Why Perform 2807
How to Perform 2807
550073240-1900YRM1620-(01-2023)-US-EN 2811
Proper Flushing after Major Hydraulic Repairs 2817
Introduction 2817
The Phases of Wear 2817
Causes of Hydraulic System Failure 2817
Progression of Contaminant Caused Hydraulic System Failure 2818
Hydraulic System Flushing Techniques 2818
Double Oil and Filter Change 2818
Mechanical Cleaning 2819
Cleaning of Components 2819
How to Clean Tubes and Hoses 2819
Filter Caddy 2819
Start-Up Procedure for Cleaned System 2820
Contaminated Oil Coolers 2820
Additional Filter Caddy Functions 2821
How to Handle Different Fluids 2821
Water Removal Filters 2821
Fluid Conditioning and System Flushing Procedures 2822
Operation of the Filter Caddy 2822
Filter Caddy operation 2822
Fluid Conditioning Procedure 2822
Filter Caddy Start-Up 2823
System Flushing Procedure 2823
Component Cleaning Procedure 2824
Reservoir Cleaning Procedure 2824
Cylinder Cleaning Procedure 2824
Hose and Tube Cleaning Procedure 2824
Valve Cleaning Procedure 2825
Front-End Attachment Cleaning Procedure 2826
System Flushing Procedure 2826
Filter Caddy Start-Up 2827
System Start-Up and Flushing 2827
Reservoir Fluid Cleaning Times 2828
Dealing With Different Fluid Types 2829
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2829
Filter Caddy Maintenance 2829
Servicing the Strainer 2829
DC Motor 2829
Hydraulic Oil Sampling Method and Procedure 2830
Hydraulic Oil Sampling Method 2830
Objective 2830
General Guidelines 2830
Synopsis 2831
Hydraulic Oil Analysis Report Guidelines 2832
Sampling Conditions 2832
Equipment 2832
Sampling Procedure 2833
Hydraulic Oil Sampling 2833
Sample Labeling 2833
Results Documentation 2833
550073240-1900YRM1620-(03-2020)-US-EN 2835
Proper Flushing after Major Hydraulic Repairs 2839
Introduction 2839
The Phases of Wear 2839
Causes of Hydraulic System Failure 2839
Progression of Contaminant Caused Hydraulic System Failure 2840
Hydraulic System Flushing Techniques 2840
Double Oil and Filter Change 2840
Mechanical Cleaning 2841
Cleaning of Components 2841
How to Clean Tubes and Hoses 2841
Filter Caddy 2841
Start-Up Procedure for Cleaned System 2842
Contaminated Oil Coolers 2842
Additional Filter Caddy Functions 2842
How to Handle Different Fluids 2842
Water Removal Filters 2843
Fluid Conditioning and System Flushing Procedures 2843
Operation of the Filter Caddy 2843
Filter Caddy operation 2843
Fluid Conditioning Procedure 2844
Filter Caddy Start-Up 2844
System Flushing Procedure 2845
Component Cleaning Procedure 2845
Reservoir Cleaning Procedure 2845
Cylinder Cleaning Procedure 2845
Hose and Tube Cleaning Procedure 2846
Valve Cleaning Procedure 2846
Front-End Attachment Cleaning Procedure 2847
System Flushing Procedure 2847
Filter Caddy Start-Up 2848
System Start-Up and Flushing 2848
Reservoir Fluid Cleaning Times 2849
Dealing With Different Fluid Types 2849
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2849
Filter Caddy Maintenance 2850
Servicing the Strainer 2850
DC Motor 2850
Hydraulic Oil Sampling Method and Procedure 2850
Hydraulic Oil Sampling Method 2850
Objective 2850
General Guidelines 2850
Synopsis 2851
Hydraulic Oil Analysis Report Guidelines 2852
Sampling Conditions 2853
Equipment 2853
Sampling Procedure 2853
Hydraulic Oil Sampling 2853
Sample Labeling 2854
Results Documentation 2854
550093750-2100YRM1668-(02-2018)-US-EN 2857
General 2861
Safety Procedures When Working Near Mast 2862
Main Lift Cylinder Repair 2864
Remove 2864
Disassemble 2866
Clean 2868
Inspect 2868
Assemble 2868
Install 2869
Main Lift Cylinder Leak Check 2869
Free-Lift Cylinder 2870
Remove 2870
Disassemble 2871
Clean 2873
Inspect 2873
Assemble 2873
Install 2873
Tilt Cylinder Repair 2874
Remove 2874
Disassemble 2876
Clean 2878
Inspect 2878
Assemble 2878
Install 2879
Tilt Cylinder Adjustment 2880
Tilt Cylinder Leak Check 2881
Integral Sideshift Cylinder Repair Prior to December 2016 2883
Remove 2883
Disassemble 2884
Clean 2885
Inspect 2885
Assemble 2885
Install 2885
Integral Sideshift Cylinder Repair After December 2016 2886
General 2886
Remove 2886
Disassemble 2888
Clean 2888
Inspect 2888
Assemble 2888
Install 2889
Integral Side-Shift Cylinder Gland Leak Checks 2890
Fork Positioner Cylinder Repair Prior to December 2016 2891
Remove 2891
Disassemble 2891
Clean 2893
Inspect 2894
Assemble 2894
Install 2894
Fork Positioner Cylinder Adjustment 2894
Fork Positioner Cylinder Repair After December 2016 2895
General 2895
Remove 2895
Disassemble 2895
Clean 2898
Inspect 2899
Assemble 2899
Install 2899
Fork Positioner Cylinder Adjustment 2899
Seal Kit Installation 2900
External Installation (Seal and Backup Ring) 2900
Internal Installation (Piston Rod Assembly) 2900
Torque Specifications 2901
Main Lift Cylinders 2901
Free-Lift Cylinder 2901
Tilt Cylinders 2901
Integral Sideshift Cylinder 2901
Fork Positioner Cylinder 2901
550093750-2100YRM1668-(04-2023)-US-EN 2905
General 2911
Safety Procedures When Working Near Mast 2914
Main Lift Cylinder Repair 2916
Remove 2916
Disassemble 2918
Clean 2920
Inspect 2920
Assemble 2920
Install 2921
Main Lift Cylinder Leak Check 2921
Free-Lift Cylinder 2922
Remove 2922
Disassemble 2923
Clean 2925
Inspect 2925
Assemble 2925
Install 2925
Tilt Cylinder Repair 2927
Remove 2927
Disassemble 2929
Clean 2930
Inspect 2931
Assemble 2931
Install 2932
Tilt Cylinder Adjustment 2932
Tilt Cylinder Leak Check 2934
Integral Sideshift Cylinder Repair Prior to December 2016 2936
Remove 2936
Disassemble 2936
Clean 2937
Inspect 2937
Assemble 2937
Install 2938
Integral Sideshift Cylinder Repair After December 2016 2939
General 2939
Remove 2939
Disassemble 2940
Clean 2941
Inspect 2941
Assemble 2941
Install 2941
Integral Side-Shift Cylinder Gland Leak Checks 2942
Fork Positioner Cylinder Repair Prior to December 2016 2943
Remove 2943
Disassemble 2943
Clean 2946
Inspect 2946
Assemble 2947
Install 2947
Fork Positioner Cylinder Adjustment 2947
Fork Positioner Cylinder Repair After December 2016 2949
General 2949
Remove 2949
Disassemble 2949
Clean 2952
Inspect 2952
Assemble 2953
Install 2953
Fork Positioner Cylinder Adjustment 2953
Seal Kit Installation 2955
External Installation (Seal and Backup Ring) 2955
Internal Installation (Piston Rod Assembly) 2955
Torque Specifications 2956
Main Lift Cylinders 2956
Free-Lift Cylinder 2956
Tilt Cylinders 2956
Integral Sideshift Cylinder 2956
Fork Positioner Cylinder 2956
550093755-4000YRM1669-(04-2023)-US-EN 2959
General 2967
Safety Procedures When Working Near Mast 2969
Fork Replacement 2971
Standard Carriage and Integral Sideshift Carriage 2971
Remove 2971
Install 2972
Checks 2972
Fork Positioner Carriage 2974
Remove 2975
Install 2975
Checks 2977
Carriages Repair, Two-Stage LFL Mast 2980
Standard Carriage 2980
Remove 2980
Clean and Inspect 2981
Install 2981
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 2981
Remove 2981
Disassemble 2983
Clean and Inspect 2984
Assemble 2985
Install 2985
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 2986
Remove 2986
Disassemble 2989
Clean and Inspect 2989
Assemble 2990
Install 2991
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 2991
Remove 2991
Disassemble 2994
Clean and Inspect 2994
Assemble 2995
Install 2996
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 2996
Remove 2996
Install 2998
Fork Positioner Hydraulic Hose Adjustment 3000
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3001
Remove 3001
Disassemble and Assemble 3005
Clean and Inspect 3005
Install 3005
Fork Positioner Hydraulic Hose Adjustment 3006
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 3007
Remove 3007
Disassemble and Assemble 3011
Clean and Inspect 3011
Install 3011
Fork Positioner Hydraulic Hose Adjustment 3012
Two-Stage LFL Mast Repair 3014
Mast With Serial Number F507 3014
Remove 3014
Disassemble 3018
Clean and Inspect 3025
Assemble 3027
Install 3028
Header Hoses 3030
Remove 3030
Installation 3030
Adjustment 3034
Mast With Serial Number F562 3035
Remove 3035
Disassemble 3039
Clean and Inspect 3046
Assemble 3048
Install 3049
Header Hose Installation and Adjustment 3050
Remove 3050
Installation 3051
Adjustment 3055
Carriages Repair, Three-Stage FFL Mast 3057
Standard Carriage 3057
Remove 3057
Clean and Inspect 3058
Install 3059
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3059
Remove 3059
Disassemble 3060
Clean and Inspect 3061
Assemble 3062
Install 3062
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3063
Remove 3063
Disassemble 3065
Clean and Inspect 3066
Assemble 3067
Install 3067
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 3068
Remove 3068
Disassemble 3070
Clean and Inspect 3071
Assemble 3072
Install 3072
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 3073
Remove 3073
Install 3075
Fork Positioner Hydraulic Hose Adjustment 3077
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3078
Remove 3078
Disassemble and Assemble 3080
Clean and Inspect 3080
Install 3080
Fork Positioner Hydraulic Hose Adjustment 3081
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 3082
Remove 3082
Disassemble and Assemble 3085
Clean and Inspect 3085
Install 3085
Fork Positioner Hydraulic Hose Adjustment 3086
Three-Stage FFL Mast Repair 3088
Mast With Serial Number F508 3088
Remove 3088
Disassemble 3091
Clean and Inspect 3101
Assemble 3104
Install 3105
Header Hose Installation and Adjustment 3107
Remove 3107
Installation 3107
Adjustment 3116
Mast With Serial Number F563 3116
Remove 3116
Disassemble 3120
Clean and Inspect 3130
Assemble 3133
Install 3134
Header Hose Installation and Adjustment 3136
Remove 3136
Installation 3136
Adjustment 3144
Mast Adjustments 3146
Load Roller, Adjust 3146
Mast Side Kicking, Adjust 3148
Carriage Adjustments 3149
Lift Chains Adjustment 3151
Hydraulic Quick Disconnect Hoses 3153
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 3153
Lift Trucks Equipped With E-Hydraulic Controls 3153
Lift Trucks Equipped With Manual Hydraulic Controls 3153
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 3154
Lift Trucks Equipped With E-Hydraulic Controls 3154
Lift Trucks Equipped With Manual Hydraulic Controls 3154
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 3154
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 3154
550093755-4000YRM1669-(06-2019)-US-EN 3157
General 3163
Safety Procedures When Working Near Mast 3164
Fork Replacement 3166
Standard Carriage and Integral Sideshift Carriage 3166
Remove 3166
Install 3168
Checks 3168
Fork Positioner Carriage 3170
Remove 3171
Install 3171
Checks 3173
Carriages Repair, Two-Stage LFL Mast 3175
Standard Carriage 3175
Remove 3175
Clean and Inspect 3176
Install 3177
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3177
Remove 3177
Disassemble 3178
Clean and Inspect 3179
Assemble 3180
Install 3180
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 3181
Remove 3181
Disassemble 3184
Clean and Inspect 3184
Assemble 3185
Install 3185
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 3186
Remove 3186
Disassemble 3189
Clean and Inspect 3189
Assemble 3190
Install 3190
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 3191
Remove 3191
Install 3193
Fork Positioner Hydraulic Hose Adjustment 3195
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3196
Remove 3196
Disassemble and Assemble 3200
Clean and Inspect 3200
Install 3200
Fork Positioner Hydraulic Hose Adjustment 3201
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 3202
Remove 3202
Disassemble and Assemble 3206
Clean and Inspect 3206
Install 3206
Fork Positioner Hydraulic Hose Adjustment 3207
Two-Stage LFL Mast Repair 3208
Mast With Serial Number F507 3208
Remove 3208
Disassemble 3212
Clean and Inspect 3219
Assemble 3221
Install 3222
Header Hoses 3224
Remove 3224
Installation 3224
Adjustment 3228
Mast With Serial Number F562 3229
Remove 3229
Disassemble 3233
Clean and Inspect 3240
Assemble 3242
Install 3243
Header Hose Installation and Adjustment 3244
Remove 3244
Installation 3245
Adjustment 3249
Carriages Repair, Three-Stage FFL Mast 3250
Standard Carriage 3250
Remove 3250
Clean and Inspect 3252
Install 3252
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3252
Remove 3252
Disassemble 3254
Clean and Inspect 3255
Assemble 3256
Install 3256
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3257
Remove 3257
Disassemble 3259
Clean and Inspect 3260
Assemble 3261
Install 3261
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 3262
Remove 3262
Disassemble 3264
Clean and Inspect 3265
Assemble 3266
Install 3266
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 3267
Remove 3267
Install 3269
Fork Positioner Hydraulic Hose Adjustment 3271
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3272
Remove 3272
Disassemble and Assemble 3274
Clean and Inspect 3274
Install 3274
Fork Positioner Hydraulic Hose Adjustment 3275
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 3276
Remove 3276
Disassemble and Assemble 3279
Clean and Inspect 3279
Install 3279
Fork Positioner Hydraulic Hose Adjustment 3280
Three-Stage FFL Mast Repair 3281
Mast With Serial Number F508 3281
Remove 3281
Disassemble 3285
Clean and Inspect 3295
Assemble 3298
Install 3299
Header Hose Installation and Adjustment 3301
Remove 3301
Installation 3301
Adjustment 3309
Mast With Serial Number F563 3310
Remove 3310
Disassemble 3313
Clean and Inspect 3323
Assemble 3326
Install 3327
Header Hose Installation and Adjustment 3329
Remove 3329
Installation 3329
Adjustment 3337
Mast Adjustments 3338
Load Roller, Adjust 3338
Mast Side Kicking, Adjust 3340
Carriage Adjustments 3340
Lift Chains Adjustment 3342
Hydraulic Quick Disconnect Hoses 3344
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 3344
Lift Trucks Equipped With E-Hydraulic Controls 3344
Lift Trucks Equipped With Manual Hydraulic Controls 3345
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 3345
Lift Trucks Equipped With E-Hydraulic Controls 3345
Lift Trucks Equipped With Manual Hydraulic Controls 3346
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 3346
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 3346
550096316-0600YRM1670-(07-2019)-US-EN 3349
General 3353
Fan Belt Installation 3353
Remove 3353
Inspect 3353
Installation 3354
Thermostat Repair 3354
Remove 3354
Thermostat Operation Check 3355
Install 3355
Water Pump Repair 3355
Remove 3355
Clean and Inspect 3355
Install 3356
Lubrication System Repair 3356
Oil Pan and Oil Pickup, Remove 3356
Oil Pan and Oil Pickup, Inspection 3356
Oil Pump, Remove 3357
Oil Pump, Inspection 3357
Rotor Lobe Clearance 3357
Rotor Cover Clearance 3358
Oil Pump, Assemble and Install 3358
Oil Pan and Oil Pickup, Assemble and Install 3358
Cylinder Head Repair 3359
Remove and Disassemble 3359
Clean and Inspect 3362
Valve Guides and Seats 3364
Valve Lapping 3364
Valve Guide, Replacement 3364
Valve Seats, Inspection and Repair 3365
Valve and Valve Seat Correction 3365
Valve Springs 3366
Assemble and Install 3367
Valve Clearance Adjustments 3370
Gear Case, Timing Gears, and Camshaft 3372
Gear Case 3372
Fan Drive Pulley, Remove 3372
Fan Drive Pulley, Install 3373
Gear Case, Remove 3373
Gear Case, Install 3373
Timing Gears 3373
Oil Pump, Remove 3373
Oil Pump, Install 3373
Crankshaft Oil Slinger, Remove 3373
Crankshaft Oil Slinger, Install 3374
Idler Gear, Remove 3374
Idler Gear, Install 3374
Camshaft 3374
Camshaft, Remove 3374
Camshaft, Install 3375
Piston and Connecting Rod Assemblies Repair 3375
Disassemble 3375
Piston, Clean and Inspect 3376
Piston Ring Gap 3376
Piston Ring Groove 3377
Connecting Rod and Piston Pin, Clean and Inspect 3377
Cylinder Bores, Clean and Inspect 3378
Cylinder Correction (Oversize) 3380
Assemble 3380
Piston Bore Preparation 3382
Cylinder Wear 3382
Cylinder Correction (Oversize) 3382
Flywheel and Bearing Case Cover 3383
Flywheel, Remove 3383
Bearing Case Cover, Remove 3383
Bearing Case Cover, Install 3384
Flywheel, Install 3384
Crankshaft Repair 3385
Crankshaft, Remove 3385
Inspect and Repair 3386
Crankshaft Journal Oil Clearance Bearing 1 3386
Crankshaft Journal Oil Clearance Bearing 2 3387
Crankshaft Bend 3388
Crankshaft, Install 3388
Crankshaft Side Clearance 3390
Engine Block Cleaning and Inspection 3391
Clean and Inspect 3391
Engine Removal and Installation 3392
Engine Specifications 3392
Engine Data 3392
Torque Specifications 3393
550096320-0900YRM1677-(04-2018)-US-EN 3395
General 3399
LPG Tank and Bracket Replacement 3399
Remove LPG Tank 3399
Install LPG Tank 3402
Remove LPG Bracket 3402
Install LPG Bracket 3405
Remove LPG Tank Bracket Alignment Pin 3405
Install LPG Tank Bracket Alignment Pin 3407
LPG Fuel Filter Unit Repair 3408
LPG Fuel Filter Element 3408
Remove/Disassemble 3408
Clean/Inspect 3409
Assemble/Install 3409
Fuel Filter Housing 3410
Remove 3410
Disassemble 3413
Clean and Inspect 3414
Assemble 3414
Install 3415
Electronic Throttle Body Repair 3415
Remove 3416
Install 3417
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 3418
Remove 3418
Install 3419
Control System 3420
Engine Control Unit (ECU) 3420
Remove 3420
Install 3421
Low LPG Pressure Switch 3421
Remove 3421
Install 3422
LPG Low Level Sensor 3422
Remove 3423
Install 3424
LPG Converter 3425
Remove 3425
Install 3428
LPG Lock-Off Valve 3429
Remove 3429
Install 3431
Exhaust System 3432
Counterweight Exhaust System 3432
Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (B910, C910) 3432
Remove and Disassemble 3432
Inspect 3433
Assemble and Install 3433
Lift Truck Models GLP20-35VX (GLP040-070VX) (C875, D875) 3434
Remove and Disassemble 3434
Inspect 3435
Assemble and Install 3436
Overhead Exhaust System 3436
Remove and Disassemble 3436
Inspect 3437
Assemble and Install 3438
Exhaust Manifold 3438
Remove 3438
Install 3439
Oxygen (HEGO) Sensor 3439
Remove 3439
Install 3440
PCV Valve 3440
LPG Fuel Testing 3441
General 3441
Available Fuel Tests 3441
Composition Test (ASTM D-2163) 3441
Ammonia Test (ASTM D-4490) 3441
Basic Nitrogen Test (ASTM UOP269-90) 3441
Residues Test (ASTM D-2158) 3441
Vapor Pressure Test (ASTM D-2598) 3441
Sulfur Compounds Test (ASTM D-5623) 3441
Methanol Test (ASTM D-4864) 3442
Copper Corrosion (ASTM D-1838) 3442
Where To Send LPG Fuel Samples For Testing 3442
550100651-2100YRM1692-(11-2016)-US-EN 3445
General 3451
Description 3453
Safety Procedures When Working Near Mast 3454
Tilt Cylinder Repair 3456
Remove 3456
Disassemble 3457
Clean 3458
Inspect 3458
Assemble 3459
Install 3459
Tilt Cylinders, Adjust 3460
Tilt Cylinders With Tilt Limit Spacers 3460
Tilt Cylinders Without Tilt Limit Spacers 3460
Tilt Cylinder Leak Check 3461
Main Lift And Free-Lift Cylinders Repair 3461
Main Lift Cylinders 3462
Remove 3462
Two-Stage FFL 3462
Four-Stage FFL 3462
Disassemble 3465
Two-Stage FFL 3465
Four-Stage FFL 3467
Clean 3469
Inspect 3469
Assemble 3469
Two-Stage FFL 3469
Four-Stage FFL 3469
Install 3470
Two-Stage FFL 3470
System Air Bleed Procedures 3470
Four-Stage FFL 3471
Free-Lift Cylinder 3471
Remove 3471
Two-Stage FFL 3471
Four-Stage FFL 3473
Disassemble 3475
Two-Stage FFL 3475
Four-Stage FFL 3476
Clean 3477
Inspect 3477
Assemble 3477
Two-Stage FFL 3477
Four-Stage FFL 3477
Install 3478
Two-Stage FFL 3478
Four-Stage FFL 3478
Lift Cylinder Leak Check 3479
Integral Sideshift Cylinder Repair
Prior to December 2016 3480
Remove 3480
Disassemble 3480
Clean and Inspect 3480
Assemble and Install 3481
Integral Sideshift Cylinder Repair
After December 2016 3483
Remove 3483
Disassemble 3483
Clean and Inspect 3483
Assemble and Install 3484
Fork Positioner Cylinder Repair Prior to December 2016 3486
Remove 3486
Disassemble 3486
Clean 3486
Inspect 3489
Assemble 3489
Install 3490
Fork Positioner Cylinder Adjustment 3490
Fork Positioner Cylinder Repair After December 2016 3491
Remove 3491
Disassemble 3491
Clean 3494
Inspect 3494
Assemble 3495
Install 3495
Fork Positioner Cylinder Adjustment 3495
Seal Kit Installation 3495
External Installation (Seal and Back-Up Ring) 3496
Internal Installation (Piston Rod Assembly) 3496
Torque Specifications 3496
Tilt Cylinders 3496
Piston Rod Nut 3496
Gland 3497
Tilt Cylinder Mounting Capscrew 3497
Tilt Cylinder Rod End Nut 3497
Main Lift and Free-Lift Cylinders 3497
Gland, Main Lift Cylinders 3497
Gland, Free-Lift Cylinder 3497
Piston, Main Lift Cylinders 3497
Main Lift Cylinder Mounting Nut To Outer
Mast 3497
Main Lift Cylinder Mounting Nut To Intermediate
Mast (Four-Stage FFL, Right Cylinder Only) 3497
Retainer Nuts 3497
Chain Guard Capscrew (Free-Lift Cylinder) 3497
Crosshead Mounting Capscrew (Free-Lift Cylinder) 3497
Free-Lift Cylinder Mounting Capscrews 3497
Cylinder Shell Capscrew, Main Lift Cylinders 3497
Fork Positioner 3497
Cylinder Rod Retainer 3497
Fork Positioner Cylinder Mounting Capscrews 3497
Cylinder Rod Anchor Plug 3498
Fork Carrier Capscrews 3498
Hose Guide Capscrews 3498
Integral Sideshift Cylinder 3498
Cylinder Rod Retainer 3498
Gland 3498
550100656-4000YRM1693-(10-2017)-US-EN 3501
General 3507
Safety Procedures When Working Near Mast 3509
Fork Replacement 3511
Standard Carriage and Integral Sideshift Carriage 3511
Remove 3511
Install 3512
Checks 3512
Fork Positioner Carriage 3514
Remove 3514
Install 3514
Checks 3516
Carriages Repair, Two-Stage FFL Mast 3517
Standard Carriage 3518
Remove 3518
Clean and Inspect 3519
Install 3519
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3520
Remove 3520
Disassemble 3520
Clean and Inspect 3523
Assemble 3524
Install 3524
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3525
Remove 3525
Disassemble 3528
Clean and Inspect 3528
Assemble 3528
Install 3529
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 3529
Remove 3529
Install 3530
Fork Positioner Hydraulic Hose Adjustment 3534
Fork Positioner Carriage, Lift Trucks Manufactured After December, 2016 3535
Remove 3535
Disassemble and Assemble 3538
Clean and Inspect 3538
Install 3538
Fork Positioner Hydraulic Hose Adjustment 3539
Two-Stage Mast With Full Free-Lift Repair 3540
Mast With Serial Number E509 3540
Remove 3540
Disassemble 3543
Clean and Inspect 3547
Assemble 3549
Install 3550
Header Hose Procedures 3551
Remove 3551
Installation 3552
Adjustment 3558
Mast With Serial Number E564 3558
Remove 3558
Disassemble 3562
Clean and Inspect 3567
Assemble 3569
Install 3570
Header Hose Procedures 3571
Remove 3571
Installation 3571
Adjustment 3578
Carriages Repair, Four-Stage FFL Mast 3578
Standard Carriage 3578
Remove 3578
Clean and Inspect 3579
Install 3580
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3581
Remove 3581
Disassemble 3583
Clean and Inspect 3583
Assemble 3584
Install 3584
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3585
Remove 3585
Disassemble 3585
Clean and Inspect 3588
Assemble 3588
Install 3588
Fork Positioner Carriage 3589
Four-Stage Mast With Full Free-Lift Repair 3590
Mast With Serial Number D515 3590
Remove 3590
Disassemble 3594
Clean and Inspect 3600
Assemble 3602
Install 3605
Header Hose Procedures 3606
Remove 3606
Installation 3606
Adjustment 3614
Carriage Adjustments 3614
Lift Chains Adjustment 3617
Mast Adjustments 3618
Load Roller, Adjust 3619
Mast Side Kicking, Adjust 3621
Hydraulic Quick Disconnect Hoses 3621
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3621
Lift Trucks Equipped With E-Hydraulic Controls 3621
Lift Trucks Equipped With Manual Hydraulic Controls 3622
Connecting Attachment Hydraulic Quick Disconnect Hoses 3622
Lift Trucks Equipped With E-Hydraulic Controls 3622
Lift Trucks Equipped With Manual Hydraulic Controls 3622
550108495-1300YRM1740-(06-2018)-US-EN 3625
General 3629
Serial Number 3629
Hydraulic Gear Pump 3629
Remove 3629
Install 3629
Housing Fittings Replacement 3630
Remove 3630
Install 3632
Charge Pump Repair 3632
Torque Converter Replacement 3635
Remove 3635
Clean and Inspect 3635
Install 3635
Stator Support Assembly Repair 3636
Remove 3636
Disassemble 3643
Clean 3644
Inspect 3644
Assemble 3645
Install 3645
Clutch Packs Repair 3647
Remove 3647
Disassemble 3649
Housings 3649
Clutch Packs 3652
Clean 3663
Inspect 3664
Assemble 3664
Clutch Packs 3664
Housings 3678
Install 3680
Drive Chains and Sprockets 3683
Remove 3683
Clean 3685
Inspect 3686
Install 3686
Proportional and Enable Solenoid Valves 3686
Proportional Valves 3686
Remove 3686
Disassemble 3688
Clean and Inspect 3689
Assemble 3689
Install 3689
Enable Solenoid Valve 3689
Remove 3689
Disassemble 3690
Clean and Inspect 3690
Assemble 3690
Install 3690
Pedal Repair Foot Directional Control 3691
Remove and Disassemble 3691
Clean and Inspect 3694
Assemble and Install 3695
550108498-1800YRM1743-(06-2018)-US-EN 3699
General 3703
Dry Brake System 3703
Wet Brake System 3703
Service Brakes Repair (Dry Brake) 3703
Remove and Disassemble 3704
Clean 3711
Inspect 3712
Assemble and Install 3712
Adjust 3720
Inching Overlap Adjustment 3720
Parking Brake Repair 3721
Remove and Disassemble 3721
Dry Brake System 3721
Wet Brake System 3723
Assemble and Install 3725
Dry Brake System 3725
Wet Brake System 3725
Adjust 3725
Master Cylinder Repair 3726
Remove (Dry Brake) 3726
Disassemble (Dry Brake) 3727
Clean and Inspect (Dry Brake) 3729
Assemble (Dry Brake) 3729
Bench Bleed Master Cylinder (Dry Brake) 3729
Install and Adjust (Dry Brake) 3729
Remove (Wet Brake) 3730
Disassemble (Wet Brake) 3731
Clean and Inspect (Wet Brake) 3732
Assemble (Wet Brake) 3733
Install and Adjust (Wet Brake) 3733
Service Brakes Adjustment (Dry Brake) 3734
Brake System Air Removal 3734
Using Pressure Bleed System 3734
Using Brake Pedal Pressure 3734
Brake Pedal Adjustment 3735
Free Pedal Adjustment 3736
Torque Specifications 3738
550108499-1900YRM1744-(06-2018)-US-EN 3741
General 3745
Hydraulic Gear Pump Assembly Repair 3746
Remove 3746
Disassemble 3750
Clean 3752
Inspect 3752
Assemble 3752
Install 3752
Quick-Lok™ Hydraulic Hose 3754
Hydraulic Gear Pump Specifications 3755
Variable Displacement Pump Repair 3757
Remove 3757
Disassemble 3762
Clean 3764
Inspect 3764
Assemble 3764
Install 3764
Variable Displacement Pump Checks and Adjustments 3767
Margin Pressure Check 3767
Flow Compensator Adjustment 3768
Pressure Compensator Adjustment 3768
Variable Displacement Pump Specifications 3769
Torque Specifications 3769
Hydraulic Gear Pump 3770
Variable Displacement Pump 3770
550108500-2000YRM1745-(06-2018)-US-EN 3773
General 3777
Electro-Hydraulic Main Control Valve 3777
Description 3777
Remove 3780
Electro-Hydraulic Control Valve Sections 3783
General 3783
Outlet Control Valve Section 3783
Remove 3783
Disassemble 3783
Clean 3785
Inspect 3785
Assemble 3785
Install 3786
Auxiliary Control Valve Sections 3786
Remove 3786
Disassemble 3788
Clean 3789
Inspect 3789
Assemble 3789
Install 3789
Tilt Control Valve Section 3790
Remove 3790
Disassemble 3790
Clean 3791
Inspect 3791
Assemble 3792
Install 3792
Lift/Lower Control Valve Section 3792
Remove 3792
Disassemble 3792
Clean 3794
Inspect 3794
Assemble 3795
Install 3795
Install 3795
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 3798
Lift Pilot Pin 3798
Lower Pilot Pin 3800
Abnormal/Erroneous EHPV Adjustment 3802
Manual Main Control Valve 3802
Description 3802
Remove 3805
OPS Solenoid Assembly 3811
General 3811
Remove 3812
Clean and Inspect 3814
Install 3814
Manual Control Valve Sections 3815
General 3815
Outlet Control Valve Section 3815
Remove 3815
Disassemble 3815
Clean 3818
Inspect 3818
Assemble 3818
Install 3819
Auxiliary Control Valve Sections 3819
Remove 3819
Disassemble 3819
Clean 3822
Inspect 3822
Assemble 3822
Install 3822
Lift/Tilt Control Valve Section 3823
Remove 3823
Disassemble 3823
Clean 3828
Inspect 3828
Assemble 3828
Install 3829
Install 3829
Pressure Relief Valve Check and Adjustment 3833
Primary Relief Valve 3834
Secondary Relief Valve 3835
Steering Control Unit Repair 3839
Steering Control Unit, Remove 3839
Steering Control Unit, Disassemble 3841
Steering Control Unit, Clean 3843
Steering Control Unit, Inspect 3843
Steering Control Unit, Assemble 3843
Relief Valve, Disassemble 3844
Relief Valve, Clean 3844
Relief Valve, Inspect 3845
Relief Valve, Assemble 3845
Steering Control Unit, Install 3845
550108507-8000YRM1753-(03-2020)-US-EN 3849
General Information About Diagrams and Schematics 3853
Symbol Definitions 3853
Diagrams Manual Applications 3854
Diagrams and Schematics 3856
550108507-8000YRM1753-(05-2022)-US-EN 3949
General Information About Diagrams and Schematics 3955
Symbol Definitions 3955
Diagrams Manual Applications 3956
Diagrams and Schematics 3958
550108889-0100YRM1754-(12-2018)-US-EN 4053
General 4057
Description 4057
Hood, Seat, and Side Covers Replacement 4058
Remove 4058
Install 4065
Steering Column 4069
Description 4069
Steering Column Repair 4070
Remove 4070
Disassemble 4071
Clean 4072
Inspect 4073
Assemble 4073
Install 4073
LPG Tank and Bracket Assembly 4073
Counterweight Replacement 4073
Remove 4074
Install 4076
Tow Pin 4076
Overhead Guard Replacement 4077
Remove and Install 4077
LED Tail, Backup, and Brake Lights, Replace 4079
Operator Restraint System Replacement 4079
Description 4079
Emergency Locking Retractor (ELR) 4079
Engine Replacement 4081
Remove 4082
Install 4087
Transmission Replacement 4089
Remove Transmission with Iron Housing 4089
Install Transmission with Iron Housing 4091
Remove Transmission with Aluminum Housing 4092
Install Transmission with Aluminum Housing 4096
Throttle Pedal and Cable Adjustment 4098
Throttle Pedal Stop Adjustment 4098
Yanmar Diesel Engine With Basic Power Shift Transmission 4099
Yanmar Diesel Engine With Electronic Throttle 4100
Exhaust System Repair 4100
Lift Trucks With Counterweight Exhaust System 4101
PSI Gas and LPG Engines 4101
Kubota LPG Engines 4101
Yanmar Diesel Engine 4101
Remove and Disassemble 4101
Inspect 4101
Assemble and Install 4101
Lift Trucks With Overhead Exhaust System 4103
PSI Gas and LPG Engines 4103
Kubota LPG Engines 4103
Yanmar Diesel Engine 4103
Remove and Disassemble 4103
Inspect 4103
Assemble and Install 4104
Kubota 2 4L Diesel Engine With Diesel Oxidation Catalyst (DOC) 4106
Remove 4108
Inspect 4111
Install 4111
Diesel Oxidation Catalyst 4113
Disassemble 4113
Assemble 4114
Heavy Duty Pre-Cleaner, Kubota 2 4L Diesel Engine 4114
Remove 4114
Clean 4114
Inspect 4115
Install 4115
Kubota 2 4L Stage V Diesel Engine With Diesel Particulate Filter (DPF) 4116
Remove 4117
Inspect 4120
Install 4120
Cooling System 4121
Description 4121
Hydraulic Filter Assembly Repair 4121
Remove 4121
Clean and Inspect 4122
Install 4122
Fuel and Hydraulic Tanks Repair 4122
Inspect 4123
Clean 4123
Steam Method of Cleaning 4123
Chemical Solution Method of Cleaning 4124
Additional Preparations for Repair 4124
Small Leaks, Repair 4124
Large Leaks, Repair 4124
Preparations for Use After Repair 4125
Safety Labels 4125
550108890-0600YRM1755-(04-2019)-US-EN 4133
General 4139
Engine Removal and Installation 4142
Cylinder Head Assembly Repair 4142
Drive Train and Lubrication System 4181
Remove 4182
Disassemble 4182
Oil Pan 4182
Oil Pump (Front Cover) 4185
Clean and Inspect 4186
Front Case 4186
Oil Seal 4186
Counterbalance Shaft 4186
Oil Pump 4186
Assemble 4187
Counterbalance Shaft Bearings 4187
Oil Pump (Front Cover) 4188
Oil Pan 4190
Install 4190
Crankshaft and Cylinder Block Repair 4191
Remove Major Attaching Components 4191
Crankshaft and Cylinder Block 4191
Remove 4191
Clean and Inspect 4192
Boring Cylinder 4193
Install 4194
Piston and Connecting Rod 4196
Remove 4196
Disassemble 4197
Clean and Inspect 4198
Assemble 4199
Install 4201
Piston 4201
Rod Bearing 4202
Install Major Attaching Components 4203
Fuel System Repair 4203
Cooling System Repair 4203
Electrical Equipment Repair 4204
Flywheel and Flywheel Housing 4204
Flywheel 4204
Remove 4204
Install 4205
Flywheel Housing 4206
Remove 4206
Install 4206
Engine Specifications 4206
Engine Data 4206
Engine Tuning 4208
Cylinder Head 4208
Intake/Exhaust Valve and Guide 4208
Valve Spring 4209
Gear Train and Camshaft 4209
Camshaft 4209
Idle Gear Shaft and Bushing 4209
Cylinder Block 4209
Crankshaft 4209
Piston 4210
Piston Ring 4210
Connecting Rod 4210
Oil Pump 4210
Engine Oil Pressure 4210
Drive Gear Clearance 4210
Driven Gear Clearance 4211
Torque Specifications 4211
Special Tools 4212
550108890-0600YRM1755-(08-2023)-US-EN 4219
General 4227
Engine Removal and Installation 4231
Cylinder Head Assembly Repair 4232
Drive Train and Lubrication System 4273
Remove 4273
Disassemble 4273
Oil Pan 4273
Oil Pump (Front Cover) 4276
Clean and Inspect 4277
Front Case 4277
Oil Seal 4277
Counterbalance Shaft 4277
Oil Pump 4277
Assemble 4278
Counterbalance Shaft Bearings 4278
Oil Pump (Front Cover) 4279
Oil Pan 4281
Install 4281
Crankshaft and Cylinder Block Repair 4283
Remove Major Attaching Components 4283
Crankshaft and Cylinder Block 4283
Remove 4283
Clean and Inspect 4284
Boring Cylinder 4285
Install 4286
Piston and Connecting Rod 4288
Remove 4288
Disassemble 4289
Clean and Inspect 4289
Assemble 4290
Install 4292
Piston 4292
Rod Bearing 4293
Install Major Attaching Components 4294
Fuel System Repair 4295
Cooling System Repair 4296
Electrical Equipment Repair 4297
Flywheel and Flywheel Housing 4298
Flywheel 4298
Remove 4298
Install 4299
Flywheel Housing 4299
Remove 4299
Install 4299
POWER TAKE OFF (PTO), REMOVE AND INSTALL 4300
REMOVE COVER 4300
INSTALL COVER 4300
Engine Specifications 4302
Engine Data 4302
Engine Tuning 4303
Cylinder Head 4304
Intake/Exhaust Valve and Guide 4304
Valve Spring 4304
Gear Train and Camshaft 4305
Camshaft 4305
Idle Gear Shaft and Bushing 4305
Cylinder Block 4305
Crankshaft 4305
Piston 4305
Piston Ring 4306
Connecting Rod 4306
Oil Pump 4306
Engine Oil Pressure 4306
Drive Gear Clearance 4306
Driven Gear Clearance 4306
Torque Specifications 4307
Special Tools 4309
550108891-0700YRM1756-(06-2019)-US-EN 4313
General 4317
Cooling System Checks 4317
Exhaust Leaks Into Cooling System 4317
Water Flow Restrictions in Radiator 4317
Radiator Hoses 4317
Water Pump 4317
Flushing the Cooling System 4318
Cooling System, Clean 4318
Radiator Replacement 4319
Radiator, Remove 4319
Radiator, Install 4330
Fan Assembly Replacement 4331
Fan Removal 4331
Inspect 4335
Fan Installation 4336
550108892-0900YRM1757-(06-2018)-US-EN 4339
General 4345
Intake-Air System 4346
Intake-Air System Manifold Vacuum Check 4346
Throttle Body 4346
Remove 4347
Install 4348
Intake Manifold 4348
LPG Tank and Bracket Replacement Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (C910) and GLP20-35VX (GLP040-070VX) (D875) 4348
Remove LPG Tank 4348
Install LPG Tank 4351
Remove LPG Bracket 4351
Install LPG Bracket 4354
Remove LPG Tank Bracket Alignment Pin 4354
Install LPG Tank Bracket Alignment Pin 4356
LPG Tank and Bracket Replacement Lift Truck Models GLC050LX, GLC050LX2 (B967) and GLP20-25LX (GLP050LX) (B974) 4357
Remove LPG Tank 4357
LPG Tank Install 4359
Remove LPG Bracket 4359
Install LPG Bracket 4359
LPG Fuel Filter Unit Repair Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (C910) and GLP20-35VX (GLP040-070VX) (D875) 4360
Fuel Filter Element 4360
Remove 4360
Clean/Inspect 4360
Install 4361
Fuel Filter Housing 4361
Remove 4361
Disassemble 4362
Assemble 4363
Install 4363
LPG Fuel Filter Unit Repair Lift Truck Models GLC050LX, GLC050LX2 (B967) and GLP/GDP20-25LX (GLP/GDP050LX) (B974) 4364
Fuel Filter Element 4364
Remove 4364
Clean/Inspect 4365
Install 4365
Fuel Filter Housing 4365
Remove 4365
Disassemble 4365
Assemble 4366
Install 4366
Electronic Throttle Body Repair 4366
Remove 4367
Install 4368
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 4369
Remove 4370
Install 4372
Gasoline Fuel System 4373
Before Repair Procedure 4374
Fuel Line Safety Procedure 4374
After Repair Procedure 4376
Fuel Hose, Install 4376
Fuel Leakage Check 4376
Fuel Line Pressure Check 4377
Fuel Injectors 4377
Remove 4377
Install 4378
Pressure Regulator 4378
Remove 4378
Install 4379
Control System 4379
Engine Control Module (ECM) 4379
Remove 4379
Install 4381
Fuel Level Sensor 4381
Remove 4381
Install 4381
Low LPG Pressure Switch 4382
Remove 4382
Install 4382
LPG Low Level Sensor 4382
Remove 4383
Install 4383
LPG Converter 4384
LPG Lock-Off Valve 4389
Remove 4389
Install 4390
Exhaust System 4392
Counterweight Exhaust System 4392
Remove and Disassemble 4392
Inspect 4393
Assemble and Install 4394
Overhead Exhaust System 4394
Remove and Disassemble 4394
Inspect 4396
Assemble and Install 4396
Exhaust Manifold 4396
Positive Crankcase Ventilation (PCV) Valve 4396
Remove 4396
Inspect 4396
Install 4397
Oxygen Sensor 4397
Remove 4397
Install 4398
LPG Fuel Testing 4398
General 4398
Available Fuel Tests 4399
Composition Test (ASTM D-2163) 4399
Ammonia Test (ASTM D-4490) 4399
Basic Nitrogen Test (ASTM UOP269-90) 4399
Residues Test (ASTM D-2158) 4399
Vapor Pressure Test (ASTM D-2598) 4399
Sulfur Compounds Test (ASTM D-5623) 4399
Methanol Test (ASTM D-4864) 4399
Copper Corrosion (ASTM D-1838) 4399
Where To Send LPG Fuel Samples For Testing 4399
Technical Data 4400
550108893-1400YRM1758-(02-2018)-US-EN 4403
General 4407
Drive Axle Repair 4407
Remove and Disassemble 4407
Clean and Inspect 4410
Assemble and Install 4410
Differential Repair 4413
Remove 4413
Disassemble 4424
Clean and Inspect 4429
Install 4438
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 4438
Ring Gear Backlash, Adjust 4450
Ring Gear, Runout Check 4452
Gear Set, Tooth Contact Pattern Check 4452
Torque Specifications 4455
550108894-1600YRM1759-(12-2014)-US-EN 4459
550108895-2200YRM1760-(01-2020)-US-EN 4483
General 4491
Display Switch Cluster 4492
Remove 4492
Install 4494
Direction Control and Turn Signal Levers 4494
Remove 4494
Install 4495
Key Switch 4496
Remove 4496
Install 4496
Display Switch Cluster Panel Bezel and Overlay 4497
Remove 4497
Install 4497
Steering Column Repair 4497
Remove 4497
Disassemble 4499
Assemble 4499
Install 4500
Sensors and Switches 4500
General 4500
Dash and Kick Panel, Remove and Install 4500
Remove 4500
Install 4501
Accelerator Pedal Position Sensor 4501
Remove 4501
Install 4503
Brake Fluid Level Switch 4504
Remove 4504
Install 4504
Service Brake Pedal Position Sensor 4505
Remove 4505
Install 4506
Parking Brake Sensor 4506
Remove 4506
Install 4507
Service Brake Pressure Sensor 4507
Remove 4507
Install 4507
Sensor MicroswitchFoot Directional Control 4508
Remove 4508
Install 4510
Low Coolant Level Sensor 4510
Remove 4510
Install 4512
Fuel Level Sensor, Gas and Diesel Engines Only 4512
Remove 4512
Install 4512
Seat Sensor (Operator Presence System) 4513
Non-Suspension and Semi-Suspension Seats 4513
Remove 4513
Install 4514
Full Suspension And Swivel Seats 4514
Remove 4514
Install 4515
Hood Shut Off Switch 4515
Remove 4515
Install 4516
Hydraulic Filter Pressure Switch 4516
Remove 4516
Install 4517
Transmission Speed Sensor 4517
Remove 4517
Install 4518
Transmission Pressure Sensors 4518
Remove 4518
Install 4518
Transmission Temperature Sensor 4518
Remove 4518
Install 4519
Return to Set Tilt (Tilt Angle) Sensor 4519
Remove 4519
Install 4519
Rear Horn Button Switch 4519
Remove 4519
Install 4520
Impact Sensor 4520
Remove 4520
Install 4521
Load Weight Sensor 4522
Remove 4522
Install 4522
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with PSI 2 4L Dual Fuel Engine 4523
Engine and Fuel Sensors and Switches, Kubota 2 5L LPG Engine 4523
Crankshaft Position Sensor 4523
Remove 4523
Install 4523
Camshaft Position Sensor 4524
Remove 4524
Install 4524
Engine Coolant Temperature (ECT) Sensor 4524
Remove 4524
Install 4524
Manifold Absolute Pressure (MAP) Sensor 4525
Remove 4525
Install 4525
Oil Pressure Sensor 4525
Remove 4525
Install 4525
Knock Sensor 4526
Remove 4526
Install 4526
Oxygen Sensors 4526
Air Flow Restriction Switch 4526
Remove 4526
Install 4527
Engine and Fuel Sensors and Switches, Yanmar Diesel Engine 4527
Air Filter Restriction Switch 4527
Remove 4527
Install 4527
Oil Pressure Sensor 4527
Remove 4527
Install 4527
Engine Speed Sensor 4527
Remove 4527
Install 4527
Engine Coolant Temperature (ECT) Sensor 4528
Remove 4528
Install 4528
Throttle Position Sensor (TPS) 4530
Remove 4530
Install 4531
Fuel/Water Separator Sensor 4531
Remove 4531
Install 4531
Glow Plug Relay 4532
Remove 4532
Install 4534
Engine and Fuel Sensors and Switches, Kubota 2 4L Diesel Engine 4534
Crankshaft Position Sensor 4534
Remove 4534
Install 4534
Camshaft Position Sensor 4534
Remove 4534
Install 4534
Engine Coolant Temperature (ECT) Sensor 4535
Remove 4535
Install 4535
Engine Oil Pressure Sensor 4535
Remove 4535
Install 4536
Intake Air Pressure (Boost) Sensor 4536
Remove 4536
Install 4537
Air Filter Restriction Switch 4537
Remove 4537
Install 4537
Mass Airflow Sensor 4537
Remove 4537
Install 4537
Glow Plugs 4538
Remove 4538
Inspect 4539
Install 4539
Engine and Fuel Sensors and Switches, Kubota 2 4L Stage V Diesel Engine 4540
Crankshaft Position Sensor 4540
Remove 4540
Install 4540
Camshaft Position Sensor 4540
Remove 4540
Install 4540
Engine Coolant Temperature (ECT) Sensor 4541
Remove 4541
Install 4541
Engine Oil Pressure Sensor 4541
Remove 4541
Install 4542
Differential Pressure Sensor 4542
Remove 4542
Install 4542
Diesel Particulate Filter (DPF) Sensors 4542
Remove 4542
Install 4542
Intake Air Pressure (Boost) Sensor 4542
Remove 4542
Install 4542
Air Filter Restriction Switch 4543
Remove 4543
Install 4543
Mass Airflow Sensor 4543
Remove 4543
Install 4543
Glow Plugs 4544
Remove 4544
Inspect 4544
Install 4545
Vehicle System Manager (VSM) 4545
General 4545
VSM Replacement 4545
Remove 4545
Install 4546
Programming a New VSM and/or Display Switch Cluster 4546
General 4546
Data Transferring 4547
New VSM 4547
New (Blank) Display Switch Cluster 4547
Used (Non-Blank) Display Switch Cluster 4547
PC Service Tool Software 4548
Power Distribution Module (PDM) and Component Parts 4549
Remove 4549
PDM as a Unit 4549
Install 4551
PDM as a Unit 4551
Remove and Install 4551
PDM Component Parts 4551
Battery 4551
Remove 4551
Install 4551
Lights 4552
Work Lights (Front and Rear) 4552
Halogen Bulb Lights 4552
Remove 4552
Install 4552
LED Lights 4552
Remove 4552
Install 4553
Strobe Light 4553
Remove 4553
Install 4553
LED Tail, Backup, and Brake Lights 4554
Remove 4554
Install 4554
Front Marker/Turn Signal Lights 4555
Replacing Whole Front Marker/Turn Signal Light Assembly 4555
Remove 4555
Install 4555
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 4556
Remove 4556
Install 4556
Electronic-Hydraulic Controls, Before January, 2020 4556
E-Hydraulic Controls – TEST 4556
Mini-Levers 4556
Full Stroke Test 4557
Function Returns to Neutral Test 4557
Push (Override) Button 4557
General 4558
Mini-levers, Remove and Install 4558
Armrest Assembly 4559
Remove 4559
Install 4562
Horn Button 4562
Remove 4562
Install 4562
Direction Control Switch 4562
Remove 4562
Install 4563
Push (Override) Buttons 4563
Remove 4563
Install 4564
Electronic-Hydraulic Controls, After January, 2020 4564
E-Hydraulic Controls – TEST 4565
Mini-Levers 4565
Full Stroke Test 4565
Function Returns to Neutral Test 4565
Push (Override) Button 4565
General 4566
Mini-levers, Remove and Install 4566
Armrest Assembly 4567
Remove 4567
Install 4570
Horn Button 4570
Remove 4570
Install 4570
Direction Control Switch 4570
Remove 4570
Install 4571
Push (Override) Button 4571
Remove 4571
Install 4572
Diesel Particulate Filter (DPF) Display 4572
Remove 4572
Clean and Inspect 4573
Install 4573
550108896-2200YRM1761-(04-2020)-US-EN 4575
General 4579
Ignition System 4579
Ignition Timing Adjustment 4579
Spark Plugs Check 4579
Coil Replacement 4579
Remove 4579
Inspect 4581
Install 4581
Starter Repair 4582
General 4582
Remove 4582
No-Load Test 4583
Magnetic Switch Test 4584
Pull-Out Test 4584
Holding Coil Test 4584
Return Test 4585
Pinion Movement Inspection 4585
Install 4585
Alternator Repair 4586
General 4586
Charging System Inspection 4587
Output Current Check 4587
No-Load Adjusted Voltage Check 4587
Remove 4588
Install 4588
Engine Sensors and Switches 4589
Oil Pressure Sensor 4589
Remove 4589
Install 4589
Air Filter Restriction Switch 4589
Remove 4589
Install 4589
Cam Angle Sensor 4590
Remove 4590
Install 4590
Crankshaft Position Sensor (CKP) 4590
Remove 4590
Install 4590
Temperature Manifold Absolute Pressure (TMAP) Sensor 4591
Remove 4591
Install 4592
Engine Coolant Temperature (ECT) Sensor 4592
Remove 4592
Install 4592
Battery Disconnect Switch 4592
Remove 4592
Install 4594
Electronic Control Module 4595
550108897-8000YRM1762-(01-2022)-US-EN 4597
General 4603
Serial Number Data 4603
How to Move Disabled Lift Truck 4604
How to Tow Lift Truck 4604
How to Put Lift Truck on Blocks 4605
How to Raise Drive Tires 4605
How to Raise Steering Tires 4605
How to Clean a Lift Truck 4607
Maintenance Schedule 4608
Recommended Lubricants 4623
Lubricant Specifications 4623
Maintenance Procedures Every 8 Hours or Daily 4627
How to Make Checks With Engine Stopped 4627
Tires and Wheels 4627
Safety Labels 4627
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4627
Operator Restraint System 4628
Emergency Locking Retractor (ELR) 4629
Adjust Seat – Full Suspension 4630
Adjust Seat – Internal Suspension 4632
Hood and Seat Latches 4632
Engine Compartment 4632
Paper Application 4632
Fuel, Oil, and Coolant Leaks, Check 4633
Hydraulic Hoses 4633
Coolant Hoses 4633
Steering Column Gas Cylinder 4633
Transmission 4633
Hydraulic System Oil 4634
Engine Oil 4634
Air Filter 4636
Forks 4637
Inspect 4637
Remove 4638
Install 4641
Adjust 4641
How to Make Checks With Engine Running 4641
Indicator Lights, Horn, Fuses, and Relays 4642
Service Brakes 4644
Brake Fluid Level 4644
Operation, Check 4645
Parking Brake 4645
Engine Oil Pressure 4645
Cooling System 4646
Steering System 4647
Control Levers and Pedals 4647
Lift System, Operate 4647
First Service After First 100 Hours of Operation 4648
Kubota Engine Oil and Oil Filter 4648
Kubota 2 5L LPG Engine 4648
Kubota 2 4L Diesel Engine 4648
PSI Engine Oil and Oil Filter 4649
Yanmar Engine Oil and Oil Filter 4649
Maintenance Procedures Every 250 Hours or 6 Months 4650
PSI 2 4L Engine Oil and Oil Filter Change 4650
Drain Oil from LPG Vaporizer Regulator (LPG Converter) – PSI Engine 4650
Cleaning Carbon Buildup From Intake Valves – PSI 2 4L LPG Engine 4652
Maintenance Procedures Every 500 Hours or 6 Months 4654
Kubota Engine Oil and Oil Filter 4654
Kubota 2 5L LPG Engine 4654
Kubota 2 4L Diesel Engine 4654
Yanmar Engine Oil and Oil Filter Change 4655
Cleaning Carbon Buildup From Intake Valves – Kubota 2 5L LPG Engine 4655
Hydraulic System Oil 4657
Hydraulic Tank Breather 4657
Inspect 4657
Battery 4658
Drive Belt 4658
Yanmar Diesel Engine 4658
Fan and Alternator Drive Belt 4658
Kubota 2 4L Diesel Engine 4659
Fan and Alternator Drive Belt 4659
Kubota 2 5L LPG Engine 4660
Fan and Alternator Drive Belt 4660
Clean Debris From Radiator Core 4660
Transmission Oil Level 4661
Wet Brake Planetary Housing Oil Level Check 4662
Forks, Inspect 4664
Mast Lubrication 4666
Header Hose Checks 4669
Lift Chain Lubrication 4669
Tilt Cylinder Lubrication 4670
Master Brake Cylinder Rod End Pin Lubrication 4671
Manual Hydraulic Levers Lubrication 4672
Brake Fluid 4672
Tie Rod Lubrication (GP/GLP/GDP040-070VX) 4673
Differential and Drive Axle Oil (Dry Brake) 4673
Fuel/Water Separator, Kubota 2 4L Diesel Engine 4673
Drain 4674
Replace Filter 4674
Remove 4674
Install 4674
Priming the Fuel System (Kubota) 4675
Maintenance Procedures Every 1000 Hours or 6 Months 4676
Valve Clearance, Check and Adjust 4676
PCV Valve, Kubota Engine 4676
Drive Belt Check 4676
LPG Fuel Filter Element Replace, Kubota 2 5L Engine 4676
Remove 4676
Install 4677
LPG Fuel Filter Replace, PSI Engine 4677
Remove 4677
Clean/Inspect 4678
Install 4678
In-Line Fuel Filter Replacement, PSI 2 4L Engine 4679
Fuel Filter Replacement, Yanmar Engine 4679
Priming the Fuel System (Yanmar) 4681
Ignition System 4682
PSI 2 4L Engines 4682
Kubota 2 5L LPG Engine 4682
Lift Chains Wear Check 4682
Lift Chain Lubrication 4682
Integral Sideshift Carriage, Check Bearings 4683
Integral Sideshift Carriage, Check Lower Mounting Hooks 4683
Steering Axle 4684
Control Levers and Pedals 4684
Maintenance Procedures Every 1500 Hours 4685
Separator Element Replacement, Kubota 2 4L Diesel Engine 4685
Remove 4685
Install 4685
Maintenance Procedures Every 2000 Hours or 1 Year 4686
Hydraulic System 4686
Hydraulic Filter, Replace 4686
Hydraulic Tank Breather, Replace 4687
Air Filter 4687
Ignition System 4690
Kubota 2 5L LPG Engine 4690
PCV Valve 4690
Kubota 2 5L LPG Engine 4690
Oxygen Sensor 4690
Fuel Injector, Yanmar Engines 4691
Fuel Injector, Kubota 2 4L Diesel Engine 4691
Forks, Inspect 4691
Integral Sideshift Carriage 4692
Bearings, Replace 4692
Transmission Oil and Filter (Dry Brake), Replace 4692
Iron Transmission Housing 4692
Aluminum Transmission Housing 4693
Remove 4693
Clean and Inspect 4694
Install 4694
Transmission Oil Change, Wet Brake Drive Axle 4695
Iron Transmission Housing 4695
Aluminum Transmission Housing 4696
Wet Brake Axle Center Section and Planetary Housing, Oil Change 4700
Brake Fluid (Master Cylinder), Change 4702
Brake Fluid (Dry Brake), Remove 4704
Steer Axle Wheel Bearings Lubrication 4704
Service Brakes (Dry Brake) 4704
Differential (Dry Brake) 4705
Maintenance Procedures Every 4000 Hours or 2 Years 4706
Hydraulic Oil, Replace 4706
Cooling System 4707
Maintenance Procedures Every 6000 Hours 4709
Timing Belt Change, PSI Engine 4709
Diesel Particulate Filter (DPF), Kubota Diesel Engine 4709
Remove 4709
Install 4713
Safety Procedures When Working Near Mast 4714
Hood Latch Check 4717
Lift Chain Adjustments 4718
Jump-Starting the Lift Truck 4720
Jump-Starting Using a Battery Charger 4720
Jump-Starting a Lift Truck Using Another Lift Truck 4720
Welding Repairs 4721
Wheel and Tire Replacement 4722
General 4722
Solid Rubber Tire, Change (GC/GLC Series) 4722
Remove and Install Tire on Wheel 4722
Pneumatic Tire With Tube, Repair 4723
Remove Wheels From Lift Truck 4723
Remove Tire From Wheel 4724
Install Wheel in Tire 4726
Install Tire on Two-Piece Wheel 4728
Add Air to Pneumatic Tires With Tube 4729
Install the Wheels 4729
Dual Drive Wheels, Install 4730
Pneumatic Tubeless Tire, Repair 4730
Remove Wheels From Lift Truck 4730
Add Air to Pneumatic Tubeless Tire 4736
Wheels, Install 4736
Solid Rubber Tires on Pneumatic Wheels, Change 4736
Overhead Guard Changes 4740
Adhesives and Sealants 4741
550108897-8000YRM1762-(08-2019)-US-EN 4743
General 4749
Serial Number Data 4749
How to Move Disabled Lift Truck 4749
How to Tow Lift Truck 4749
How to Put Lift Truck on Blocks 4750
How to Raise Drive Tires 4750
How to Raise Steering Tires 4751
How to Clean a Lift Truck 4751
Maintenance Schedule 4752
Recommended Lubricants 4767
Lubricant Specifications 4767
Maintenance Procedures Every 8 Hours or Daily 4770
How to Make Checks With Engine Stopped 4770
Tires and Wheels 4770
Safety Labels 4771
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4771
Operator Restraint System 4772
Emergency Locking Retractor (ELR) 4772
Adjust Seat – Full Suspension 4774
Adjust Seat – Internal Suspension 4775
Hood and Seat Latches 4776
Engine Compartment 4776
Paper Application 4776
Fuel, Oil, and Coolant Leaks, Check 4777
Hydraulic Hoses 4777
Coolant Hoses 4777
Steering Column Gas Cylinder 4777
Transmission 4777
Hydraulic System Oil 4777
Engine Oil 4778
Air Filter 4780
Forks 4781
Inspect 4781
Remove 4782
Install 4785
Adjust 4785
How to Make Checks With Engine Running 4786
Indicator Lights, Horn, Fuses, and Relays 4786
Service Brakes 4788
Brake Fluid Level 4788
Operation, Check 4789
Parking Brake 4789
Engine Oil Pressure 4789
Cooling System 4790
Steering System 4790
Control Levers and Pedals 4791
Lift System, Operate 4791
First Service After First 100 Hours of Operation 4791
Kubota Engine Oil and Oil Filter 4791
Kubota 2 5L LPG Engine 4791
Kubota 2 4L Diesel Engine 4791
PSI Engine Oil and Oil Filter 4792
Yanmar Engine Oil and Oil Filter 4792
Maintenance Procedures Every 250 Hours or 6 Months 4793
PSI 2 4L Engine Oil and Oil Filter Change 4793
Drain Oil from LPG Vaporizer Regulator (LPG Converter) – PSI Engine 4794
Cleaning Carbon Buildup From Intake Valves – PSI 2 4L LPG Engine 4795
Maintenance Procedures Every 500 Hours or 6 Months 4797
Kubota Engine Oil and Oil Filter 4797
Kubota 2 5L LPG Engine 4797
Kubota 2 4L Diesel Engine 4798
Cleaning Carbon Buildup From Intake Valves – Kubota 2 5L LPG Engine 4799
Hydraulic System Oil 4800
Hydraulic Tank Breather 4801
Inspect 4801
Battery 4801
Yanmar Engine Oil and Oil Filter Change 4802
Drive Belt 4802
Yanmar Diesel Engine 4802
Fan and Alternator Drive Belt 4802
Kubota 2 4L Diesel Engine 4803
Fan and Alternator Drive Belt 4803
Kubota 2 5L LPG Engine 4804
Fan and Alternator Drive Belt 4804
Clean Debris From Radiator Core 4804
Transmission Oil Level 4805
Wet Brake Planetary Housing Oil Level Check 4806
Forks, Inspect 4808
Mast Lubrication 4809
Header Hose Checks 4813
Lift Chain Lubrication 4813
Tilt Cylinder Lubrication 4813
Master Brake Cylinder Rod End Pin Lubrication 4814
Manual Hydraulic Levers Lubrication 4815
Brake Fluid 4815
Tie Rod Lubrication (GP/GLP/GDP040-070VX) 4816
Differential and Drive Axle Oil (Dry Brake) 4816
Fuel/Water Separator, Kubota 2 4L Diesel Engine 4817
Drain 4817
Replace Filter 4818
Remove 4818
Install 4818
Priming the Fuel System (Kubota) 4818
Maintenance Procedures Every 1000 Hours or 6 Months 4819
Valve Clearance, Check and Adjust 4819
PCV Valve, Kubota Engine 4819
Drive Belt Check 4819
LPG Fuel Filter Element Replace, Kubota 2 5L Engine 4819
Remove 4819
Install 4819
LPG Fuel Filter Replace, PSI Engine 4820
Remove 4820
Clean/Inspect 4821
Install 4821
In-Line Fuel Filter Replacement, PSI 2 4L Engine 4822
Fuel Filter Replacement, Yanmar Engine 4822
Priming the Fuel System (Yanmar) 4824
Ignition System 4824
PSI 2 4L Engines 4824
Kubota 2 5L LPG Engine 4824
Lift Chains Wear Check 4825
Lift Chain Lubrication 4825
Integral Sideshift Carriage, Check Bearings 4825
Integral Sideshift Carriage, Check Lower Mounting Hooks 4826
Steering Axle 4826
Control Levers and Pedals 4827
Maintenance Procedures Every 1500 Hours 4827
Separator Element Replacement, Kubota 2 4L Diesel Engine 4827
Remove 4827
Install 4828
Maintenance Procedures Every 2000 Hours or 1 Year 4828
Hydraulic System 4828
Hydraulic Filter, Replace 4828
Hydraulic Tank Breather, Replace 4830
Air Filter 4830
Ignition System 4833
Kubota 2 5L LPG Engine 4833
PCV Valve 4833
Kubota 2 5L LPG Engine 4833
Oxygen Sensor 4833
Fuel Injector, Yanmar Engines 4833
Fuel Injector, Kubota 2 4L Diesel Engine 4834
Forks, Inspect 4834
Integral Sideshift Carriage 4835
Bearings, Replace 4835
Transmission Oil and Filter (Dry Brake), Replace 4835
Iron Transmission Housing 4835
Aluminum Transmission Housing 4836
Remove 4836
Clean and Inspect 4837
Install 4837
Transmission Oil Change, Wet Brake Drive Axle 4837
Iron Transmission Housing 4837
Aluminum Transmission Housing 4839
Wet Brake Axle Center Section and Planetary Housing, Oil Change 4842
Brake Fluid (Master Cylinder), Change 4844
Brake Fluid (Dry Brake), Remove 4846
Steer Axle Wheel Bearings Lubrication 4846
Service Brakes (Dry Brake) 4846
Differential (Dry Brake) 4846
Maintenance Procedures Every 4000 Hours or 2 Years 4847
Hydraulic Oil, Replace 4847
Cooling System 4849
Maintenance Procedures Every 6000 Hours 4850
Timing Belt Change, PSI Engine 4850
Diesel Particulate Filter (DPF), Kubota Diesel Engine 4850
Remove 4850
Install 4854
Safety Procedures When Working Near Mast 4855
Hood Latch Check 4857
Lift Chain Adjustments 4858
Jump-Starting the Lift Truck 4860
Jump-Starting Using a Battery Charger 4860
Jump-Starting a Lift Truck Using Another Lift Truck 4860
Welding Repairs 4860
Wheel and Tire Replacement 4861
General 4861
Solid Rubber Tire, Change (GC/GLC Series) 4861
Remove and Install Tire on Wheel 4861
Pneumatic Tire With Tube, Repair 4862
Remove Wheels From Lift Truck 4862
Remove Tire From Wheel 4863
Install Wheel in Tire 4866
Install Tire on Two-Piece Wheel 4868
Add Air to Pneumatic Tires With Tube 4869
Install the Wheels 4869
Dual Drive Wheels, Install 4869
Pneumatic Tubeless Tire, Repair 4870
Remove Wheels From Lift Truck 4870
Add Air to Pneumatic Tubeless Tire 4876
Wheels, Install 4876
Solid Rubber Tires on Pneumatic Wheels, Change 4876
Overhead Guard Changes 4880
Adhesives and Sealants 4880
550108898-8000YRM1763-(06-2022)-US-EN 4883
Lift Truck Lifting Capacity 4889
Counterweight Weights 4889
Tire Sizes 4889
Capacities 4890
Recommended Lubricants 4896
Lubricant Specifications 4896
Electrical System 4902
Transmission Oil Pressures 4904
Hydraulic System Relief Pressures 4906
Steering System 4907
Stall Speeds (in RPM ±100 rpm) 4908
PSI 2 4L 4908
Kubota 2 5L 4908
Yanmar 2 6L 4908
Yanmar 3 0L 4908
Yanmar 3 3L 4908
Kubota 2 4L 4908
Mast Speeds 4909
Tilt Angles 4923
Front End Equipment – Mast Creep 4924
Mast Creep 4924
Engine Specifications 4925
Diesel Fuel Cleanliness Levels 4928
Torque Specifications 4929
Frame 4929
Mast 4929
Steering System, Cushioned Tire Trucks 4929
Steering System, Pneumatic Tire Trucks 4929
Drive Axle (Dry Brake) 4929
Drive Axle (Wet Brake) 4930
Transmission – Iron Housing 4930
Transmission – Aluminum Housing 4931
Engine – PSI 2 4L Dual Fuel 4931
Engine – Yanmar 2 6L, 3 0L, and 3 3L Diesel 4932
Engine – Kubota 2 5L LPG 4933
Kubota 2 4L Diesel 4934
550108898-8000YRM1763-(08-2019)-US-EN 4937
Lift Truck Lifting Capacity 4941
Counterweight Weights 4941
Tire Sizes 4942
Capacities 4942
Recommended Lubricants 4948
Lubricant Specifications 4948
Electrical System 4951
Transmission Oil Pressures 4953
Hydraulic System Relief Pressures 4954
Steering System 4955
Stall Speeds (in RPM ±100 rpm) 4956
PSI 2 4L 4956
Kubota 2 5L 4956
Yanmar 2 6L 4956
Yanmar 3 0L 4956
Yanmar 3 3L 4957
Kubota 2 4L 4957
Mast Speeds 4958
Tilt Angles 4972
Front End Equipment – Mast Creep 4973
Mast Creep 4973
Engine Specifications 4974
Diesel Fuel Cleanliness Levels 4977
Torque Specifications 4977
Frame 4977
Mast 4977
Steering System, Cushioned Tire Trucks 4977
Steering System, Pneumatic Tire Trucks 4977
Drive Axle (Dry Brake) 4978
Drive Axle (Wet Brake) 4978
Transmission – Iron Housing 4979
Transmission – Aluminum Housing 4979
Engine – PSI 2 4L Dual Fuel 4979
Engine – Yanmar 2 6L, 3 0L, and 3 3L Diesel 4981
Engine – Kubota 2 5L LPG 4981
Kubota 2 4L Diesel 4982
550158688-2040YRM2075-(06-2017)-US-EN 4985
General 4989
Description 4989
Precautions 4989
Clamp Assembly Installation 4989
Hydraulic Hose Flush 4990
Clamp Installation (With Lifting Device) 4990
Clamp Installation (Without Lifting Device) 4992
Hose Connections 4992
Clamp Series 4992
Connecting The Hoses 4993
Operating Checks 4993
Clamping Force Test 4993
Troubleshooting 4995
General 4995
Hydraulic Schematics 4997
550158693-2040YRM2081-(09-2017)-US-EN 5001
General 5005
Description 5005
Precautions 5005
Rotator Assembly Installation 5006
Removing Rotator From Skid 5007
Rotator Attachment Installation 5008
Hydraulic Hose Flush And Connection 5010
Fork Installation 5011
S.V 06/24
