Yale Forklift B967 (GLC050LX, GLC050LX2) Service Manual – PDF DOWNLOAD

Description

Yale Forklift B967 (GLC050LX, GLC050LX2) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift B967 (GLC050LX, GLC050LX2) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1940
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift B967 (GLC050LX, GLC050LX2) 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
524223769-2200YRM1128-(01-2023)-US-EN 43
Series Code / Model Designation Reference Table 51
General 53
Deutsch Crimping Tool 54
How to Strip a Wire for Use With Deutsch Crimping Tool 54
How to Crimp With the Deutsch Crimping Tool 55
Calibration Test for the Deutsch Crimping Tool 57
Deutsch Connectors 59
DT, DTM, and DTP Series Connectors 59
HD Series Connectors 102
Metri-Pack Connectors 124
Remove and Install 124
Micro-Pack Connectors 127
Weather-Pack Connectors 128
AMPSEAL Crimping Tools 130
AMP Hand Crimping Tool With Certi-Crimp 130
Description 130
Stripping Wire for Use with AMP Hand Crimping Tool 131
Insulation Crimp Adjustment 132
Maintenance and Inspection for AMP Hand Crimping Tool 132
AMP Hand Crimping Tool 132
Crimp Height Inspection 132
How to use AMP Hand Crimping Tool 133
AMP Pro-Crimper II Tool 133
Description 133
Remove and Install Die Set and Locator Assembly 134
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 134
Contact Support Adjustment 135
Crimp Height Adjustment 136
Maintenance and Inspection Procedures 136
PRO-CRIMPER II Tool 136
Crimp Height Inspection 136
How to Use AMP PRO-CRIMPER II Tool 137
AMPSEAL Connector Assemblies 138
Description for Plug Connector Assembly 138
Seal Plug 139
Contact Crimping 139
Description for Plug Connector and Header Assembly 144
Voltage Reading 147
Seal Plug 147
Contact Crimping 147
AMP Superseal 1 5 Crimping Tools 154
Mini Mic Receptacle and Tab Contacts 154
Description 154
Crimping Conditions and Measurements 154
Insertion of Rubber Seal on Cable 156
AMP Hand Application Tool 161
Description 161
Maintenance and Inspection 161
Crimp Height Inspection 161
Crimp Height Adjustment 162
How to Use AMP Hand Application Tool 162
AMP Pro-Crimper II Tool 163
Description 163
Remove and Install Die Set and Locator Assembly 163
Adjustments 164
Contact Support 164
Crimp Height 165
Inspections and Maintenance 166
Crimp Height Inspection 166
Visual Inspection 166
Maintenance 167
How to Use Pro-Crimper II Tool 167
AMP Superseal 1 5 Connector Assemblies 168
Description 168
Repair and Maintenance 175
Panel Mount Option 175
AMP Fastin-Faston Hand Tools 176
Description – AMP Double Action Hand Tool 176
Maintenance and Inspection Procedures 176
Daily Maintenance 176
Periodic Tool Inspection 177
Lubrication 177
Visual Inspection 177
Crimp Height Inspection 177
Certi-Crimp Ratchet Inspection 178
How to Use AMP Double Action Hand Tool 179
Description – AMP Extraction Tool 180
Maintenance and Inspection 181
How to Use AMP Extraction Tool 181
AMP Fastin-Faston Receptacles and Housings 183
Description 183
Wire Repair 191
Wire Splicing Requirements 191
Deutsch Jiffy Splice 192
Twisted/Shielded Cable and Leads Repair 198
Special Tools 200
524223769-2200YRM1128-(07-2020)-US-EN 209
Series Code / Model Designation Reference Table 215
General 218
Deutsch Crimping Tool 218
How to Strip a Wire for Use With Deutsch Crimping Tool 218
How to Crimp With the Deutsch Crimping Tool 219
Calibration Test for the Deutsch Crimping Tool 221
Deutsch Connectors 223
DT, DTM, and DTP Series Connectors 223
HD Series Connectors 265
Metri-Pack Connectors 288
Remove and Install 288
Micro-Pack Connectors 290
Weather-Pack Connectors 291
AMPSEAL Crimping Tools 293
AMP Hand Crimping Tool With Certi-Crimp 293
Description 293
Stripping Wire for Use with AMP Hand Crimping Tool 293
Insulation Crimp Adjustment 294
Maintenance and Inspection for AMP Hand Crimping Tool 294
AMP Hand Crimping Tool 294
Crimp Height Inspection 294
How to use AMP Hand Crimping Tool 295
AMP Pro-Crimper II Tool 295
Description 295
Remove and Install Die Set and Locator Assembly 296
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 297
Contact Support Adjustment 297
Crimp Height Adjustment 298
Maintenance and Inspection Procedures 298
PRO-CRIMPER II Tool 298
Crimp Height Inspection 298
How to Use AMP PRO-CRIMPER II Tool 299
AMPSEAL Connector Assemblies 300
Description for Plug Connector Assembly 300
Seal Plug 301
Contact Crimping 301
Description for Plug Connector and Header Assembly 306
Voltage Reading 308
Seal Plug 308
Contact Crimping 308
AMP Superseal 1 5 Crimping Tools 315
Mini Mic Receptacle and Tab Contacts 315
Description 315
Crimping Conditions and Measurements 315
Insertion of Rubber Seal on Cable 317
AMP Hand Application Tool 322
Description 322
Maintenance and Inspection 322
Crimp Height Inspection 322
Crimp Height Adjustment 323
How to Use AMP Hand Application Tool 323
AMP Pro-Crimper II Tool 324
Description 324
Remove and Install Die Set and Locator Assembly 325
Adjustments 325
Contact Support 325
Crimp Height 326
Inspections and Maintenance 327
Crimp Height Inspection 327
Visual Inspection 327
Maintenance 328
How to Use Pro-Crimper II Tool 328
AMP Superseal 1 5 Connector Assemblies 329
Description 329
Repair and Maintenance 336
Panel Mount Option 336
AMP Fastin-Faston Hand Tools 337
Description – AMP Double Action Hand Tool 337
Maintenance and Inspection Procedures 337
Daily Maintenance 337
Periodic Tool Inspection 338
Lubrication 338
Visual Inspection 338
Crimp Height Inspection 338
Certi-Crimp Ratchet Inspection 339
How to Use AMP Double Action Hand Tool 340
Description – AMP Extraction Tool 341
Maintenance and Inspection 341
How to Use AMP Extraction Tool 342
AMP Fastin-Faston Receptacles and Housings 343
Description 343
Wire Repair 350
Wire Splicing Requirements 350
Deutsch Jiffy Splice 351
Twisted/Shielded Cable and Leads Repair 356
Special Tools 359
550022929-9000YRM1434-(02-2018)-US-EN 367
SECTION 9010 Operational Diagnostic Procedures 373
Group 05 – Operational Checkout 375
SECTION 9020 Engine 385
Group 10 – Principles of Operation 389
Group 30 – Observed Symptoms 445
Group 40 – Tests and Adjustments 499
SECTION 9030 Electrical System 511
Group 03 – General Maintenance and Diagnostic Data 517
Group 10 – Principles of Operation 539
Group 20 – Diagnostic Trouble Codes 549
Group 30 – Observed Symptoms 735
SECTION 9040 Drive Train 771
Group 10 – Principles of Operation 773
Group 30 – Observed Symptoms 787
Group 40 – Tests and Adjustments 817
SECTION 9050 Hydraulic Systems 821
Group 10 – Principles of Operation 823
Group 33 – Observed Symptoms-Gear Pump 839
Group 43 – Tests and Adjustments-Gear Pump 873
SECTION 9060 Operators Station 889
Group 10 – Principles of Operation 891
SECTION 9070 Front End (Mast) and Chassis 901
Group 10 – Principles of Operation 903
Group 30 – Observed Symptoms 913
SECTION 9080 Supplementary Data 955
Group 50 – Abbreviations and Acronyms 957
Group 60 – Special Tools List 965
Group 70 – Fault Mode Indicator Reference 967
Group 80 – Supplier Specification Data 969
550073240-1900YRM1620-(01-2023)-US-EN 973
Proper Flushing after Major Hydraulic Repairs 979
Introduction 979
The Phases of Wear 979
Causes of Hydraulic System Failure 979
Progression of Contaminant Caused Hydraulic System Failure 980
Hydraulic System Flushing Techniques 980
Double Oil and Filter Change 980
Mechanical Cleaning 981
Cleaning of Components 981
How to Clean Tubes and Hoses 981
Filter Caddy 981
Start-Up Procedure for Cleaned System 982
Contaminated Oil Coolers 982
Additional Filter Caddy Functions 983
How to Handle Different Fluids 983
Water Removal Filters 983
Fluid Conditioning and System Flushing Procedures 984
Operation of the Filter Caddy 984
Filter Caddy operation 984
Fluid Conditioning Procedure 984
Filter Caddy Start-Up 985
System Flushing Procedure 985
Component Cleaning Procedure 986
Reservoir Cleaning Procedure 986
Cylinder Cleaning Procedure 986
Hose and Tube Cleaning Procedure 986
Valve Cleaning Procedure 987
Front-End Attachment Cleaning Procedure 988
System Flushing Procedure 988
Filter Caddy Start-Up 989
System Start-Up and Flushing 989
Reservoir Fluid Cleaning Times 990
Dealing With Different Fluid Types 991
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 991
Filter Caddy Maintenance 991
Servicing the Strainer 991
DC Motor 991
Hydraulic Oil Sampling Method and Procedure 992
Hydraulic Oil Sampling Method 992
Objective 992
General Guidelines 992
Synopsis 993
Hydraulic Oil Analysis Report Guidelines 994
Sampling Conditions 994
Equipment 994
Sampling Procedure 995
Hydraulic Oil Sampling 995
Sample Labeling 995
Results Documentation 995
550073240-1900YRM1620-(03-2020)-US-EN 997
Proper Flushing after Major Hydraulic Repairs 1001
Introduction 1001
The Phases of Wear 1001
Causes of Hydraulic System Failure 1001
Progression of Contaminant Caused Hydraulic System Failure 1002
Hydraulic System Flushing Techniques 1002
Double Oil and Filter Change 1002
Mechanical Cleaning 1003
Cleaning of Components 1003
How to Clean Tubes and Hoses 1003
Filter Caddy 1003
Start-Up Procedure for Cleaned System 1004
Contaminated Oil Coolers 1004
Additional Filter Caddy Functions 1004
How to Handle Different Fluids 1004
Water Removal Filters 1005
Fluid Conditioning and System Flushing Procedures 1005
Operation of the Filter Caddy 1005
Filter Caddy operation 1005
Fluid Conditioning Procedure 1006
Filter Caddy Start-Up 1006
System Flushing Procedure 1007
Component Cleaning Procedure 1007
Reservoir Cleaning Procedure 1007
Cylinder Cleaning Procedure 1007
Hose and Tube Cleaning Procedure 1008
Valve Cleaning Procedure 1008
Front-End Attachment Cleaning Procedure 1009
System Flushing Procedure 1009
Filter Caddy Start-Up 1010
System Start-Up and Flushing 1010
Reservoir Fluid Cleaning Times 1011
Dealing With Different Fluid Types 1011
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 1011
Filter Caddy Maintenance 1012
Servicing the Strainer 1012
DC Motor 1012
Hydraulic Oil Sampling Method and Procedure 1012
Hydraulic Oil Sampling Method 1012
Objective 1012
General Guidelines 1012
Synopsis 1013
Hydraulic Oil Analysis Report Guidelines 1014
Sampling Conditions 1015
Equipment 1015
Sampling Procedure 1015
Hydraulic Oil Sampling 1015
Sample Labeling 1016
Results Documentation 1016
550108495-1300YRM1740-(06-2018)-US-EN 1019
General 1023
Serial Number 1023
Hydraulic Gear Pump 1023
Remove 1023
Install 1023
Housing Fittings Replacement 1024
Remove 1024
Install 1026
Charge Pump Repair 1026
Torque Converter Replacement 1029
Remove 1029
Clean and Inspect 1029
Install 1029
Stator Support Assembly Repair 1030
Remove 1030
Disassemble 1037
Clean 1038
Inspect 1038
Assemble 1039
Install 1039
Clutch Packs Repair 1041
Remove 1041
Disassemble 1043
Housings 1043
Clutch Packs 1046
Clean 1057
Inspect 1058
Assemble 1058
Clutch Packs 1058
Housings 1072
Install 1074
Drive Chains and Sprockets 1077
Remove 1077
Clean 1079
Inspect 1080
Install 1080
Proportional and Enable Solenoid Valves 1080
Proportional Valves 1080
Remove 1080
Disassemble 1082
Clean and Inspect 1083
Assemble 1083
Install 1083
Enable Solenoid Valve 1083
Remove 1083
Disassemble 1084
Clean and Inspect 1084
Assemble 1084
Install 1084
Pedal Repair Foot Directional Control 1085
Remove and Disassemble 1085
Clean and Inspect 1088
Assemble and Install 1089
550108498-1800YRM1743-(06-2018)-US-EN 1093
General 1097
Dry Brake System 1097
Wet Brake System 1097
Service Brakes Repair (Dry Brake) 1097
Remove and Disassemble 1098
Clean 1105
Inspect 1106
Assemble and Install 1106
Adjust 1114
Inching Overlap Adjustment 1114
Parking Brake Repair 1115
Remove and Disassemble 1115
Dry Brake System 1115
Wet Brake System 1117
Assemble and Install 1119
Dry Brake System 1119
Wet Brake System 1119
Adjust 1119
Master Cylinder Repair 1120
Remove (Dry Brake) 1120
Disassemble (Dry Brake) 1121
Clean and Inspect (Dry Brake) 1123
Assemble (Dry Brake) 1123
Bench Bleed Master Cylinder (Dry Brake) 1123
Install and Adjust (Dry Brake) 1123
Remove (Wet Brake) 1124
Disassemble (Wet Brake) 1125
Clean and Inspect (Wet Brake) 1126
Assemble (Wet Brake) 1127
Install and Adjust (Wet Brake) 1127
Service Brakes Adjustment (Dry Brake) 1128
Brake System Air Removal 1128
Using Pressure Bleed System 1128
Using Brake Pedal Pressure 1128
Brake Pedal Adjustment 1129
Free Pedal Adjustment 1130
Torque Specifications 1132
550108499-1900YRM1744-(06-2018)-US-EN 1135
General 1139
Hydraulic Gear Pump Assembly Repair 1140
Remove 1140
Disassemble 1144
Clean 1146
Inspect 1146
Assemble 1146
Install 1146
Quick-Lok™ Hydraulic Hose 1148
Hydraulic Gear Pump Specifications 1149
Variable Displacement Pump Repair 1151
Remove 1151
Disassemble 1156
Clean 1158
Inspect 1158
Assemble 1158
Install 1158
Variable Displacement Pump Checks and Adjustments 1161
Margin Pressure Check 1161
Flow Compensator Adjustment 1162
Pressure Compensator Adjustment 1162
Variable Displacement Pump Specifications 1163
Torque Specifications 1163
Hydraulic Gear Pump 1164
Variable Displacement Pump 1164
550108500-2000YRM1745-(06-2018)-US-EN 1167
General 1171
Electro-Hydraulic Main Control Valve 1171
Description 1171
Remove 1174
Electro-Hydraulic Control Valve Sections 1177
General 1177
Outlet Control Valve Section 1177
Remove 1177
Disassemble 1177
Clean 1179
Inspect 1179
Assemble 1179
Install 1180
Auxiliary Control Valve Sections 1180
Remove 1180
Disassemble 1182
Clean 1183
Inspect 1183
Assemble 1183
Install 1183
Tilt Control Valve Section 1184
Remove 1184
Disassemble 1184
Clean 1185
Inspect 1185
Assemble 1186
Install 1186
Lift/Lower Control Valve Section 1186
Remove 1186
Disassemble 1186
Clean 1188
Inspect 1188
Assemble 1189
Install 1189
Install 1189
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 1192
Lift Pilot Pin 1192
Lower Pilot Pin 1194
Abnormal/Erroneous EHPV Adjustment 1196
Manual Main Control Valve 1196
Description 1196
Remove 1199
OPS Solenoid Assembly 1205
General 1205
Remove 1206
Clean and Inspect 1208
Install 1208
Manual Control Valve Sections 1209
General 1209
Outlet Control Valve Section 1209
Remove 1209
Disassemble 1209
Clean 1212
Inspect 1212
Assemble 1212
Install 1213
Auxiliary Control Valve Sections 1213
Remove 1213
Disassemble 1213
Clean 1216
Inspect 1216
Assemble 1216
Install 1216
Lift/Tilt Control Valve Section 1217
Remove 1217
Disassemble 1217
Clean 1222
Inspect 1222
Assemble 1222
Install 1223
Install 1223
Pressure Relief Valve Check and Adjustment 1227
Primary Relief Valve 1228
Secondary Relief Valve 1229
Steering Control Unit Repair 1233
Steering Control Unit, Remove 1233
Steering Control Unit, Disassemble 1235
Steering Control Unit, Clean 1237
Steering Control Unit, Inspect 1237
Steering Control Unit, Assemble 1237
Relief Valve, Disassemble 1238
Relief Valve, Clean 1238
Relief Valve, Inspect 1239
Relief Valve, Assemble 1239
Steering Control Unit, Install 1239
550108890-0600YRM1755-(04-2019)-US-EN 1243
General 1249
Engine Removal and Installation 1252
Cylinder Head Assembly Repair 1252
Drive Train and Lubrication System 1291
Remove 1292
Disassemble 1292
Oil Pan 1292
Oil Pump (Front Cover) 1295
Clean and Inspect 1296
Front Case 1296
Oil Seal 1296
Counterbalance Shaft 1296
Oil Pump 1296
Assemble 1297
Counterbalance Shaft Bearings 1297
Oil Pump (Front Cover) 1298
Oil Pan 1300
Install 1300
Crankshaft and Cylinder Block Repair 1301
Remove Major Attaching Components 1301
Crankshaft and Cylinder Block 1301
Remove 1301
Clean and Inspect 1302
Boring Cylinder 1303
Install 1304
Piston and Connecting Rod 1306
Remove 1306
Disassemble 1307
Clean and Inspect 1308
Assemble 1309
Install 1311
Piston 1311
Rod Bearing 1312
Install Major Attaching Components 1313
Fuel System Repair 1313
Cooling System Repair 1313
Electrical Equipment Repair 1314
Flywheel and Flywheel Housing 1314
Flywheel 1314
Remove 1314
Install 1315
Flywheel Housing 1316
Remove 1316
Install 1316
Engine Specifications 1316
Engine Data 1316
Engine Tuning 1318
Cylinder Head 1318
Intake/Exhaust Valve and Guide 1318
Valve Spring 1319
Gear Train and Camshaft 1319
Camshaft 1319
Idle Gear Shaft and Bushing 1319
Cylinder Block 1319
Crankshaft 1319
Piston 1320
Piston Ring 1320
Connecting Rod 1320
Oil Pump 1320
Engine Oil Pressure 1320
Drive Gear Clearance 1320
Driven Gear Clearance 1321
Torque Specifications 1321
Special Tools 1322
550108890-0600YRM1755-(08-2023)-US-EN 1329
General 1337
Engine Removal and Installation 1341
Cylinder Head Assembly Repair 1342
Drive Train and Lubrication System 1383
Remove 1383
Disassemble 1383
Oil Pan 1383
Oil Pump (Front Cover) 1386
Clean and Inspect 1387
Front Case 1387
Oil Seal 1387
Counterbalance Shaft 1387
Oil Pump 1387
Assemble 1388
Counterbalance Shaft Bearings 1388
Oil Pump (Front Cover) 1389
Oil Pan 1391
Install 1391
Crankshaft and Cylinder Block Repair 1393
Remove Major Attaching Components 1393
Crankshaft and Cylinder Block 1393
Remove 1393
Clean and Inspect 1394
Boring Cylinder 1395
Install 1396
Piston and Connecting Rod 1398
Remove 1398
Disassemble 1399
Clean and Inspect 1399
Assemble 1400
Install 1402
Piston 1402
Rod Bearing 1403
Install Major Attaching Components 1404
Fuel System Repair 1405
Cooling System Repair 1406
Electrical Equipment Repair 1407
Flywheel and Flywheel Housing 1408
Flywheel 1408
Remove 1408
Install 1409
Flywheel Housing 1409
Remove 1409
Install 1409
POWER TAKE OFF (PTO), REMOVE AND INSTALL 1410
REMOVE COVER 1410
INSTALL COVER 1410
Engine Specifications 1412
Engine Data 1412
Engine Tuning 1413
Cylinder Head 1414
Intake/Exhaust Valve and Guide 1414
Valve Spring 1414
Gear Train and Camshaft 1415
Camshaft 1415
Idle Gear Shaft and Bushing 1415
Cylinder Block 1415
Crankshaft 1415
Piston 1415
Piston Ring 1416
Connecting Rod 1416
Oil Pump 1416
Engine Oil Pressure 1416
Drive Gear Clearance 1416
Driven Gear Clearance 1416
Torque Specifications 1417
Special Tools 1419
550108892-0900YRM1757-(06-2018)-US-EN 1423
General 1429
Intake-Air System 1430
Intake-Air System Manifold Vacuum Check 1430
Throttle Body 1430
Remove 1431
Install 1432
Intake Manifold 1432
LPG Tank and Bracket Replacement Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (C910) and GLP20-35VX (GLP040-070VX) (D875) 1432
Remove LPG Tank 1432
Install LPG Tank 1435
Remove LPG Bracket 1435
Install LPG Bracket 1438
Remove LPG Tank Bracket Alignment Pin 1438
Install LPG Tank Bracket Alignment Pin 1440
LPG Tank and Bracket Replacement Lift Truck Models GLC050LX, GLC050LX2 (B967) and GLP20-25LX (GLP050LX) (B974) 1441
Remove LPG Tank 1441
LPG Tank Install 1443
Remove LPG Bracket 1443
Install LPG Bracket 1443
LPG Fuel Filter Unit Repair Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (C910) and GLP20-35VX (GLP040-070VX) (D875) 1444
Fuel Filter Element 1444
Remove 1444
Clean/Inspect 1444
Install 1445
Fuel Filter Housing 1445
Remove 1445
Disassemble 1446
Assemble 1447
Install 1447
LPG Fuel Filter Unit Repair Lift Truck Models GLC050LX, GLC050LX2 (B967) and GLP/GDP20-25LX (GLP/GDP050LX) (B974) 1448
Fuel Filter Element 1448
Remove 1448
Clean/Inspect 1449
Install 1449
Fuel Filter Housing 1449
Remove 1449
Disassemble 1449
Assemble 1450
Install 1450
Electronic Throttle Body Repair 1450
Remove 1451
Install 1452
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 1453
Remove 1454
Install 1456
Gasoline Fuel System 1457
Before Repair Procedure 1458
Fuel Line Safety Procedure 1458
After Repair Procedure 1460
Fuel Hose, Install 1460
Fuel Leakage Check 1460
Fuel Line Pressure Check 1461
Fuel Injectors 1461
Remove 1461
Install 1462
Pressure Regulator 1462
Remove 1462
Install 1463
Control System 1463
Engine Control Module (ECM) 1463
Remove 1463
Install 1465
Fuel Level Sensor 1465
Remove 1465
Install 1465
Low LPG Pressure Switch 1466
Remove 1466
Install 1466
LPG Low Level Sensor 1466
Remove 1467
Install 1467
LPG Converter 1468
LPG Lock-Off Valve 1473
Remove 1473
Install 1474
Exhaust System 1476
Counterweight Exhaust System 1476
Remove and Disassemble 1476
Inspect 1477
Assemble and Install 1478
Overhead Exhaust System 1478
Remove and Disassemble 1478
Inspect 1480
Assemble and Install 1480
Exhaust Manifold 1480
Positive Crankcase Ventilation (PCV) Valve 1480
Remove 1480
Inspect 1480
Install 1481
Oxygen Sensor 1481
Remove 1481
Install 1482
LPG Fuel Testing 1482
General 1482
Available Fuel Tests 1483
Composition Test (ASTM D-2163) 1483
Ammonia Test (ASTM D-4490) 1483
Basic Nitrogen Test (ASTM UOP269-90) 1483
Residues Test (ASTM D-2158) 1483
Vapor Pressure Test (ASTM D-2598) 1483
Sulfur Compounds Test (ASTM D-5623) 1483
Methanol Test (ASTM D-4864) 1483
Copper Corrosion (ASTM D-1838) 1483
Where To Send LPG Fuel Samples For Testing 1483
Technical Data 1484
550109110-0100YRM1766-(06-2018)-US-EN 1487
General 1491
Hood, Seat, and Side Covers Replacement 1493
Remove 1493
Install 1500
Steering Column 1501
Description 1502
Steering Column Repair 1502
Remove 1502
Disassemble 1503
Clean 1504
Inspect 1505
Assemble 1505
Install 1505
Counterweight Replacement 1505
Remove 1505
Install 1507
Overhead Guard Replacement 1507
Remove 1508
Install 1508
Rain Top (Optional) 1509
Remove 1509
Clean and Inspect 1510
Install 1510
Operator Restraint System Replacement 1511
Description 1511
Emergency Locking Retractor (ELR) 1511
Engine Replacement 1512
Remove 1512
LPG Engine 1512
Diesel Engine 1520
Install 1526
LPG Engine 1526
Diesel Engine 1527
Transmission Replacement 1528
Remove 1528
Install 1530
Throttle Pedal and Cable Adjustment 1530
PSI 2 4L Engine 1530
Throttle Pedal Stop Adjustment 1530
Yanmar Diesel Engine 1531
Yanmar Diesel Engine With Electronic Throttle 1532
Exhaust System Repair 1533
Lift Trucks With Counterweight Exhaust System 1533
PSI Engines 1533
Yanmar Diesel Engine 1533
Remove and Disassemble 1533
Inspect 1533
Assemble and Install 1533
Lift Trucks With Overhead Exhaust System 1535
PSI Engines 1535
Yanmar Diesel Engine 1535
Remove and Disassemble 1535
Inspect 1535
Assemble and Install 1535
Cooling System 1538
Description 1538
Hydraulic Filter Repair 1538
Remove 1538
Clean and Inspect 1539
Install 1539
Tank Repair 1539
Hydraulic and Diesel Tanks 1539
Inspect 1539
Clean 1540
Steam Method of Cleaning 1541
Chemical Solution Method of Cleaning 1541
Additional Preparations for Repair 1542
Small Leaks, Repair 1542
Large Leaks, Repair 1542
Preparations for Use After Repair 1542
Label Replacement 1542
550109111-0700YRM1767-(06-2018)-US-EN 1549
General 1553
Cooling System Checks 1553
Exhaust Leaks Into Cooling System 1553
Water Flow Restrictions in Radiator 1553
Radiator Hoses 1553
Water Pump 1553
Flushing the Cooling System 1554
Cooling System, Clean 1554
Radiator Replacement 1554
Radiator, Remove 1555
Radiator, Install 1558
Fan Assembly Replacement 1559
Fan Removal 1559
Inspect 1562
Fan Installation 1562
550109112-1400YRM1768-(06-2018)-US-EN 1565
General 1569
Identification Plate 1569
Drive Axle Repair 1569
Remove and Disassemble 1569
Clean and Inspect 1573
Assemble and Install 1573
Differential Repair 1576
Remove 1576
Disassemble 1584
Clean and Inspect 1590
Assemble 1591
Install 1600
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 1600
Hypoid Gear Backlash, Adjust 1610
Hypoid Gear, Runout Check 1611
Gear Set, Tooth Contact Pattern Check 1612
Torque Specifications 1615
550109113-1600YRM1769-(06-2018)-US-EN 1619
General 1623
Steering Axle Assembly Repair 1623
Remove 1624
Disassemble 1624
Clean 1626
Inspect 1627
Assemble 1627
Install 1628
Spindles, Bearings, and Tie Rods Repair 1630
Spindles and Bearings 1630
Remove 1630
Disassemble 1631
Clean 1631
Inspect 1632
Assemble 1632
Install 1632
Tie Rods 1633
Remove 1633
Disassemble 1633
Clean 1634
Inspect 1634
Assemble 1634
Install 1634
Steering Cylinder Repair 1634
Remove 1635
Disassemble 1635
Clean 1636
Inspect 1636
Assemble 1637
Install 1637
Torque Specifications 1637
550109114-2100YRM1770-(06-2018)-US-EN 1641
General 1645
Description 1647
Safety Procedures When Working Near Mast 1648
Tilt Cylinder Repair 1649
Remove 1649
Disassemble 1650
Inspect 1651
Clean 1651
Assemble 1651
Install 1652
Tilt Cylinders, Adjust 1652
Tilt Cylinder Leak Check 1653
Torque Specifications 1654
Lift Cylinder Repair 1655
Main Lift Cylinders 1655
Remove 1655
Disassemble 1656
Clean 1657
Inspect 1658
Assemble 1658
Install 1658
System Air Bleed Procedures 1659
Three-Stage FFL Left Side Main Lift Cylinder 1659
Disassemble 1659
Clean 1661
Inspect 1661
Assemble 1661
Install 1661
Free-Lift Cylinder 1661
Remove 1661
Disassemble 1662
Clean 1662
Inspect 1663
Assemble 1663
Install 1663
Torque Specifications 1664
Lift Cylinder Leak Check 1664
Integral Sideshift Cylinder Repair 1664
Before December 2016 1664
Remove 1664
Disassemble 1665
Clean 1666
Inspect 1666
Assemble 1666
Install 1667
After December 2016 1667
Remove 1667
Disassemble 1667
Clean 1668
Inspect 1668
Assemble 1668
Install 1669
Integral Sideshift Cylinder Gland Leak Checks 1669
Seal Kit Installation 1670
External Installation (Seal and Back-Up Ring) 1670
Internal Installation (Piston Rod Assembly) 1670
550109115-2200YRM1771-(06-2018)-US-EN 1673
General 1677
Engine Control Module (ECM), Yanmar Diesel Engine 1677
Remove 1677
Install 1678
Display Switch Cluster 1679
Remove 1679
Install 1681
Direction Control Lever 1681
Remove 1681
Install 1682
Key Switch 1682
Remove 1682
Install 1683
Display Switch Cluster Panel Bezel and Overlay 1683
Remove 1683
Install 1683
Steering Column Repair 1683
Remove 1684
Disassemble 1685
Assemble 1685
Install 1686
Sensors and Switches 1686
General 1686
Dash Panel, Kick Panel, and Seal Plate, Remove and Install 1686
Remove 1686
Install 1687
Accelerator Pedal Position Sensor 1687
Remove 1687
Install 1689
Brake Fluid Level Switch 1689
Remove 1689
Install 1690
Brake Pedal Position Sensor 1691
Remove 1691
Install 1692
Parking Brake Position Sensor 1692
Remove 1692
Install 1692
Seat Sensor (Operator Presence System) 1693
Non-Suspension Seat 1693
Remove 1693
Install 1694
Full Suspension Seats 1694
Remove 1694
Install 1694
Transmission Pressure Sensors (Transducers) 1695
Remove 1695
Install 1695
Transmission Temperature Sensor 1695
Remove 1695
Install 1696
Rear Horn Button Switch 1696
Remove 1696
Install 1696
Engine and Fuel Sensors and Switches, PSI 2 4L Dual Fuel Trucks 1697
Engine and Fuel Sensors, Yanmar 2 6L Diesel Trucks 1697
Engine Speed Sensor 1697
Remove 1697
Install 1698
Oil Pressure Sensor 1698
Remove 1698
Install 1698
Engine Coolant Temperature (ECT) Sensor 1699
Remove 1699
Install 1699
Fuel/Water Separator Sensor 1699
Remove 1699
Install 1699
Glow Plug Relay 1700
Remove 1700
Install 1702
Power Distribution Module (PDM) and Component Parts 1702
Power Distribution Module (PDM) as a Unit 1702
Remove 1702
Install 1703
Power Distribution Module (PDM) Components 1704
Remove and Install 1704
Battery 1704
Remove 1704
Install 1704
Lights 1705
Work Lights (Front and Rear) 1705
Remove 1705
Install 1705
Strobe Light 1705
Remove 1706
Install 1706
LED Tail, Backup, and Brake Lights 1706
Remove 1706
Install 1707
Reflectors 1707
Remove 1707
Install 1707
550109116-2200YRM1772-(06-2018)-US-EN 1711
General 1715
Ignition System 1715
Ignition Timing Adjustment 1715
Spark Plugs Check 1715
Coil Replacement 1715
Remove 1715
Inspect 1717
Install 1717
Starter Repair 1718
General 1718
Remove 1719
No-Load Test 1720
Magnetic Switch Test 1721
Pull-Out Test 1721
Holding Coil Test 1721
Return Test 1721
Pinion Movement Inspection 1722
Install 1722
Alternator Repair 1723
General 1723
Charging System Inspection 1723
Output Current Check 1724
No-Load Adjusted Voltage Check 1724
Remove 1725
Install 1725
Engine Sensors and Switches 1725
Oil Pressure Sensor 1726
Remove 1726
Install 1726
Air Filter Restriction Switch 1726
Remove 1726
Install 1726
Cam Angle Sensor 1727
Remove 1727
Install 1727
Crankshaft Position Sensor (CKP) 1727
Remove 1727
Install 1727
Temperature Manifold Absolute Pressure (TMAP) Sensor 1728
Remove 1728
Install 1729
Engine Coolant Temperature (ECT) Sensor 1729
Remove 1729
Install 1729
Electronic Control Module 1729
550109117-4000YRM1773-(06-2018)-US-EN 1733
General 1737
Safety Procedures When Working Near Mast 1737
Forks Replacement 1739
Remove 1739
Install 1740
Checks 1740
Adjustment 1741
Carriage Repair 1741
Standard Carriage 1742
Remove 1742
Clean and Inspect 1743
Install 1744
Integral Sideshift Carriage Prior to December, 2016 1745
Remove 1745
Disassemble 1747
Clean and Inspect 1747
Assemble 1748
Install 1748
Integral Sideshift Carriage After December, 2016 1749
Remove 1749
Disassemble 1752
Clean and Inspect 1752
Assemble 1752
Install 1753
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 1754
Connecting Attachment Hydraulic Quick Disconnect Hoses 1754
Two-Stage Mast With Limited Free-Lift Repair 1754
Mast 1754
Remove 1754
Disassemble 1755
Clean and Inspect 1758
Assemble 1758
Install 1759
Header Hoses, Installation and Adjustment 1760
Install 1760
Adjustment 1765
Three-Stage Mast With Full Free-Lift Repair 1765
Remove 1765
Disassemble 1766
Clean and Inspect 1772
Assemble 1773
Install 1774
Header Hose Installation and Adjustment 1775
Standard 1775
Install 1775
Adjust 1780
Optional Equipment, Lift Truck GLP/GDP050LX (B974) 1781
Install 1781
Adjust 1790
Main Lift Cylinder Repair 1790
Lift and Tilt System Leak Check 1790
Tilt Cylinders Adjustment 1790
Lift Chain Adjustment 1790
Mast Adjustments 1791
Load Roller Adjustment 1792
Mast Side Kicking Adjustment 1794
Carriage Adjustment 1795
550109118-8000YRM1774-(10-2019)-US-EN 1799
General 1805
Serial Number Data 1805
How to Move Disabled Lift Truck 1805
How to Tow Lift Truck 1805
How to Put Lift Truck on Blocks 1806
How to Raise Drive Tires 1806
How to Raise Steering Tires 1807
How to Clean a Lift Truck 1807
Maintenance Schedule 1808
Maintenance Procedures Every 8 Hours or Daily 1818
How to Make Checks With Engine Stopped 1818
Tires and Wheels 1818
Safety Labels 1819
Mast, Carriage, Lift Chains, Header Hoses, Attachment 1819
Operator Restraint System 1820
Emergency Locking Retractor (ELR) 1821
Hood and Seat Latches 1822
Engine Compartment 1822
Ground Static Strap 1822
Fuel, Oil, and Coolant Leaks, Check 1823
Hydraulic Hoses 1823
Coolant Hoses 1823
Steering Column Gas Cylinder 1823
Transmission 1823
Hydraulic System Oil 1824
Engine Oil 1824
Air Filter 1826
Forks 1826
Inspect 1826
Remove 1828
Install 1828
Adjust 1828
How To Make Checks With Engine Running 1829
Indicator Lights, Horn, Fuses, and Relays 1829
Service Brakes 1832
Brake Fluid Level 1832
Operation, Check 1832
Parking Brake 1832
Engine Oil Pressure 1832
Cooling System 1832
Steering System 1833
Control Levers and Pedals 1833
Lift System, Operate 1834
First Service After First 100 Hours of Operation 1834
PSI Engine Oil and Oil Filter Change 1834
Yanmar Engine Oil and Oil Filter Change 1835
Maintenance Procedures Every 250 Hours or 6 Months 1835
PSI 2 4L Engine Oil and Oil Filter Change 1835
Drain Oil from LPG Vaporizer Regulator (LPG Converter) 1836
Maintenance Procedures Every 500 Hours or 6 Months 1837
Hydraulic System Oil 1838
Hydraulic Tank Breather 1839
Inspect 1839
Battery 1839
Yanmar 2 6L Engine Oil and Oil Filter Change 1839
Yanmar 2 6L Engine Drive Belt 1839
Clean Debris From Radiator Core 1840
Transmission Oil Level 1841
Forks 1841
Inspect 1841
Mast Lubrication 1842
Header Hose Checks 1845
Lift Chain Lubrication 1845
Tilt Cylinder Lubrication 1845
Master Cylinder Rod End Pin Lubrication 1846
Manual Hydraulic Levers Lubrication 1847
Brake Fluid 1847
Parking Brake Adjustment 1847
Tie Rod Lubrication 1848
Differential and Drive Axle Oil 1848
Maintenance Procedures Every 1000 Hours or 6 Months 1849
Drive Belt Check, PSI 2 4L Engine 1849
LPG Fuel Filter Replace – PSI 2 4L LPG Engine 1849
Remove 1849
Clean/Inspect 1850
Install 1850
In-Line Fuel Filter Replacement – PSI 2 4L Dual Fuel Engine 1851
Fuel Filter Replacement – Yanmar 2 6L Engine 1851
Priming the Fuel System (Yanmar) 1853
Lift Chains Wear Check 1853
Lift Chain Lubrication 1854
Integral Sideshift Carriage, Check Bearings 1854
Steering Axle 1855
Control Levers and Pedals 1855
Maintenance Procedures Every 2000 Hours or 1 Year 1855
Hydraulic System 1856
Hydraulic Oil Filter Element, Replace 1856
Remove 1856
Clean and Inspect 1856
Install 1856
Hydraulic Tank Breather, Replace 1857
Air Filter 1858
Oxygen Sensor 1860
Ignition System – PSI Engine 1861
Forks, Inspect 1861
Fuel Injector, Yanmar Engines 1863
Integral Sideshift Carriage 1863
Bearings, Replace 1863
Transmission Oil and Oil Filter, Replace 1863
Remove 1863
Clean and Inspect 1864
Install 1864
Brake Fluid Change 1864
Service Brakes 1866
Drive Axle and Differential Oil, Change 1866
Wheel Bearings 1868
Steer Wheels, Lubrication 1868
Maintenance Procedures Every 4000 Hours or 2 Years 1868
Hydraulic Oil, Change 1868
Cooling System 1870
Maintenance Procedures Every 6000 Hours 1871
Timing Belt Change, PSI Engine 1871
Safety Procedures When Working Near Mast 1872
Hood Latch Check 1874
Lift Chain Adjustments 1875
Jump-Starting the Lift Truck 1877
Jump-Starting Using a Battery Charger 1877
Jump-Starting a Lift Truck Using Another Lift Truck 1877
Welding Repairs 1877
Overhead Guard Changes 1878
Wheels and Tires Replacement 1878
General 1878
How to Change Solid Rubber Tire (GC Series) 1878
Remove and Install Tire on Wheel 1878
Pneumatic Tire With Tube, Repair 1879
Remove Wheels From Lift Truck 1879
Remove Tire From Wheel 1880
Install Wheel in Tire 1883
Add Air to Pneumatic Tires With Tube 1885
Wheels, Install 1886
Pneumatic Tubeless Tire, Repair 1886
Remove Wheels From Lift Truck 1886
Add Air to Pneumatic Tubeless Tire 1891
Wheels, Install 1891
Solid Rubber Tires on Pneumatic Wheels, Change 1892
Adhesives and Sealants 1895
550109119-8000YRM1775-(09-2019)-US-EN 1897
Lift Truck Lifting Capacity 1901
Counterweight Weights 1901
Tire Sizes 1901
Capacities 1901
Electrical System 1904
Transmission Oil Pressures 1905
Hydraulic System Relief Pressures 1905
Steering System 1906
Stall Speeds 1906
Mast Speeds 1906
Tilt Angles 1907
Front End Equipment 1908
Mast Creep 1908
Engine Specifications 1908
Torque Specifications 1909
Frame 1909
Mast 1909
Steering System 1909
Drive Axle 1909
Transmission 1910
Engine – PSI 2 4L LPG and Dual Fuel 1910
Engine – Yanmar 2 6L Diesel 1911
550109120-8000YRM1776-(12-2019)-US-EN 1915
Diagrams and Schematics 1919

S.V 06/24