Yale Forklift C910 (GLC20VX, GLC25VX,GLC30VX, GLC35VX) Service Manual PDF

Description

Yale Forklift C910 (GLC20VX, GLC25VX,GLC30VX, GLC35VX) Service Manual – PDF DOWNLOAD

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Yale Forklift C910 (GLC20VX, GLC25VX,GLC30VX, GLC35VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4976
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift C910 (GLC20VX, GLC25VX,GLC30VX, GLC35VX) 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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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-(04-2023)-US-EN 2857
General 2863
Safety Procedures When Working Near Mast 2866
Main Lift Cylinder Repair 2868
Remove 2868
Disassemble 2870
Clean 2872
Inspect 2872
Assemble 2872
Install 2873
Main Lift Cylinder Leak Check 2873
Free-Lift Cylinder 2874
Remove 2874
Disassemble 2875
Clean 2877
Inspect 2877
Assemble 2877
Install 2877
Tilt Cylinder Repair 2879
Remove 2879
Disassemble 2881
Clean 2882
Inspect 2883
Assemble 2883
Install 2884
Tilt Cylinder Adjustment 2884
Tilt Cylinder Leak Check 2886
Integral Sideshift Cylinder Repair Prior to December 2016 2888
Remove 2888
Disassemble 2888
Clean 2889
Inspect 2889
Assemble 2889
Install 2890
Integral Sideshift Cylinder Repair After December 2016 2891
General 2891
Remove 2891
Disassemble 2892
Clean 2893
Inspect 2893
Assemble 2893
Install 2893
Integral Side-Shift Cylinder Gland Leak Checks 2894
Fork Positioner Cylinder Repair Prior to December 2016 2895
Remove 2895
Disassemble 2895
Clean 2898
Inspect 2898
Assemble 2899
Install 2899
Fork Positioner Cylinder Adjustment 2899
Fork Positioner Cylinder Repair After December 2016 2901
General 2901
Remove 2901
Disassemble 2901
Clean 2904
Inspect 2904
Assemble 2905
Install 2905
Fork Positioner Cylinder Adjustment 2905
Seal Kit Installation 2907
External Installation (Seal and Backup Ring) 2907
Internal Installation (Piston Rod Assembly) 2907
Torque Specifications 2908
Main Lift Cylinders 2908
Free-Lift Cylinder 2908
Tilt Cylinders 2908
Integral Sideshift Cylinder 2908
Fork Positioner Cylinder 2908
550093755-4000YRM1669-(04-2023)-US-EN 2911
General 2919
Safety Procedures When Working Near Mast 2921
Fork Replacement 2923
Standard Carriage and Integral Sideshift Carriage 2923
Remove 2923
Install 2924
Checks 2924
Fork Positioner Carriage 2926
Remove 2927
Install 2927
Checks 2929
Carriages Repair, Two-Stage LFL Mast 2932
Standard Carriage 2932
Remove 2932
Clean and Inspect 2933
Install 2933
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 2933
Remove 2933
Disassemble 2935
Clean and Inspect 2936
Assemble 2937
Install 2937
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 2938
Remove 2938
Disassemble 2941
Clean and Inspect 2941
Assemble 2942
Install 2943
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 2943
Remove 2943
Disassemble 2946
Clean and Inspect 2946
Assemble 2947
Install 2948
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 2948
Remove 2948
Install 2950
Fork Positioner Hydraulic Hose Adjustment 2952
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 2953
Remove 2953
Disassemble and Assemble 2957
Clean and Inspect 2957
Install 2957
Fork Positioner Hydraulic Hose Adjustment 2958
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 2959
Remove 2959
Disassemble and Assemble 2963
Clean and Inspect 2963
Install 2963
Fork Positioner Hydraulic Hose Adjustment 2964
Two-Stage LFL Mast Repair 2966
Mast With Serial Number F507 2966
Remove 2966
Disassemble 2970
Clean and Inspect 2977
Assemble 2979
Install 2980
Header Hoses 2982
Remove 2982
Installation 2982
Adjustment 2986
Mast With Serial Number F562 2987
Remove 2987
Disassemble 2991
Clean and Inspect 2998
Assemble 3000
Install 3001
Header Hose Installation and Adjustment 3002
Remove 3002
Installation 3003
Adjustment 3007
Carriages Repair, Three-Stage FFL Mast 3009
Standard Carriage 3009
Remove 3009
Clean and Inspect 3010
Install 3011
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3011
Remove 3011
Disassemble 3012
Clean and Inspect 3013
Assemble 3014
Install 3014
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3015
Remove 3015
Disassemble 3017
Clean and Inspect 3018
Assemble 3019
Install 3019
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 3020
Remove 3020
Disassemble 3022
Clean and Inspect 3023
Assemble 3024
Install 3024
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 3025
Remove 3025
Install 3027
Fork Positioner Hydraulic Hose Adjustment 3029
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3030
Remove 3030
Disassemble and Assemble 3032
Clean and Inspect 3032
Install 3032
Fork Positioner Hydraulic Hose Adjustment 3033
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 3034
Remove 3034
Disassemble and Assemble 3037
Clean and Inspect 3037
Install 3037
Fork Positioner Hydraulic Hose Adjustment 3038
Three-Stage FFL Mast Repair 3040
Mast With Serial Number F508 3040
Remove 3040
Disassemble 3043
Clean and Inspect 3053
Assemble 3056
Install 3057
Header Hose Installation and Adjustment 3059
Remove 3059
Installation 3059
Adjustment 3068
Mast With Serial Number F563 3068
Remove 3068
Disassemble 3072
Clean and Inspect 3082
Assemble 3085
Install 3086
Header Hose Installation and Adjustment 3088
Remove 3088
Installation 3088
Adjustment 3096
Mast Adjustments 3098
Load Roller, Adjust 3098
Mast Side Kicking, Adjust 3100
Carriage Adjustments 3101
Lift Chains Adjustment 3103
Hydraulic Quick Disconnect Hoses 3105
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) 3105
Lift Trucks Equipped With E-Hydraulic Controls 3105
Lift Trucks Equipped With Manual Hydraulic Controls 3105
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) 3106
Lift Trucks Equipped With E-Hydraulic Controls 3106
Lift Trucks Equipped With Manual Hydraulic Controls 3106
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 3106
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 3106
550093755-4000YRM1669-(06-2019)-UK-EN 3109
General 3115
Safety Procedures When Working Near Mast 3116
Fork Replacement 3118
Standard Carriage and Integral Sideshift Carriage 3118
Remove 3118
Install 3120
Checks 3120
Fork Positioner Carriage 3122
Remove 3123
Install 3123
Checks 3125
Carriages Repair, Two-Stage LFL Mast 3127
Standard Carriage 3127
Remove 3127
Clean and Inspect 3128
Install 3129
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3129
Remove 3129
Disassemble 3130
Clean and Inspect 3131
Assemble 3132
Install 3132
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 3133
Remove 3133
Disassemble 3136
Clean and Inspect 3136
Assemble 3137
Install 3137
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 3138
Remove 3138
Disassemble 3141
Clean and Inspect 3141
Assemble 3142
Install 3142
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 3143
Remove 3143
Install 3145
Fork Positioner Hydraulic Hose Adjustment 3147
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3148
Remove 3148
Disassemble and Assemble 3152
Clean and Inspect 3152
Install 3152
Fork Positioner Hydraulic Hose Adjustment 3153
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 3154
Remove 3154
Disassemble and Assemble 3158
Clean and Inspect 3158
Install 3158
Fork Positioner Hydraulic Hose Adjustment 3159
Two-Stage LFL Mast Repair 3160
Mast With Serial Number F507 3160
Remove 3160
Disassemble 3164
Clean and Inspect 3171
Assemble 3173
Install 3174
Header Hoses 3176
Remove 3176
Installation 3176
Adjustment 3180
Mast With Serial Number F562 3181
Remove 3181
Disassemble 3185
Clean and Inspect 3192
Assemble 3194
Install 3195
Header Hose Installation and Adjustment 3196
Remove 3196
Installation 3197
Adjustment 3201
Carriages Repair, Three-Stage FFL Mast 3202
Standard Carriage 3202
Remove 3202
Clean and Inspect 3204
Install 3204
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3204
Remove 3204
Disassemble 3206
Clean and Inspect 3207
Assemble 3208
Install 3208
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3209
Remove 3209
Disassemble 3211
Clean and Inspect 3212
Assemble 3213
Install 3213
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 3214
Remove 3214
Disassemble 3216
Clean and Inspect 3217
Assemble 3218
Install 3218
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 3219
Remove 3219
Install 3221
Fork Positioner Hydraulic Hose Adjustment 3223
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3224
Remove 3224
Disassemble and Assemble 3226
Clean and Inspect 3226
Install 3226
Fork Positioner Hydraulic Hose Adjustment 3227
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 3228
Remove 3228
Disassemble and Assemble 3231
Clean and Inspect 3231
Install 3231
Fork Positioner Hydraulic Hose Adjustment 3232
Three-Stage FFL Mast Repair 3233
Mast With Serial Number F508 3233
Remove 3233
Disassemble 3237
Clean and Inspect 3247
Assemble 3250
Install 3251
Header Hose Installation and Adjustment 3253
Remove 3253
Installation 3253
Adjustment 3261
Mast With Serial Number F563 3262
Remove 3262
Disassemble 3265
Clean and Inspect 3275
Assemble 3278
Install 3279
Header Hose Installation and Adjustment 3281
Remove 3281
Installation 3281
Adjustment 3289
Mast Adjustments 3290
Load Roller, Adjust 3290
Mast Side Kicking, Adjust 3292
Carriage Adjustments 3292
Lift Chains Adjustment 3294
Hydraulic Quick Disconnect Hoses 3296
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) 3296
Lift Trucks Equipped With E-Hydraulic Controls 3296
Lift Trucks Equipped With Manual Hydraulic Controls 3297
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) 3297
Lift Trucks Equipped With E-Hydraulic Controls 3297
Lift Trucks Equipped With Manual Hydraulic Controls 3298
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 3298
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 3298
550096316-0600YRM1670-(07-2019)-US-EN 3301
General 3305
Fan Belt Installation 3305
Remove 3305
Inspect 3305
Installation 3306
Thermostat Repair 3306
Remove 3306
Thermostat Operation Check 3307
Install 3307
Water Pump Repair 3307
Remove 3307
Clean and Inspect 3307
Install 3308
Lubrication System Repair 3308
Oil Pan and Oil Pickup, Remove 3308
Oil Pan and Oil Pickup, Inspection 3308
Oil Pump, Remove 3309
Oil Pump, Inspection 3309
Rotor Lobe Clearance 3309
Rotor Cover Clearance 3310
Oil Pump, Assemble and Install 3310
Oil Pan and Oil Pickup, Assemble and Install 3310
Cylinder Head Repair 3311
Remove and Disassemble 3311
Clean and Inspect 3314
Valve Guides and Seats 3316
Valve Lapping 3316
Valve Guide, Replacement 3316
Valve Seats, Inspection and Repair 3317
Valve and Valve Seat Correction 3317
Valve Springs 3318
Assemble and Install 3319
Valve Clearance Adjustments 3322
Gear Case, Timing Gears, and Camshaft 3324
Gear Case 3324
Fan Drive Pulley, Remove 3324
Fan Drive Pulley, Install 3325
Gear Case, Remove 3325
Gear Case, Install 3325
Timing Gears 3325
Oil Pump, Remove 3325
Oil Pump, Install 3325
Crankshaft Oil Slinger, Remove 3325
Crankshaft Oil Slinger, Install 3326
Idler Gear, Remove 3326
Idler Gear, Install 3326
Camshaft 3326
Camshaft, Remove 3326
Camshaft, Install 3327
Piston and Connecting Rod Assemblies Repair 3327
Disassemble 3327
Piston, Clean and Inspect 3328
Piston Ring Gap 3328
Piston Ring Groove 3329
Connecting Rod and Piston Pin, Clean and Inspect 3329
Cylinder Bores, Clean and Inspect 3330
Cylinder Correction (Oversize) 3332
Assemble 3332
Piston Bore Preparation 3334
Cylinder Wear 3334
Cylinder Correction (Oversize) 3334
Flywheel and Bearing Case Cover 3335
Flywheel, Remove 3335
Bearing Case Cover, Remove 3335
Bearing Case Cover, Install 3336
Flywheel, Install 3336
Crankshaft Repair 3337
Crankshaft, Remove 3337
Inspect and Repair 3338
Crankshaft Journal Oil Clearance Bearing 1 3338
Crankshaft Journal Oil Clearance Bearing 2 3339
Crankshaft Bend 3340
Crankshaft, Install 3340
Crankshaft Side Clearance 3342
Engine Block Cleaning and Inspection 3343
Clean and Inspect 3343
Engine Removal and Installation 3344
Engine Specifications 3344
Engine Data 3344
Torque Specifications 3345
550096320-0900YRM1677-(04-2018)-US-EN 3347
General 3351
LPG Tank and Bracket Replacement 3351
Remove LPG Tank 3351
Install LPG Tank 3354
Remove LPG Bracket 3354
Install LPG Bracket 3357
Remove LPG Tank Bracket Alignment Pin 3357
Install LPG Tank Bracket Alignment Pin 3359
LPG Fuel Filter Unit Repair 3360
LPG Fuel Filter Element 3360
Remove/Disassemble 3360
Clean/Inspect 3361
Assemble/Install 3361
Fuel Filter Housing 3362
Remove 3362
Disassemble 3365
Clean and Inspect 3366
Assemble 3366
Install 3367
Electronic Throttle Body Repair 3367
Remove 3368
Install 3369
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 3370
Remove 3370
Install 3371
Control System 3372
Engine Control Unit (ECU) 3372
Remove 3372
Install 3373
Low LPG Pressure Switch 3373
Remove 3373
Install 3374
LPG Low Level Sensor 3374
Remove 3375
Install 3376
LPG Converter 3377
Remove 3377
Install 3380
LPG Lock-Off Valve 3381
Remove 3381
Install 3383
Exhaust System 3384
Counterweight Exhaust System 3384
Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (B910, C910) 3384
Remove and Disassemble 3384
Inspect 3385
Assemble and Install 3385
Lift Truck Models GLP20-35VX (GLP040-070VX) (C875, D875) 3386
Remove and Disassemble 3386
Inspect 3387
Assemble and Install 3388
Overhead Exhaust System 3388
Remove and Disassemble 3388
Inspect 3389
Assemble and Install 3390
Exhaust Manifold 3390
Remove 3390
Install 3391
Oxygen (HEGO) Sensor 3391
Remove 3391
Install 3392
PCV Valve 3392
LPG Fuel Testing 3393
General 3393
Available Fuel Tests 3393
Composition Test (ASTM D-2163) 3393
Ammonia Test (ASTM D-4490) 3393
Basic Nitrogen Test (ASTM UOP269-90) 3393
Residues Test (ASTM D-2158) 3393
Vapor Pressure Test (ASTM D-2598) 3393
Sulfur Compounds Test (ASTM D-5623) 3393
Methanol Test (ASTM D-4864) 3394
Copper Corrosion (ASTM D-1838) 3394
Where To Send LPG Fuel Samples For Testing 3394
550100651-2100YRM1692-(11-2016)-US-EN 3397
General 3403
Description 3405
Safety Procedures When Working Near Mast 3406
Tilt Cylinder Repair 3408
Remove 3408
Disassemble 3409
Clean 3410
Inspect 3410
Assemble 3411
Install 3411
Tilt Cylinders, Adjust 3412
Tilt Cylinders With Tilt Limit Spacers 3412
Tilt Cylinders Without Tilt Limit Spacers 3412
Tilt Cylinder Leak Check 3413
Main Lift And Free-Lift Cylinders Repair 3413
Main Lift Cylinders 3414
Remove 3414
Two-Stage FFL 3414
Four-Stage FFL 3414
Disassemble 3417
Two-Stage FFL 3417
Four-Stage FFL 3419
Clean 3421
Inspect 3421
Assemble 3421
Two-Stage FFL 3421
Four-Stage FFL 3421
Install 3422
Two-Stage FFL 3422
System Air Bleed Procedures 3422
Four-Stage FFL 3423
Free-Lift Cylinder 3423
Remove 3423
Two-Stage FFL 3423
Four-Stage FFL 3425
Disassemble 3427
Two-Stage FFL 3427
Four-Stage FFL 3428
Clean 3429
Inspect 3429
Assemble 3429
Two-Stage FFL 3429
Four-Stage FFL 3429
Install 3430
Two-Stage FFL 3430
Four-Stage FFL 3430
Lift Cylinder Leak Check 3431
Integral Sideshift Cylinder Repair
Prior to December 2016 3432
Remove 3432
Disassemble 3432
Clean and Inspect 3432
Assemble and Install 3433
Integral Sideshift Cylinder Repair
After December 2016 3435
Remove 3435
Disassemble 3435
Clean and Inspect 3435
Assemble and Install 3436
Fork Positioner Cylinder Repair Prior to December 2016 3438
Remove 3438
Disassemble 3438
Clean 3438
Inspect 3441
Assemble 3441
Install 3442
Fork Positioner Cylinder Adjustment 3442
Fork Positioner Cylinder Repair After December 2016 3443
Remove 3443
Disassemble 3443
Clean 3446
Inspect 3446
Assemble 3447
Install 3447
Fork Positioner Cylinder Adjustment 3447
Seal Kit Installation 3447
External Installation (Seal and Back-Up Ring) 3448
Internal Installation (Piston Rod Assembly) 3448
Torque Specifications 3448
Tilt Cylinders 3448
Piston Rod Nut 3448
Gland 3449
Tilt Cylinder Mounting Capscrew 3449
Tilt Cylinder Rod End Nut 3449
Main Lift and Free-Lift Cylinders 3449
Gland, Main Lift Cylinders 3449
Gland, Free-Lift Cylinder 3449
Piston, Main Lift Cylinders 3449
Main Lift Cylinder Mounting Nut To Outer
Mast 3449
Main Lift Cylinder Mounting Nut To Intermediate
Mast (Four-Stage FFL, Right Cylinder Only) 3449
Retainer Nuts 3449
Chain Guard Capscrew (Free-Lift Cylinder) 3449
Crosshead Mounting Capscrew (Free-Lift Cylinder) 3449
Free-Lift Cylinder Mounting Capscrews 3449
Cylinder Shell Capscrew, Main Lift Cylinders 3449
Fork Positioner 3449
Cylinder Rod Retainer 3449
Fork Positioner Cylinder Mounting Capscrews 3449
Cylinder Rod Anchor Plug 3450
Fork Carrier Capscrews 3450
Hose Guide Capscrews 3450
Integral Sideshift Cylinder 3450
Cylinder Rod Retainer 3450
Gland 3450
550100656-4000YRM1693-(10-2017)-US-EN 3453
General 3459
Safety Procedures When Working Near Mast 3461
Fork Replacement 3463
Standard Carriage and Integral Sideshift Carriage 3463
Remove 3463
Install 3464
Checks 3464
Fork Positioner Carriage 3466
Remove 3466
Install 3466
Checks 3468
Carriages Repair, Two-Stage FFL Mast 3469
Standard Carriage 3470
Remove 3470
Clean and Inspect 3471
Install 3471
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3472
Remove 3472
Disassemble 3472
Clean and Inspect 3475
Assemble 3476
Install 3476
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3477
Remove 3477
Disassemble 3480
Clean and Inspect 3480
Assemble 3480
Install 3481
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 3481
Remove 3481
Install 3482
Fork Positioner Hydraulic Hose Adjustment 3486
Fork Positioner Carriage, Lift Trucks Manufactured After December, 2016 3487
Remove 3487
Disassemble and Assemble 3490
Clean and Inspect 3490
Install 3490
Fork Positioner Hydraulic Hose Adjustment 3491
Two-Stage Mast With Full Free-Lift Repair 3492
Mast With Serial Number E509 3492
Remove 3492
Disassemble 3495
Clean and Inspect 3499
Assemble 3501
Install 3502
Header Hose Procedures 3503
Remove 3503
Installation 3504
Adjustment 3510
Mast With Serial Number E564 3510
Remove 3510
Disassemble 3514
Clean and Inspect 3519
Assemble 3521
Install 3522
Header Hose Procedures 3523
Remove 3523
Installation 3523
Adjustment 3530
Carriages Repair, Four-Stage FFL Mast 3530
Standard Carriage 3530
Remove 3530
Clean and Inspect 3531
Install 3532
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3533
Remove 3533
Disassemble 3535
Clean and Inspect 3535
Assemble 3536
Install 3536
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3537
Remove 3537
Disassemble 3537
Clean and Inspect 3540
Assemble 3540
Install 3540
Fork Positioner Carriage 3541
Four-Stage Mast With Full Free-Lift Repair 3542
Mast With Serial Number D515 3542
Remove 3542
Disassemble 3546
Clean and Inspect 3552
Assemble 3554
Install 3557
Header Hose Procedures 3558
Remove 3558
Installation 3558
Adjustment 3566
Carriage Adjustments 3566
Lift Chains Adjustment 3569
Mast Adjustments 3570
Load Roller, Adjust 3571
Mast Side Kicking, Adjust 3573
Hydraulic Quick Disconnect Hoses 3573
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3573
Lift Trucks Equipped With E-Hydraulic Controls 3573
Lift Trucks Equipped With Manual Hydraulic Controls 3574
Connecting Attachment Hydraulic Quick Disconnect Hoses 3574
Lift Trucks Equipped With E-Hydraulic Controls 3574
Lift Trucks Equipped With Manual Hydraulic Controls 3574
550108495-1300YRM1740-(06-2018)-US-EN 3577
General 3581
Serial Number 3581
Hydraulic Gear Pump 3581
Remove 3581
Install 3581
Housing Fittings Replacement 3582
Remove 3582
Install 3584
Charge Pump Repair 3584
Torque Converter Replacement 3587
Remove 3587
Clean and Inspect 3587
Install 3587
Stator Support Assembly Repair 3588
Remove 3588
Disassemble 3595
Clean 3596
Inspect 3596
Assemble 3597
Install 3597
Clutch Packs Repair 3599
Remove 3599
Disassemble 3601
Housings 3601
Clutch Packs 3604
Clean 3615
Inspect 3616
Assemble 3616
Clutch Packs 3616
Housings 3630
Install 3632
Drive Chains and Sprockets 3635
Remove 3635
Clean 3637
Inspect 3638
Install 3638
Proportional and Enable Solenoid Valves 3638
Proportional Valves 3638
Remove 3638
Disassemble 3640
Clean and Inspect 3641
Assemble 3641
Install 3641
Enable Solenoid Valve 3641
Remove 3641
Disassemble 3642
Clean and Inspect 3642
Assemble 3642
Install 3642
Pedal Repair Foot Directional Control 3643
Remove and Disassemble 3643
Clean and Inspect 3646
Assemble and Install 3647
550108498-1800YRM1743-(06-2018)-US-EN 3651
General 3655
Dry Brake System 3655
Wet Brake System 3655
Service Brakes Repair (Dry Brake) 3655
Remove and Disassemble 3656
Clean 3663
Inspect 3664
Assemble and Install 3664
Adjust 3672
Inching Overlap Adjustment 3672
Parking Brake Repair 3673
Remove and Disassemble 3673
Dry Brake System 3673
Wet Brake System 3675
Assemble and Install 3677
Dry Brake System 3677
Wet Brake System 3677
Adjust 3677
Master Cylinder Repair 3678
Remove (Dry Brake) 3678
Disassemble (Dry Brake) 3679
Clean and Inspect (Dry Brake) 3681
Assemble (Dry Brake) 3681
Bench Bleed Master Cylinder (Dry Brake) 3681
Install and Adjust (Dry Brake) 3681
Remove (Wet Brake) 3682
Disassemble (Wet Brake) 3683
Clean and Inspect (Wet Brake) 3684
Assemble (Wet Brake) 3685
Install and Adjust (Wet Brake) 3685
Service Brakes Adjustment (Dry Brake) 3686
Brake System Air Removal 3686
Using Pressure Bleed System 3686
Using Brake Pedal Pressure 3686
Brake Pedal Adjustment 3687
Free Pedal Adjustment 3688
Torque Specifications 3690
550108499-1900YRM1744-(06-2018)-US-EN 3693
General 3697
Hydraulic Gear Pump Assembly Repair 3698
Remove 3698
Disassemble 3702
Clean 3704
Inspect 3704
Assemble 3704
Install 3704
Quick-Lok™ Hydraulic Hose 3706
Hydraulic Gear Pump Specifications 3707
Variable Displacement Pump Repair 3709
Remove 3709
Disassemble 3714
Clean 3716
Inspect 3716
Assemble 3716
Install 3716
Variable Displacement Pump Checks and Adjustments 3719
Margin Pressure Check 3719
Flow Compensator Adjustment 3720
Pressure Compensator Adjustment 3720
Variable Displacement Pump Specifications 3721
Torque Specifications 3721
Hydraulic Gear Pump 3722
Variable Displacement Pump 3722
550108500-2000YRM1745-(06-2018)-US-EN 3725
General 3729
Electro-Hydraulic Main Control Valve 3729
Description 3729
Remove 3732
Electro-Hydraulic Control Valve Sections 3735
General 3735
Outlet Control Valve Section 3735
Remove 3735
Disassemble 3735
Clean 3737
Inspect 3737
Assemble 3737
Install 3738
Auxiliary Control Valve Sections 3738
Remove 3738
Disassemble 3740
Clean 3741
Inspect 3741
Assemble 3741
Install 3741
Tilt Control Valve Section 3742
Remove 3742
Disassemble 3742
Clean 3743
Inspect 3743
Assemble 3744
Install 3744
Lift/Lower Control Valve Section 3744
Remove 3744
Disassemble 3744
Clean 3746
Inspect 3746
Assemble 3747
Install 3747
Install 3747
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 3750
Lift Pilot Pin 3750
Lower Pilot Pin 3752
Abnormal/Erroneous EHPV Adjustment 3754
Manual Main Control Valve 3754
Description 3754
Remove 3757
OPS Solenoid Assembly 3763
General 3763
Remove 3764
Clean and Inspect 3766
Install 3766
Manual Control Valve Sections 3767
General 3767
Outlet Control Valve Section 3767
Remove 3767
Disassemble 3767
Clean 3770
Inspect 3770
Assemble 3770
Install 3771
Auxiliary Control Valve Sections 3771
Remove 3771
Disassemble 3771
Clean 3774
Inspect 3774
Assemble 3774
Install 3774
Lift/Tilt Control Valve Section 3775
Remove 3775
Disassemble 3775
Clean 3780
Inspect 3780
Assemble 3780
Install 3781
Install 3781
Pressure Relief Valve Check and Adjustment 3785
Primary Relief Valve 3786
Secondary Relief Valve 3787
Steering Control Unit Repair 3791
Steering Control Unit, Remove 3791
Steering Control Unit, Disassemble 3793
Steering Control Unit, Clean 3795
Steering Control Unit, Inspect 3795
Steering Control Unit, Assemble 3795
Relief Valve, Disassemble 3796
Relief Valve, Clean 3796
Relief Valve, Inspect 3797
Relief Valve, Assemble 3797
Steering Control Unit, Install 3797
550108507-8000YRM1753-(03-2020)-UK-EN 3801
General Information About Diagrams and Schematics 3805
Symbol Definitions 3805
Diagrams Manual Applications 3806
Diagrams and Schematics 3808
550108507-8000YRM1753-(05-2022)-US-EN 3901
General Information About Diagrams and Schematics 3907
Symbol Definitions 3907
Diagrams Manual Applications 3908
Diagrams and Schematics 3910
550108889-0100YRM1754-(12-2018)-US-EN 4005
General 4009
Description 4009
Hood, Seat, and Side Covers Replacement 4010
Remove 4010
Install 4017
Steering Column 4021
Description 4021
Steering Column Repair 4022
Remove 4022
Disassemble 4023
Clean 4024
Inspect 4025
Assemble 4025
Install 4025
LPG Tank and Bracket Assembly 4025
Counterweight Replacement 4025
Remove 4026
Install 4028
Tow Pin 4028
Overhead Guard Replacement 4029
Remove and Install 4029
LED Tail, Backup, and Brake Lights, Replace 4031
Operator Restraint System Replacement 4031
Description 4031
Emergency Locking Retractor (ELR) 4031
Engine Replacement 4033
Remove 4034
Install 4039
Transmission Replacement 4041
Remove Transmission with Iron Housing 4041
Install Transmission with Iron Housing 4043
Remove Transmission with Aluminum Housing 4044
Install Transmission with Aluminum Housing 4048
Throttle Pedal and Cable Adjustment 4050
Throttle Pedal Stop Adjustment 4050
Yanmar Diesel Engine With Basic Power Shift Transmission 4051
Yanmar Diesel Engine With Electronic Throttle 4052
Exhaust System Repair 4052
Lift Trucks With Counterweight Exhaust System 4053
PSI Gas and LPG Engines 4053
Kubota LPG Engines 4053
Yanmar Diesel Engine 4053
Remove and Disassemble 4053
Inspect 4053
Assemble and Install 4053
Lift Trucks With Overhead Exhaust System 4055
PSI Gas and LPG Engines 4055
Kubota LPG Engines 4055
Yanmar Diesel Engine 4055
Remove and Disassemble 4055
Inspect 4055
Assemble and Install 4056
Kubota 2 4L Diesel Engine With Diesel Oxidation Catalyst (DOC) 4058
Remove 4060
Inspect 4063
Install 4063
Diesel Oxidation Catalyst 4065
Disassemble 4065
Assemble 4066
Heavy Duty Pre-Cleaner, Kubota 2 4L Diesel Engine 4066
Remove 4066
Clean 4066
Inspect 4067
Install 4067
Kubota 2 4L Stage V Diesel Engine With Diesel Particulate Filter (DPF) 4068
Remove 4069
Inspect 4072
Install 4072
Cooling System 4073
Description 4073
Hydraulic Filter Assembly Repair 4073
Remove 4073
Clean and Inspect 4074
Install 4074
Fuel and Hydraulic Tanks Repair 4074
Inspect 4075
Clean 4075
Steam Method of Cleaning 4075
Chemical Solution Method of Cleaning 4076
Additional Preparations for Repair 4076
Small Leaks, Repair 4076
Large Leaks, Repair 4076
Preparations for Use After Repair 4077
Safety Labels 4077
550108890-0600YRM1755-(04-2019)-UK-EN 4085
General 4091
Engine Removal and Installation 4094
Cylinder Head Assembly Repair 4094
Drive Train and Lubrication System 4133
Remove 4134
Disassemble 4134
Oil Pan 4134
Oil Pump (Front Cover) 4137
Clean and Inspect 4138
Front Case 4138
Oil Seal 4138
Counterbalance Shaft 4138
Oil Pump 4138
Assemble 4139
Counterbalance Shaft Bearings 4139
Oil Pump (Front Cover) 4140
Oil Pan 4142
Install 4142
Crankshaft and Cylinder Block Repair 4143
Remove Major Attaching Components 4143
Crankshaft and Cylinder Block 4143
Remove 4143
Clean and Inspect 4144
Boring Cylinder 4145
Install 4146
Piston and Connecting Rod 4148
Remove 4148
Disassemble 4149
Clean and Inspect 4150
Assemble 4151
Install 4153
Piston 4153
Rod Bearing 4154
Install Major Attaching Components 4155
Fuel System Repair 4155
Cooling System Repair 4155
Electrical Equipment Repair 4156
Flywheel and Flywheel Housing 4156
Flywheel 4156
Remove 4156
Install 4157
Flywheel Housing 4158
Remove 4158
Install 4158
Engine Specifications 4158
Engine Data 4158
Engine Tuning 4160
Cylinder Head 4160
Intake/Exhaust Valve and Guide 4160
Valve Spring 4161
Gear Train and Camshaft 4161
Camshaft 4161
Idle Gear Shaft and Bushing 4161
Cylinder Block 4161
Crankshaft 4161
Piston 4162
Piston Ring 4162
Connecting Rod 4162
Oil Pump 4162
Engine Oil Pressure 4162
Drive Gear Clearance 4162
Driven Gear Clearance 4163
Torque Specifications 4163
Special Tools 4164
550108890-0600YRM1755-(08-2023)-US-EN 4171
General 4179
Engine Removal and Installation 4183
Cylinder Head Assembly Repair 4184
Drive Train and Lubrication System 4225
Remove 4225
Disassemble 4225
Oil Pan 4225
Oil Pump (Front Cover) 4228
Clean and Inspect 4229
Front Case 4229
Oil Seal 4229
Counterbalance Shaft 4229
Oil Pump 4229
Assemble 4230
Counterbalance Shaft Bearings 4230
Oil Pump (Front Cover) 4231
Oil Pan 4233
Install 4233
Crankshaft and Cylinder Block Repair 4235
Remove Major Attaching Components 4235
Crankshaft and Cylinder Block 4235
Remove 4235
Clean and Inspect 4236
Boring Cylinder 4237
Install 4238
Piston and Connecting Rod 4240
Remove 4240
Disassemble 4241
Clean and Inspect 4241
Assemble 4242
Install 4244
Piston 4244
Rod Bearing 4245
Install Major Attaching Components 4246
Fuel System Repair 4247
Cooling System Repair 4248
Electrical Equipment Repair 4249
Flywheel and Flywheel Housing 4250
Flywheel 4250
Remove 4250
Install 4251
Flywheel Housing 4251
Remove 4251
Install 4251
POWER TAKE OFF (PTO), REMOVE AND INSTALL 4252
REMOVE COVER 4252
INSTALL COVER 4252
Engine Specifications 4254
Engine Data 4254
Engine Tuning 4255
Cylinder Head 4256
Intake/Exhaust Valve and Guide 4256
Valve Spring 4256
Gear Train and Camshaft 4257
Camshaft 4257
Idle Gear Shaft and Bushing 4257
Cylinder Block 4257
Crankshaft 4257
Piston 4257
Piston Ring 4258
Connecting Rod 4258
Oil Pump 4258
Engine Oil Pressure 4258
Drive Gear Clearance 4258
Driven Gear Clearance 4258
Torque Specifications 4259
Special Tools 4261
550108891-0700YRM1756-(06-2019)-US-EN 4265
General 4269
Cooling System Checks 4269
Exhaust Leaks Into Cooling System 4269
Water Flow Restrictions in Radiator 4269
Radiator Hoses 4269
Water Pump 4269
Flushing the Cooling System 4270
Cooling System, Clean 4270
Radiator Replacement 4271
Radiator, Remove 4271
Radiator, Install 4282
Fan Assembly Replacement 4283
Fan Removal 4283
Inspect 4287
Fan Installation 4288
550108892-0900YRM1757-(06-2018)-US-EN 4291
General 4297
Intake-Air System 4298
Intake-Air System Manifold Vacuum Check 4298
Throttle Body 4298
Remove 4299
Install 4300
Intake Manifold 4300
LPG Tank and Bracket Replacement Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (C910) and GLP20-35VX (GLP040-070VX) (D875) 4300
Remove LPG Tank 4300
Install LPG Tank 4303
Remove LPG Bracket 4303
Install LPG Bracket 4306
Remove LPG Tank Bracket Alignment Pin 4306
Install LPG Tank Bracket Alignment Pin 4308
LPG Tank and Bracket Replacement Lift Truck Models GLC050LX, GLC050LX2 (B967) and GLP20-25LX (GLP050LX) (B974) 4309
Remove LPG Tank 4309
LPG Tank Install 4311
Remove LPG Bracket 4311
Install LPG Bracket 4311
LPG Fuel Filter Unit Repair Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (C910) and GLP20-35VX (GLP040-070VX) (D875) 4312
Fuel Filter Element 4312
Remove 4312
Clean/Inspect 4312
Install 4313
Fuel Filter Housing 4313
Remove 4313
Disassemble 4314
Assemble 4315
Install 4315
LPG Fuel Filter Unit Repair Lift Truck Models GLC050LX, GLC050LX2 (B967) and GLP/GDP20-25LX (GLP/GDP050LX) (B974) 4316
Fuel Filter Element 4316
Remove 4316
Clean/Inspect 4317
Install 4317
Fuel Filter Housing 4317
Remove 4317
Disassemble 4317
Assemble 4318
Install 4318
Electronic Throttle Body Repair 4318
Remove 4319
Install 4320
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 4321
Remove 4322
Install 4324
Gasoline Fuel System 4325
Before Repair Procedure 4326
Fuel Line Safety Procedure 4326
After Repair Procedure 4328
Fuel Hose, Install 4328
Fuel Leakage Check 4328
Fuel Line Pressure Check 4329
Fuel Injectors 4329
Remove 4329
Install 4330
Pressure Regulator 4330
Remove 4330
Install 4331
Control System 4331
Engine Control Module (ECM) 4331
Remove 4331
Install 4333
Fuel Level Sensor 4333
Remove 4333
Install 4333
Low LPG Pressure Switch 4334
Remove 4334
Install 4334
LPG Low Level Sensor 4334
Remove 4335
Install 4335
LPG Converter 4336
LPG Lock-Off Valve 4341
Remove 4341
Install 4342
Exhaust System 4344
Counterweight Exhaust System 4344
Remove and Disassemble 4344
Inspect 4345
Assemble and Install 4346
Overhead Exhaust System 4346
Remove and Disassemble 4346
Inspect 4348
Assemble and Install 4348
Exhaust Manifold 4348
Positive Crankcase Ventilation (PCV) Valve 4348
Remove 4348
Inspect 4348
Install 4349
Oxygen Sensor 4349
Remove 4349
Install 4350
LPG Fuel Testing 4350
General 4350
Available Fuel Tests 4351
Composition Test (ASTM D-2163) 4351
Ammonia Test (ASTM D-4490) 4351
Basic Nitrogen Test (ASTM UOP269-90) 4351
Residues Test (ASTM D-2158) 4351
Vapor Pressure Test (ASTM D-2598) 4351
Sulfur Compounds Test (ASTM D-5623) 4351
Methanol Test (ASTM D-4864) 4351
Copper Corrosion (ASTM D-1838) 4351
Where To Send LPG Fuel Samples For Testing 4351
Technical Data 4352
550108893-1400YRM1758-(02-2018)-US-EN 4355
General 4359
Drive Axle Repair 4359
Remove and Disassemble 4359
Clean and Inspect 4362
Assemble and Install 4362
Differential Repair 4365
Remove 4365
Disassemble 4376
Clean and Inspect 4381
Install 4390
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 4390
Ring Gear Backlash, Adjust 4402
Ring Gear, Runout Check 4404
Gear Set, Tooth Contact Pattern Check 4404
Torque Specifications 4407
550108894-1600YRM1759-(12-2014)-US-EN 4411
550108895-2200YRM1760-(01-2020)-US-EN 4435
General 4443
Display Switch Cluster 4444
Remove 4444
Install 4446
Direction Control and Turn Signal Levers 4446
Remove 4446
Install 4447
Key Switch 4448
Remove 4448
Install 4448
Display Switch Cluster Panel Bezel and Overlay 4449
Remove 4449
Install 4449
Steering Column Repair 4449
Remove 4449
Disassemble 4451
Assemble 4451
Install 4452
Sensors and Switches 4452
General 4452
Dash and Kick Panel, Remove and Install 4452
Remove 4452
Install 4453
Accelerator Pedal Position Sensor 4453
Remove 4453
Install 4455
Brake Fluid Level Switch 4456
Remove 4456
Install 4456
Service Brake Pedal Position Sensor 4457
Remove 4457
Install 4458
Parking Brake Sensor 4458
Remove 4458
Install 4459
Service Brake Pressure Sensor 4459
Remove 4459
Install 4459
Sensor MicroswitchFoot Directional Control 4460
Remove 4460
Install 4462
Low Coolant Level Sensor 4462
Remove 4462
Install 4464
Fuel Level Sensor, Gas and Diesel Engines Only 4464
Remove 4464
Install 4464
Seat Sensor (Operator Presence System) 4465
Non-Suspension and Semi-Suspension Seats 4465
Remove 4465
Install 4466
Full Suspension And Swivel Seats 4466
Remove 4466
Install 4467
Hood Shut Off Switch 4467
Remove 4467
Install 4468
Hydraulic Filter Pressure Switch 4468
Remove 4468
Install 4469
Transmission Speed Sensor 4469
Remove 4469
Install 4470
Transmission Pressure Sensors 4470
Remove 4470
Install 4470
Transmission Temperature Sensor 4470
Remove 4470
Install 4471
Return to Set Tilt (Tilt Angle) Sensor 4471
Remove 4471
Install 4471
Rear Horn Button Switch 4471
Remove 4471
Install 4472
Impact Sensor 4472
Remove 4472
Install 4473
Load Weight Sensor 4474
Remove 4474
Install 4474
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with PSI 2 4L Dual Fuel Engine 4475
Engine and Fuel Sensors and Switches, Kubota 2 5L LPG Engine 4475
Crankshaft Position Sensor 4475
Remove 4475
Install 4475
Camshaft Position Sensor 4476
Remove 4476
Install 4476
Engine Coolant Temperature (ECT) Sensor 4476
Remove 4476
Install 4476
Manifold Absolute Pressure (MAP) Sensor 4477
Remove 4477
Install 4477
Oil Pressure Sensor 4477
Remove 4477
Install 4477
Knock Sensor 4478
Remove 4478
Install 4478
Oxygen Sensors 4478
Air Flow Restriction Switch 4478
Remove 4478
Install 4479
Engine and Fuel Sensors and Switches, Yanmar Diesel Engine 4479
Air Filter Restriction Switch 4479
Remove 4479
Install 4479
Oil Pressure Sensor 4479
Remove 4479
Install 4479
Engine Speed Sensor 4479
Remove 4479
Install 4479
Engine Coolant Temperature (ECT) Sensor 4480
Remove 4480
Install 4480
Throttle Position Sensor (TPS) 4482
Remove 4482
Install 4483
Fuel/Water Separator Sensor 4483
Remove 4483
Install 4483
Glow Plug Relay 4484
Remove 4484
Install 4486
Engine and Fuel Sensors and Switches, Kubota 2 4L Diesel Engine 4486
Crankshaft Position Sensor 4486
Remove 4486
Install 4486
Camshaft Position Sensor 4486
Remove 4486
Install 4486
Engine Coolant Temperature (ECT) Sensor 4487
Remove 4487
Install 4487
Engine Oil Pressure Sensor 4487
Remove 4487
Install 4488
Intake Air Pressure (Boost) Sensor 4488
Remove 4488
Install 4489
Air Filter Restriction Switch 4489
Remove 4489
Install 4489
Mass Airflow Sensor 4489
Remove 4489
Install 4489
Glow Plugs 4490
Remove 4490
Inspect 4491
Install 4491
Engine and Fuel Sensors and Switches, Kubota 2 4L Stage V Diesel Engine 4492
Crankshaft Position Sensor 4492
Remove 4492
Install 4492
Camshaft Position Sensor 4492
Remove 4492
Install 4492
Engine Coolant Temperature (ECT) Sensor 4493
Remove 4493
Install 4493
Engine Oil Pressure Sensor 4493
Remove 4493
Install 4494
Differential Pressure Sensor 4494
Remove 4494
Install 4494
Diesel Particulate Filter (DPF) Sensors 4494
Remove 4494
Install 4494
Intake Air Pressure (Boost) Sensor 4494
Remove 4494
Install 4494
Air Filter Restriction Switch 4495
Remove 4495
Install 4495
Mass Airflow Sensor 4495
Remove 4495
Install 4495
Glow Plugs 4496
Remove 4496
Inspect 4496
Install 4497
Vehicle System Manager (VSM) 4497
General 4497
VSM Replacement 4497
Remove 4497
Install 4498
Programming a New VSM and/or Display Switch Cluster 4498
General 4498
Data Transferring 4499
New VSM 4499
New (Blank) Display Switch Cluster 4499
Used (Non-Blank) Display Switch Cluster 4499
PC Service Tool Software 4500
Power Distribution Module (PDM) and Component Parts 4501
Remove 4501
PDM as a Unit 4501
Install 4503
PDM as a Unit 4503
Remove and Install 4503
PDM Component Parts 4503
Battery 4503
Remove 4503
Install 4503
Lights 4504
Work Lights (Front and Rear) 4504
Halogen Bulb Lights 4504
Remove 4504
Install 4504
LED Lights 4504
Remove 4504
Install 4505
Strobe Light 4505
Remove 4505
Install 4505
LED Tail, Backup, and Brake Lights 4506
Remove 4506
Install 4506
Front Marker/Turn Signal Lights 4507
Replacing Whole Front Marker/Turn Signal Light Assembly 4507
Remove 4507
Install 4507
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 4508
Remove 4508
Install 4508
Electronic-Hydraulic Controls, Before January, 2020 4508
E-Hydraulic Controls – TEST 4508
Mini-Levers 4508
Full Stroke Test 4509
Function Returns to Neutral Test 4509
Push (Override) Button 4509
General 4510
Mini-levers, Remove and Install 4510
Armrest Assembly 4511
Remove 4511
Install 4514
Horn Button 4514
Remove 4514
Install 4514
Direction Control Switch 4514
Remove 4514
Install 4515
Push (Override) Buttons 4515
Remove 4515
Install 4516
Electronic-Hydraulic Controls, After January, 2020 4516
E-Hydraulic Controls – TEST 4517
Mini-Levers 4517
Full Stroke Test 4517
Function Returns to Neutral Test 4517
Push (Override) Button 4517
General 4518
Mini-levers, Remove and Install 4518
Armrest Assembly 4519
Remove 4519
Install 4522
Horn Button 4522
Remove 4522
Install 4522
Direction Control Switch 4522
Remove 4522
Install 4523
Push (Override) Button 4523
Remove 4523
Install 4524
Diesel Particulate Filter (DPF) Display 4524
Remove 4524
Clean and Inspect 4525
Install 4525
550108896-2200YRM1761-(04-2020)-US-EN 4527
General 4531
Ignition System 4531
Ignition Timing Adjustment 4531
Spark Plugs Check 4531
Coil Replacement 4531
Remove 4531
Inspect 4533
Install 4533
Starter Repair 4534
General 4534
Remove 4534
No-Load Test 4535
Magnetic Switch Test 4536
Pull-Out Test 4536
Holding Coil Test 4536
Return Test 4537
Pinion Movement Inspection 4537
Install 4537
Alternator Repair 4538
General 4538
Charging System Inspection 4539
Output Current Check 4539
No-Load Adjusted Voltage Check 4539
Remove 4540
Install 4540
Engine Sensors and Switches 4541
Oil Pressure Sensor 4541
Remove 4541
Install 4541
Air Filter Restriction Switch 4541
Remove 4541
Install 4541
Cam Angle Sensor 4542
Remove 4542
Install 4542
Crankshaft Position Sensor (CKP) 4542
Remove 4542
Install 4542
Temperature Manifold Absolute Pressure (TMAP) Sensor 4543
Remove 4543
Install 4544
Engine Coolant Temperature (ECT) Sensor 4544
Remove 4544
Install 4544
Battery Disconnect Switch 4544
Remove 4544
Install 4546
Electronic Control Module 4547
550108897-8000YRM1762-(01-2022)-US-EN 4549
General 4555
Serial Number Data 4555
How to Move Disabled Lift Truck 4556
How to Tow Lift Truck 4556
How to Put Lift Truck on Blocks 4557
How to Raise Drive Tires 4557
How to Raise Steering Tires 4557
How to Clean a Lift Truck 4559
Maintenance Schedule 4560
Recommended Lubricants 4575
Lubricant Specifications 4575
Maintenance Procedures Every 8 Hours or Daily 4579
How to Make Checks With Engine Stopped 4579
Tires and Wheels 4579
Safety Labels 4579
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4579
Operator Restraint System 4580
Emergency Locking Retractor (ELR) 4581
Adjust Seat – Full Suspension 4582
Adjust Seat – Internal Suspension 4584
Hood and Seat Latches 4584
Engine Compartment 4584
Paper Application 4584
Fuel, Oil, and Coolant Leaks, Check 4585
Hydraulic Hoses 4585
Coolant Hoses 4585
Steering Column Gas Cylinder 4585
Transmission 4585
Hydraulic System Oil 4586
Engine Oil 4586
Air Filter 4588
Forks 4589
Inspect 4589
Remove 4590
Install 4593
Adjust 4593
How to Make Checks With Engine Running 4593
Indicator Lights, Horn, Fuses, and Relays 4594
Service Brakes 4596
Brake Fluid Level 4596
Operation, Check 4597
Parking Brake 4597
Engine Oil Pressure 4597
Cooling System 4598
Steering System 4599
Control Levers and Pedals 4599
Lift System, Operate 4599
First Service After First 100 Hours of Operation 4600
Kubota Engine Oil and Oil Filter 4600
Kubota 2 5L LPG Engine 4600
Kubota 2 4L Diesel Engine 4600
PSI Engine Oil and Oil Filter 4601
Yanmar Engine Oil and Oil Filter 4601
Maintenance Procedures Every 250 Hours or 6 Months 4602
PSI 2 4L Engine Oil and Oil Filter Change 4602
Drain Oil from LPG Vaporizer Regulator (LPG Converter) – PSI Engine 4602
Cleaning Carbon Buildup From Intake Valves – PSI 2 4L LPG Engine 4604
Maintenance Procedures Every 500 Hours or 6 Months 4606
Kubota Engine Oil and Oil Filter 4606
Kubota 2 5L LPG Engine 4606
Kubota 2 4L Diesel Engine 4606
Yanmar Engine Oil and Oil Filter Change 4607
Cleaning Carbon Buildup From Intake Valves – Kubota 2 5L LPG Engine 4607
Hydraulic System Oil 4609
Hydraulic Tank Breather 4609
Inspect 4609
Battery 4610
Drive Belt 4610
Yanmar Diesel Engine 4610
Fan and Alternator Drive Belt 4610
Kubota 2 4L Diesel Engine 4611
Fan and Alternator Drive Belt 4611
Kubota 2 5L LPG Engine 4612
Fan and Alternator Drive Belt 4612
Clean Debris From Radiator Core 4612
Transmission Oil Level 4613
Wet Brake Planetary Housing Oil Level Check 4614
Forks, Inspect 4616
Mast Lubrication 4618
Header Hose Checks 4621
Lift Chain Lubrication 4621
Tilt Cylinder Lubrication 4622
Master Brake Cylinder Rod End Pin Lubrication 4623
Manual Hydraulic Levers Lubrication 4624
Brake Fluid 4624
Tie Rod Lubrication (GP/GLP/GDP040-070VX) 4625
Differential and Drive Axle Oil (Dry Brake) 4625
Fuel/Water Separator, Kubota 2 4L Diesel Engine 4625
Drain 4626
Replace Filter 4626
Remove 4626
Install 4626
Priming the Fuel System (Kubota) 4627
Maintenance Procedures Every 1000 Hours or 6 Months 4628
Valve Clearance, Check and Adjust 4628
PCV Valve, Kubota Engine 4628
Drive Belt Check 4628
LPG Fuel Filter Element Replace, Kubota 2 5L Engine 4628
Remove 4628
Install 4629
LPG Fuel Filter Replace, PSI Engine 4629
Remove 4629
Clean/Inspect 4630
Install 4630
In-Line Fuel Filter Replacement, PSI 2 4L Engine 4631
Fuel Filter Replacement, Yanmar Engine 4631
Priming the Fuel System (Yanmar) 4633
Ignition System 4634
PSI 2 4L Engines 4634
Kubota 2 5L LPG Engine 4634
Lift Chains Wear Check 4634
Lift Chain Lubrication 4634
Integral Sideshift Carriage, Check Bearings 4635
Integral Sideshift Carriage, Check Lower Mounting Hooks 4635
Steering Axle 4636
Control Levers and Pedals 4636
Maintenance Procedures Every 1500 Hours 4637
Separator Element Replacement, Kubota 2 4L Diesel Engine 4637
Remove 4637
Install 4637
Maintenance Procedures Every 2000 Hours or 1 Year 4638
Hydraulic System 4638
Hydraulic Filter, Replace 4638
Hydraulic Tank Breather, Replace 4639
Air Filter 4639
Ignition System 4642
Kubota 2 5L LPG Engine 4642
PCV Valve 4642
Kubota 2 5L LPG Engine 4642
Oxygen Sensor 4642
Fuel Injector, Yanmar Engines 4643
Fuel Injector, Kubota 2 4L Diesel Engine 4643
Forks, Inspect 4643
Integral Sideshift Carriage 4644
Bearings, Replace 4644
Transmission Oil and Filter (Dry Brake), Replace 4644
Iron Transmission Housing 4644
Aluminum Transmission Housing 4645
Remove 4645
Clean and Inspect 4646
Install 4646
Transmission Oil Change, Wet Brake Drive Axle 4647
Iron Transmission Housing 4647
Aluminum Transmission Housing 4648
Wet Brake Axle Center Section and Planetary Housing, Oil Change 4652
Brake Fluid (Master Cylinder), Change 4654
Brake Fluid (Dry Brake), Remove 4656
Steer Axle Wheel Bearings Lubrication 4656
Service Brakes (Dry Brake) 4656
Differential (Dry Brake) 4657
Maintenance Procedures Every 4000 Hours or 2 Years 4658
Hydraulic Oil, Replace 4658
Cooling System 4659
Maintenance Procedures Every 6000 Hours 4661
Timing Belt Change, PSI Engine 4661
Diesel Particulate Filter (DPF), Kubota Diesel Engine 4661
Remove 4661
Install 4665
Safety Procedures When Working Near Mast 4666
Hood Latch Check 4669
Lift Chain Adjustments 4670
Jump-Starting the Lift Truck 4672
Jump-Starting Using a Battery Charger 4672
Jump-Starting a Lift Truck Using Another Lift Truck 4672
Welding Repairs 4673
Wheel and Tire Replacement 4674
General 4674
Solid Rubber Tire, Change (GC/GLC Series) 4674
Remove and Install Tire on Wheel 4674
Pneumatic Tire With Tube, Repair 4675
Remove Wheels From Lift Truck 4675
Remove Tire From Wheel 4676
Install Wheel in Tire 4678
Install Tire on Two-Piece Wheel 4680
Add Air to Pneumatic Tires With Tube 4681
Install the Wheels 4681
Dual Drive Wheels, Install 4682
Pneumatic Tubeless Tire, Repair 4682
Remove Wheels From Lift Truck 4682
Add Air to Pneumatic Tubeless Tire 4688
Wheels, Install 4688
Solid Rubber Tires on Pneumatic Wheels, Change 4688
Overhead Guard Changes 4692
Adhesives and Sealants 4693
550108898-8000YRM1763-(06-2022)-US-EN 4695
Lift Truck Lifting Capacity 4701
Counterweight Weights 4701
Tire Sizes 4701
Capacities 4702
Recommended Lubricants 4708
Lubricant Specifications 4708
Electrical System 4714
Transmission Oil Pressures 4716
Hydraulic System Relief Pressures 4718
Steering System 4719
Stall Speeds (in RPM ±100 rpm) 4720
PSI 2 4L 4720
Kubota 2 5L 4720
Yanmar 2 6L 4720
Yanmar 3 0L 4720
Yanmar 3 3L 4720
Kubota 2 4L 4720
Mast Speeds 4721
Tilt Angles 4735
Front End Equipment – Mast Creep 4736
Mast Creep 4736
Engine Specifications 4737
Diesel Fuel Cleanliness Levels 4740
Torque Specifications 4741
Frame 4741
Mast 4741
Steering System, Cushioned Tire Trucks 4741
Steering System, Pneumatic Tire Trucks 4741
Drive Axle (Dry Brake) 4741
Drive Axle (Wet Brake) 4742
Transmission – Iron Housing 4742
Transmission – Aluminum Housing 4743
Engine – PSI 2 4L Dual Fuel 4743
Engine – Yanmar 2 6L, 3 0L, and 3 3L Diesel 4744
Engine – Kubota 2 5L LPG 4745
Kubota 2 4L Diesel 4746
550108898-8000YRM1763-(08-2019)-UK-EN 4749
Lift Truck Lifting Capacity 4753
Counterweight Weights 4753
Tire Sizes 4754
Capacities 4754
Recommended Lubricants 4760
Lubricant Specifications 4760
Electrical System 4763
Transmission Oil Pressures 4765
Hydraulic System Relief Pressures 4766
Steering System 4767
Stall Speeds (in RPM ±100 rpm) 4768
PSI 2 4L 4768
Kubota 2 5L 4768
Yanmar 2 6L 4768
Yanmar 3 0L 4768
Yanmar 3 3L 4769
Kubota 2 4L 4769
Mast Speeds 4770
Tilt Angles 4784
Front End Equipment – Mast Creep 4785
Mast Creep 4785
Engine Specifications 4786
Diesel Fuel Cleanliness Levels 4789
Torque Specifications 4789
Frame 4789
Mast 4789
Steering System, Cushioned Tire Trucks 4789
Steering System, Pneumatic Tire Trucks 4789
Drive Axle (Dry Brake) 4790
Drive Axle (Wet Brake) 4790
Transmission – Iron Housing 4791
Transmission – Aluminum Housing 4791
Engine – PSI 2 4L Dual Fuel 4791
Engine – Yanmar 2 6L, 3 0L, and 3 3L Diesel 4793
Engine – Kubota 2 5L LPG 4793
Kubota 2 4L Diesel 4794
550108939-8000YRM1762-(08-2019)-UK-EN 4797
General 4803
Serial Number Data 4803
How to Move Disabled Lift Truck 4803
How to Tow Lift Truck 4803
How to Put Lift Truck on Blocks 4804
How to Raise Drive Tires 4804
How to Raise Steering Tires 4805
How to Clean a Lift Truck 4805
Maintenance Schedule 4806
Recommended Lubricants 4825
Lubricant Specifications 4825
Maintenance Procedures Every 8 Hours or Daily 4828
How to Make Checks With Engine Stopped 4828
Tires and Wheels 4828
Safety Labels 4829
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4829
Operator Restraint System 4830
Emergency Locking Retractor (ELR) 4830
Adjust Seat – Full Suspension 4831
Adjust Seat – Air Suspension 4834
Adjust Seat – Internal Suspension 4835
Hood and Seat Latches 4835
Engine Compartment 4835
Paper Application 4835
Fuel, Oil, and Coolant Leaks, Check 4836
Hydraulic Hoses 4836
Coolant Hoses 4836
Steering Column Gas Cylinder 4836
Transmission 4837
Hydraulic System Oil 4837
Engine Oil 4837
Air Filter 4840
Forks 4841
Inspect 4841
Remove 4842
Install 4845
Adjust 4845
How to Make Checks With Engine Running 4846
Indicator Lights, Horn, Fuses, and Relays 4846
Service Brakes 4848
Brake Fluid Level 4848
Operation, Check 4849
Parking Brake 4849
Engine Oil Pressure 4849
Cooling System 4850
Steering System 4850
Control Levers and Pedals 4851
Lift System, Operate 4851
First Service After First 100 Hours of Operation 4851
Kubota Engine Oil and Oil Filter 4851
Kubota 2 5L LPG Engine 4851
Kubota 2 4L Diesel Engine 4851
PSI Engine Oil and Oil Filter 4853
Yanmar Engine Oil and Oil Filter 4853
Maintenance Procedures Every 500 Hours or 1 Year 4853
Hydraulic System Oil 4854
Hydraulic Tank Breather 4854
Inspect 4854
Battery 4854
Engine Oil and Oil Filter, Yanmar Engines 4855
Engine Oil and Oil Filter, Kubota Engines 4855
Kubota 2 5L LPG Engine 4855
Kubota 2 4L Diesel Engine 4855
Engine Oil and Oil Filter, PSI 2 4L Engine 4856
Drive Belt 4856
Yanmar Diesel Engine 4856
Fan and Alternator Drive Belt 4856
Kubota 2 5L LPG Engine 4857
Fan and Alternator Drive Belt 4857
Kubota 2 4L Diesel Engine 4858
Fan and Alternator Drive Belt 4858
Clean Debris From Radiator Core 4858
Transmission Oil Level 4859
Wet Brake Planetary Housing Oil Level Check 4860
Forks, Inspect 4862
Mast Lubrication 4863
Header Hose Checks 4867
Lift Chain Lubrication 4867
Tilt Cylinder Lubrication 4867
Master Brake Cylinder Rod End Pin Lubrication 4868
Manual Hydraulic Levers Lubrication 4869
Brake Fluid 4869
Tie Rod Lubrication 4870
Lift Truck Models GLP/GDP20-35VX 4870
Differential and Drive Axle Oil (Dry Brake) 4871
Drain Oil from LPG Vaporizer Regulator (LPG Converter) – PSI 2 4L LPG Engine 4872
Fuel/Water Separator, Kubota 2 4L Diesel Engine 4873
Drain 4873
Replace Filter 4874
Remove 4874
Install 4874
Priming the Fuel System (Kubota) 4875
Maintenance Procedures Every 1000 Hours or 1 Year 4875
Valve Clearance, Check and Adjust 4876
PCV Valve, Kubota Engine 4876
Drive Belt Check 4876
PSI 2 4L Engine 4876
LPG Fuel Filter Element Replacement, Kubota 2 5L Engine 4876
Remove 4876
Install 4876
LPG Fuel Filter Replacement, PSI 2 4L Engine 4877
Remove 4877
Clean/Inspect 4878
Install 4878
In-Line Fuel Filter Replacement, PSI 2 4L Engine 4878
Fuel Filter Replacement, Yanmar Engine 4879
Priming the Fuel System (Yanmar) 4880
Ignition System, PSI Engine 4881
PSI 2 4L Engines 4881
Kubotal 2 5L Engine 4881
Lift Chains Wear Check 4881
Lift Chain Lubrication 4882
Integral Sideshift Carriage, Check Bearings 4882
Integral Sideshift Carriage, Check Lower Mounting Hooks 4882
Steering Axle 4883
Control Levers and Pedals 4883
Maintenance Procedures Every 1500 Hours 4884
Separator Element Replacement, Kubota 2 4L Diesel Engine 4884
Remove 4884
Install 4884
Maintenance Procedures Every 2000 Hours or 1 Year 4885
Hydraulic System 4885
Hydraulic Filter, Replace 4885
Hydraulic Tank Breather, Replace 4886
Air Filter 4886
Ignition System 4889
Kubota 2 5L LPG Engine 4889
PCV Valve 4889
Kubota 2 5L LPG Engine 4889
Oxygen Sensor 4889
Fuel Injector, Yanmar Engines 4889
Fuel Injector, Kubota 2 4L Diesel Engine 4890
Forks, Inspect 4890
Integral Sideshift Carriage 4891
Bearings, Replace 4891
Transmission Oil and Filter (Dry Brake), Replace 4891
Iron Transmission Housing 4891
Aluminum Transmission Housing 4892
Remove 4892
Clean and Inspect 4894
Install 4894
Transmission Oil Change, Wet Brake Drive Axle 4894
Iron Transmission Housing 4894
Aluminum Transmission Housing 4895
Wet Brake Axle Center Section and Planetary Housing, Oil Change 4898
Brake Fluid (Master Cylinder), Change 4901
Brake Fluid (Dry Brake), Remove 4903
Steer Axle Wheel Bearings Lubrication 4903
Service Brakes (Dry Brake) 4903
Differential (Dry Brake) 4903
Maintenance Procedures Every 4000 Hours or 2 Years 4904
Hydraulic Oil, Replace 4904
Cooling System 4906
Maintenance Procedures Every 6000 Hours 4907
Timing Belt Change, PSI Engine 4907
Diesel Particulate Filter (DPF), Kubota Diesel Engine 4907
Remove 4907
Install 4911
Safety Procedures When Working Near Mast 4912
Hood Latch Check 4914
Lift Chain Adjustments 4915
Jump-Starting the Lift Truck 4917
Jump-Starting Using a Battery Charger 4917
Jump-Starting a Lift Truck Using Another Lift Truck 4917
Welding Repairs 4917
Wheel and Tire Replacement 4918
General 4918
Solid Rubber Tire, Change ( Series)GLC 4918
Remove and Install Tire on Wheel 4918
Pneumatic Tire With Tube, Repair 4919
Remove Wheels From Lift Truck 4919
Remove Tire From Wheel 4920
Install Wheel in Tire 4923
Install Tire on Two-Piece Wheel 4925
Add Air to Pneumatic Tires With Tube 4926
Install the Wheels 4926
Dual Drive Wheels, Install 4926
Pneumatic Tubeless Tire, Repair 4927
Remove Wheels From Lift Truck 4927
Add Air to Pneumatic Tubeless Tire 4933
Wheels, Install 4933
Solid Rubber Tires on Pneumatic Wheels, Change 4933
Snap-On-Tire, Change 4937
Easy Mounting Style Solid Rubber Tires on Pneumatic Wheels, Change 4939
Overhead Guard Changes 4945
Adhesives and Sealants 4945
550158688-2040YRM2075-(06-2017)-US-EN 4947
General 4951
Description 4951
Precautions 4951
Clamp Assembly Installation 4951
Hydraulic Hose Flush 4952
Clamp Installation (With Lifting Device) 4952
Clamp Installation (Without Lifting Device) 4954
Hose Connections 4954
Clamp Series 4954
Connecting The Hoses 4955
Operating Checks 4955
Clamping Force Test 4955
Troubleshooting 4957
General 4957
Hydraulic Schematics 4959
550158693-2040YRM2081-(09-2017)-US-EN 4963
General 4967
Description 4967
Precautions 4967
Rotator Assembly Installation 4968
Removing Rotator From Skid 4969
Rotator Attachment Installation 4970
Hydraulic Hose Flush And Connection 4972
Fork Installation 4973

S.V 06/24