Yale Forklift D809 (GLC030-035VX, GLC040SVX) Service Manual PDF

Description

Yale Forklift D809 (GLC030-035VX, GLC040SVX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift D809 (GLC030-035VX, GLC040SVX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 3972
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift D809 (GLC030-035VX, GLC040SVX) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524221866-9000YRM1112-(10-2020)-US-EN 43
SECTION 9010 Operational Diagnostic Procedures 59
Group 05 – Operational Checkout 61
SECTION 9020 Engine 79
Group 10 – Principles of Operation 89
Group 30 – Observed Symptoms 287
Group 40 – Tests and Adjustments 389
SECTION 9030 Electrical System 421
Group 03 – General Maintenance and Diagnostic Data 445
Group 10 – Principles of Operation 539
Group 20 – Diagnostic Trouble Codes 563
Group 30 – Observed Symptoms 1535
SECTION 9040 Drive Train 1591
Group 10 – Principles of Operation 1595
Group 30 – Observed Symptoms 1651
Group 40 – Tests and Adjustments 1701
SECTION 9050 Hydraulic Systems 1711
Group 10 – Principles of Operation 1715
Group 30 – Observed Symptoms 1773
Group 33 – Observed Symptoms-Gear Pump 1775
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1863
Group 40 – Tests and Adjustments 1907
Group 43 – Tests and Adjustments-Gear Pump 1909
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1933
SECTION 9060 Operators Station 1951
Group 10 – Principles of Operation 1953
SECTION 9070 Front End (Mast) and Chassis 1989
Group 10 – Principles of Operation 1991
Group 30 – Observed Symptoms 2013
SECTION 9080 Supplementary Data 2071
Group 50 – Abbreviations and Acronyms 2073
Group 60 – Special Tools List 2081
Group 70 – Fault Mode Indicator Reference 2091
Group 80 – Supplier Specification Data 2093
524223769-2200YRM1128-(01-2023)-US-EN 2097
Series Code / Model Designation Reference Table 2105
General 2107
Deutsch Crimping Tool 2108
How to Strip a Wire for Use With Deutsch Crimping Tool 2108
How to Crimp With the Deutsch Crimping Tool 2109
Calibration Test for the Deutsch Crimping Tool 2111
Deutsch Connectors 2113
DT, DTM, and DTP Series Connectors 2113
HD Series Connectors 2156
Metri-Pack Connectors 2178
Remove and Install 2178
Micro-Pack Connectors 2181
Weather-Pack Connectors 2182
AMPSEAL Crimping Tools 2184
AMP Hand Crimping Tool With Certi-Crimp 2184
Description 2184
Stripping Wire for Use with AMP Hand Crimping Tool 2185
Insulation Crimp Adjustment 2186
Maintenance and Inspection for AMP Hand Crimping Tool 2186
AMP Hand Crimping Tool 2186
Crimp Height Inspection 2186
How to use AMP Hand Crimping Tool 2187
AMP Pro-Crimper II Tool 2187
Description 2187
Remove and Install Die Set and Locator Assembly 2188
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2188
Contact Support Adjustment 2189
Crimp Height Adjustment 2190
Maintenance and Inspection Procedures 2190
PRO-CRIMPER II Tool 2190
Crimp Height Inspection 2190
How to Use AMP PRO-CRIMPER II Tool 2191
AMPSEAL Connector Assemblies 2192
Description for Plug Connector Assembly 2192
Seal Plug 2193
Contact Crimping 2193
Description for Plug Connector and Header Assembly 2198
Voltage Reading 2201
Seal Plug 2201
Contact Crimping 2201
AMP Superseal 1 5 Crimping Tools 2208
Mini Mic Receptacle and Tab Contacts 2208
Description 2208
Crimping Conditions and Measurements 2208
Insertion of Rubber Seal on Cable 2210
AMP Hand Application Tool 2215
Description 2215
Maintenance and Inspection 2215
Crimp Height Inspection 2215
Crimp Height Adjustment 2216
How to Use AMP Hand Application Tool 2216
AMP Pro-Crimper II Tool 2217
Description 2217
Remove and Install Die Set and Locator Assembly 2217
Adjustments 2218
Contact Support 2218
Crimp Height 2219
Inspections and Maintenance 2220
Crimp Height Inspection 2220
Visual Inspection 2220
Maintenance 2221
How to Use Pro-Crimper II Tool 2221
AMP Superseal 1 5 Connector Assemblies 2222
Description 2222
Repair and Maintenance 2229
Panel Mount Option 2229
AMP Fastin-Faston Hand Tools 2230
Description – AMP Double Action Hand Tool 2230
Maintenance and Inspection Procedures 2230
Daily Maintenance 2230
Periodic Tool Inspection 2231
Lubrication 2231
Visual Inspection 2231
Crimp Height Inspection 2231
Certi-Crimp Ratchet Inspection 2232
How to Use AMP Double Action Hand Tool 2233
Description – AMP Extraction Tool 2234
Maintenance and Inspection 2235
How to Use AMP Extraction Tool 2235
AMP Fastin-Faston Receptacles and Housings 2237
Description 2237
Wire Repair 2245
Wire Splicing Requirements 2245
Deutsch Jiffy Splice 2246
Twisted/Shielded Cable and Leads Repair 2252
Special Tools 2254
524223769-2200YRM1128-(07-2020)-US-EN 2263
Series Code / Model Designation Reference Table 2269
General 2272
Deutsch Crimping Tool 2272
How to Strip a Wire for Use With Deutsch Crimping Tool 2272
How to Crimp With the Deutsch Crimping Tool 2273
Calibration Test for the Deutsch Crimping Tool 2275
Deutsch Connectors 2277
DT, DTM, and DTP Series Connectors 2277
HD Series Connectors 2319
Metri-Pack Connectors 2342
Remove and Install 2342
Micro-Pack Connectors 2344
Weather-Pack Connectors 2345
AMPSEAL Crimping Tools 2347
AMP Hand Crimping Tool With Certi-Crimp 2347
Description 2347
Stripping Wire for Use with AMP Hand Crimping Tool 2347
Insulation Crimp Adjustment 2348
Maintenance and Inspection for AMP Hand Crimping Tool 2348
AMP Hand Crimping Tool 2348
Crimp Height Inspection 2348
How to use AMP Hand Crimping Tool 2349
AMP Pro-Crimper II Tool 2349
Description 2349
Remove and Install Die Set and Locator Assembly 2350
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2351
Contact Support Adjustment 2351
Crimp Height Adjustment 2352
Maintenance and Inspection Procedures 2352
PRO-CRIMPER II Tool 2352
Crimp Height Inspection 2352
How to Use AMP PRO-CRIMPER II Tool 2353
AMPSEAL Connector Assemblies 2354
Description for Plug Connector Assembly 2354
Seal Plug 2355
Contact Crimping 2355
Description for Plug Connector and Header Assembly 2360
Voltage Reading 2362
Seal Plug 2362
Contact Crimping 2362
AMP Superseal 1 5 Crimping Tools 2369
Mini Mic Receptacle and Tab Contacts 2369
Description 2369
Crimping Conditions and Measurements 2369
Insertion of Rubber Seal on Cable 2371
AMP Hand Application Tool 2376
Description 2376
Maintenance and Inspection 2376
Crimp Height Inspection 2376
Crimp Height Adjustment 2377
How to Use AMP Hand Application Tool 2377
AMP Pro-Crimper II Tool 2378
Description 2378
Remove and Install Die Set and Locator Assembly 2379
Adjustments 2379
Contact Support 2379
Crimp Height 2380
Inspections and Maintenance 2381
Crimp Height Inspection 2381
Visual Inspection 2381
Maintenance 2382
How to Use Pro-Crimper II Tool 2382
AMP Superseal 1 5 Connector Assemblies 2383
Description 2383
Repair and Maintenance 2390
Panel Mount Option 2390
AMP Fastin-Faston Hand Tools 2391
Description – AMP Double Action Hand Tool 2391
Maintenance and Inspection Procedures 2391
Daily Maintenance 2391
Periodic Tool Inspection 2392
Lubrication 2392
Visual Inspection 2392
Crimp Height Inspection 2392
Certi-Crimp Ratchet Inspection 2393
How to Use AMP Double Action Hand Tool 2394
Description – AMP Extraction Tool 2395
Maintenance and Inspection 2395
How to Use AMP Extraction Tool 2396
AMP Fastin-Faston Receptacles and Housings 2397
Description 2397
Wire Repair 2404
Wire Splicing Requirements 2404
Deutsch Jiffy Splice 2405
Twisted/Shielded Cable and Leads Repair 2410
Special Tools 2413
524223770-2200YRM1130-(03-2020)-US-EN 2421
General 2425
Description 2425
Dash Display Menu Access 2425
Menu Navigation 2426
Standard Display 2426
Main Menu 2426
Passwords Menu 2427
Password Administration 2427
Add Password 2427
Delete Password 2428
Edit Password 2428
Other Password Functions 2429
Operator Passwords – Enable/Disable 2429
Password Time-Out Delay 2429
Passwords – Number Wrong to Disable 2430
Lockout Reset Password 2430
View Password Log 2431
View Versions 2432
VSM Versions 2432
Dash Display Versions 2433
Engine Controller Version 2434
Transmission (Xmsn) Controller Version 2435
Truck Serial Number 2436
Diagnostics 2437
View Fault Log 2437
Set Travel and Braking 2438
Speed Limit 2438
Acceleration Rate 2439
Auto-Deceleration Rate 2439
Set Power Reversal Rate 2440
Set Inching/Brake Overlap 2441
Setup Display Menu 2442
Set Operator Language 2442
Set Units 2443
Set Time Format (12/24 Hour) 2443
Set Daylight Saving Time 2443
Set Time 2446
Set Date Format 2447
Set Date 2447
Setup Hydraulics 2448
Return to Set Tilt Delay/On/Off 2448
Setup General Items 2449
Light Shutdown Time-Out 2449
Impact Sensor – Enable/Disable 2450
Impact Sensor – Soft Impact Settings 2451
Impact Sensor – Hard Impact Settings 2452
Adjust Impact Sensor Settings 2452
Initial Adjustment of Soft and Hard Impact Settings 2454
Readjustment of Soft and Hard Impact Settings 2454
Impact Sensor – Impact Alarm/Shutdown Reset 2455
Impact Sensor – Alarm Time Duration and Deactivation 2456
Impact Sensor – View Impact Event Log 2457
Engine Mode Indicator 2458
Generation 1 (ECO-eLo ONLY) 2458
Generation 2 2459
Operator Checklist 2460
Operator Checklist Off-On Mode 2460
Edit Operator Checklist 2460
Set Operator Checklist Expiration 2461
View Checklist Log 2461
Clear Operator Checklist Log 2462
Clear Operator Checklist Fault 2462
Calibrations 2463
Set Tilt Stop Point 2463
Calibrate Loaded Weight 2463
524223770-2200YRM1130-(05-2021)-US-EN 2465
General 2469
Description 2469
Dash Display Menu Access 2469
Menu Navigation 2470
Standard Display 2470
Main Menu 2470
Passwords Menu 2471
Password Administration 2471
Add Password 2471
Delete Password 2471
Edit Password 2472
Other Password Functions 2473
Operator Passwords – Enable/Disable 2473
Password Time-Out Delay 2473
Passwords – Number Wrong to Disable 2473
Lockout Reset Password 2474
View Password Log 2474
View Versions 2475
VSM Versions 2475
Dash Display Versions 2476
Engine Controller Version 2477
Transmission (Xmsn) Controller Version 2478
Truck Serial Number 2479
Diagnostics 2480
View Fault Log 2480
Set Travel and Braking 2481
Speed Limit 2481
Acceleration Rate 2482
Auto-Deceleration Rate 2482
Set Power Reversal Rate 2483
Set Inching/Brake Overlap 2484
Setup Display Menu 2485
Set Operator Language 2485
Set Units 2486
Set Time Format (12/24 Hour) 2486
Set Daylight Saving Time 2487
Set Time 2490
Set Date Format 2490
Set Date 2491
Setup Hydraulics 2492
Return to Set Tilt Delay/On/Off 2492
Setup General Items 2493
Light Shutdown Time-Out 2493
Impact Sensor – Enable/Disable 2494
Impact Sensor – Soft Impact Settings 2495
Impact Sensor – Hard Impact Settings 2495
Adjust Impact Sensor Settings 2496
Initial Adjustment of Soft and Hard Impact Settings 2498
Readjustment of Soft and Hard Impact Settings 2498
Impact Sensor – Impact Alarm/Shutdown Reset 2499
Impact Sensor – Alarm Time Duration and Deactivation 2500
Impact Sensor – View Impact Event Log 2501
Engine Mode Indicator 2501
Generation 1 (ECO-eLo ONLY) 2501
Generation 2 2502
Operator Checklist 2503
Operator Checklist Off-On Mode 2503
Edit Operator Checklist 2503
Set Operator Checklist Expiration 2503
View Checklist Log 2504
Clear Operator Checklist Log 2505
Clear Operator Checklist Fault 2505
Calibrations 2506
Set Tilt Stop Point 2506
Calibrate Loaded Weight 2506
524223771-2200YRM1131-(03-2020)-US-EN 2509
Series Code / Model Designation Reference Table 2515
General 2517
Description 2517
Dash Display Menu Access 2517
Menu Navigation 2518
Main Menu 2518
Passwords 2519
Adding Passwords 2519
Hourmeters 2521
View Versions 2522
VSM Versions 2522
Dash Display Versions 2523
Engine Controller Version 2524
Transmission (Xmsn) Controller Version 2525
Truck Serial Number 2526
Truck Configuration 2527
Diagnostics 2528
Clear Fault Log 2528
View Fault Log 2529
No-Run Data Display 2530
Engine Accelerator and Throttle Data Display 2530
Engine Speeds and Governor Data Display 2531
Engine Fuel and Emissions Data Display 2532
Engine General Data Display 2534
XMSN/Brake Data Display 2535
Hydraulic Data Display 2538
General Truck Data Display 2540
Set Travel and Braking 2541
Speed Limit 2541
Acceleration Rate 2542
Auto-Deceleration Rate 2543
Set Power Reversal Rate 2543
Set Inching/Brake Overlap 2544
Setup Hydraulics 2544
Lift Maximum Speed 2545
Lower Maximum Speed 2545
Tilt Maximum Speed 2546
Auxiliary Function One, Direction A, Maximum Speed 2548
Auxiliary Function One, Direction B, Maximum Speed 2550
Auxiliary Function Two, Direction A, Maximum Speed 2550
Auxiliary Function Two, Direction B, Maximum Speed 2551
Auxiliary Function Three, Direction A, Maximum Speed 2552
Auxiliary Function Three, Direction B, Maximum Speed 2552
Lift/Lower Ramp Rate 2553
Hydraulic Auxiliary Ramp Rate 2553
Return to Set Tilt Delay/On/Off 2554
Hydraulic Input Device 2555
Auxiliary Solenoid 2555
Dual Function 2556
Setup Display 2557
Set Service Language 2557
Setup General Items 2557
Motion Alarm Activation Type 2558
Light Shutdown Time-Out 2559
Restore Default Settings 2559
Restore Engine Controller Default Calibration 2560
Impact Sensor – Enable/Disable 2560
Impact Sensor – Soft Impact Settings 2561
Impact Sensor – Hard Impact Settings 2562
Adjust Impact Sensor Settings 2563
Initial Adjustment of Soft and Hard Impact Settings 2565
Readjustment of Soft and Hard Impact Settings 2565
Impact Sensor – Impact Alarm/Shutdown Reset 2566
Impact Sensor – Alarm Time Duration and Deactivation 2567
Impact Sensor – View Impact Event Log 2568
Engine Mode Indicator 2568
Generation 1 (ECO-eLo ONLY) 2568
Generation 2 2569
Diesel Particulate Filter (DPF) Display 2570
General Description 2570
Passive Regeneration Only 2570
Regeneration Level 0 2570
Auto/Active Regeneration Inhibited 2571
Auto/Active Regeneration 2571
Regeneration Level 1 2571
Parked Regeneration Request 2572
Regeneration Level 2 2572
Warning Level 2572
Regeneration Level 3 2572
Service Level 2573
Regeneration Level 4 2573
Display, Diesel Particulate Filter (DPF), Revised 2573
Operator Interface 2573
Refer to Operator Manual 2573
CAN Communication Lost 2574
Passive Regeneration Only 2574
Regeneration Level 0 2574
Auto/Active Regeneration Inhibited 2574
Auto/Active Regeneration 2575
Regeneration Level 1 2575
Idle-up Auto/Active Regeneration 2575
Parked Regeneration Request 2575
Regeneration Level 2 2575
Warning Level 2577
Regeneration Level 3 2577
Service Level 2577
Regeneration Level 4 2577
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2577
Display, Diesel Particulate Filter (DPF), Stage V Engine 2577
Operator Interface 2578
Refer to Operator Manual 2578
CAN Communication Lost 2578
Passive Regeneration Only 2578
Regeneration Level 0 2578
Auto/Active Regeneration Inhibited 2579
Auto/Active Regeneration 2579
Regeneration Level 1 2579
Idle-up Auto/Active Regeneration 2580
Parked Regeneration Request 2580
Regeneration Level 2 2580
Warning Level 2581
Regeneration Level 3 2581
Service Level 2582
Regeneration Level 4 2582
Stage V Content 2582
Emissions System Malfunction 2582
Ash Load 2582
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2583
Operator Interface 2583
Refer to Operator Manual 2583
CAN Communication Lost 2584
Passive Regeneration Only 2584
Regeneration Level 0 2584
Auto/Active Regeneration Inhibited 2584
Auto/Active Regeneration 2585
Regeneration Level 1 2585
Idle-up Auto/Active Regeneration 2585
Parked Regeneration Request 2585
Regeneration Level 2 2585
Warning Level 2587
Regeneration Level 3 2587
Service Level 2587
Regeneration Level 4 2587
Calibrations 2588
Calibrate Transmission Valve 2590
Set Tilt Stop Point 2590
Calibrate Loaded Weight 2590
Calibrate Travel Speed Sensor 2591
Calibrate Mazda LP and Gas Accelerator Pedal 2591
524223771-2200YRM1131-(05-2021)-US-EN 2593
Series Code / Model Designation Reference Table 2599
General 2601
Description 2601
Dash Display Menu Access 2601
Menu Navigation 2602
Main Menu 2603
Passwords 2603
Adding Passwords 2603
Hourmeters 2605
View Versions 2606
VSM Versions 2606
Dash Display Versions 2607
Engine Controller Version 2608
Transmission (Xmsn) Controller Version 2609
Truck Serial Number 2610
Truck Configuration 2611
Diagnostics 2612
Clear Fault Log 2612
View Fault Log 2613
No-Run Data Display 2614
Engine Accelerator and Throttle Data Display 2615
Engine Speeds and Governor Data Display 2617
Engine Fuel and Emissions Data Display 2618
Engine General Data Display 2620
XMSN/Brake Data Display 2621
Hydraulic Data Display 2623
General Truck Data Display 2626
Set Travel and Braking 2628
Speed Limit 2628
Acceleration Rate 2629
Auto-Deceleration Rate 2629
Set Power Reversal Rate 2630
Set Inching/Brake Overlap 2630
Setup Hydraulics 2631
Lift Maximum Speed 2631
Lower Maximum Speed 2632
Tilt Maximum Speed 2632
Auxiliary Function One, Direction A, Maximum Speed 2634
Auxiliary Function One, Direction B, Maximum Speed 2637
Auxiliary Function Two, Direction A, Maximum Speed 2637
Auxiliary Function Two, Direction B, Maximum Speed 2638
Auxiliary Function Three, Direction A, Maximum Speed 2639
Auxiliary Function Three, Direction B, Maximum Speed 2639
Lift/Lower Ramp Rate 2640
Hydraulic Auxiliary Ramp Rate 2640
Return to Set Tilt Delay/On/Off 2641
Hydraulic Input Device 2642
Auxiliary Solenoid 2642
Dual Function 2643
Setup Display 2644
Set Service Language 2644
Setup General Items 2644
Motion Alarm Activation Type 2645
Light Shutdown Time-Out 2646
Restore Default Settings 2646
Restore Engine Controller Default Calibration 2647
Impact Sensor – Enable/Disable 2647
Impact Sensor – Soft Impact Settings 2648
Impact Sensor – Hard Impact Settings 2648
Adjust Impact Sensor Settings 2649
Initial Adjustment of Soft and Hard Impact Settings 2651
Readjustment of Soft and Hard Impact Settings 2651
Impact Sensor – Impact Alarm/Shutdown Reset 2652
Impact Sensor – Alarm Time Duration and Deactivation 2653
Impact Sensor – View Impact Event Log 2654
Engine Mode Indicator 2654
Generation 1 (ECO-eLo ONLY) 2654
Generation 2 2655
Diesel Particulate Filter (DPF) Display 2656
General Description 2656
Passive Regeneration Only 2656
Regeneration Level 0 2656
Auto/Active Regeneration Inhibited 2657
Auto/Active Regeneration 2657
Regeneration Level 1 2657
Parked Regeneration Request 2658
Regeneration Level 2 2658
Warning Level 2659
Regeneration Level 3 2659
Service Level 2659
Regeneration Level 4 2659
Display, Diesel Particulate Filter (DPF), Revised 2659
Operator Interface 2660
Refer to Operator Manual 2660
CAN Communication Lost 2660
Passive Regeneration Only 2660
Regeneration Level 0 2660
Auto/Active Regeneration Inhibited 2661
Auto/Active Regeneration 2661
Regeneration Level 1 2661
Idle-up Auto/Active Regeneration 2661
Parked Regeneration Request 2662
Regeneration Level 2 2662
Warning Level 2663
Regeneration Level 3 2663
Service Level 2663
Regeneration Level 4 2663
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2664
Display, Diesel Particulate Filter (DPF), Stage V Engine 2664
Operator Interface 2664
Refer to Operator Manual 2664
CAN Communication Lost 2665
Passive Regeneration Only 2665
Regeneration Level 0 2665
Auto/Active Regeneration Inhibited 2665
Auto/Active Regeneration 2666
Regeneration Level 1 2666
Idle-up Auto/Active Regeneration 2666
Parked Regeneration Request 2666
Regeneration Level 2 2666
Warning Level 2668
Regeneration Level 3 2668
Service Level 2668
Regeneration Level 4 2668
Stage V Content 2668
Emissions System Malfunction 2668
Ash Load 2669
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2670
Operator Interface 2670
Refer to Operator Manual 2670
CAN Communication Lost 2671
Passive Regeneration Only 2671
Regeneration Level 0 2671
Auto/Active Regeneration Inhibited 2671
Auto/Active Regeneration 2672
Regeneration Level 1 2672
Idle-up Auto/Active Regeneration 2672
Parked Regeneration Request 2672
Regeneration Level 2 2672
Warning Level 2674
Regeneration Level 3 2674
Service Level 2674
Regeneration Level 4 2674
Calibrations 2675
Calibrate Transmission Valve 2677
Set Tilt Stop Point 2677
Calibrate Loaded Weight 2678
Calibrate Travel Speed Sensor 2678
Calibrate Mazda LP and Gas Accelerator Pedal 2679
524223780-8000YRM1134-(03-2020)-US-EN 2681
Series Code / Model Designation Reference Table 2687
Description 2689
Proc_Cal_001: Service Password Entry 2691
When to Perform 2691
Why Perform 2691
How to Perform 2691
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2692
When to Perform 2692
Calibration Order 2692
Why Perform 2692
How to Perform 2693
Proc_Cal_003: Save and Exit 2694
When to Perform 2694
Why Perform 2694
How to Perform 2694
Proc_Cal_004: Lift Valve Output Threshold 2695
When to Perform 2695
Calibration Order 2695
Why Perform 2695
How to Perform 2696
Proc_Cal_005: Lower Valve Output Threshold 2698
When to Perform 2698
Calibration Order 2698
Why Perform 2698
How to Perform 2698
Proc_Cal_006: Tilt Back Valve Output Threshold 2701
When to Perform 2701
Calibration Order 2701
Why Perform 2701
How to Perform 2701
Proc_Cal_007: Tilt Forward Valve Output Threshold 2704
When to Perform 2704
Calibration Order 2704
Why Perform 2704
How to Perform 2704
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2707
When to Perform 2707
Calibration Order 2707
Why Perform 2707
How to Perform 2707
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2710
When to Perform 2710
Calibration Order 2710
Why Perform 2710
How to Perform 2710
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2713
When to Perform 2713
Calibration Order 2713
Why Perform 2713
How to Perform 2713
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2716
When to Perform 2716
Calibration Order 2716
Why Perform 2716
How to Perform 2716
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2719
When to Perform 2719
Calibration Order 2719
Why Perform 2719
How to Perform 2719
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2722
When to Perform 2722
Calibration Order 2722
Why Perform 2722
How to Perform 2722
Proc_Cal_014: Load Weight Zero Point 2726
When to Perform 2726
Calibration Order 2726
Why Perform 2726
How to Perform 2726
Proc_Cal_015: Loaded Weight Calibration 2728
When to Perform 2728
Calibration Order 2728
Why Perform 2728
How to Perform 2728
Proc_Cal_016: Transmission Valve Calibration 2731
Applicable System/Option 2731
When to Perform 2731
Calibration Order 2731
Why Perform 2731
How to Perform 2731
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2733
Applicable System/Option 2733
When to Perform 2733
Calibration Order 2733
Why Perform 2733
How to Perform 2733
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2735
Applicable System/Option 2735
When to Perform 2735
Calibration Order 2735
Why Perform 2735
How to Perform 2736
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2737
Required Tools 2737
When to Perform 2737
Calibration Order 2737
Why Perform 2738
How to Perform 2738
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2739
When to Perform 2739
Why Perform 2739
How to Perform 2739
Proc_Cal_026: Travel Speed Calibration 2741
When to Perform 2741
Calibration Order 2741
Why Perform 2741
How to Perform 2741
524223780-8000YRM1134-(05-2022)-US-EN 2745
Series Code / Model Designation Reference Table 2751
Description 2754
Proc_Cal_001: Service Password Entry 2756
When to Perform 2756
Why Perform 2756
How to Perform 2756
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2757
When to Perform 2757
Calibration Order 2757
Why Perform 2757
How to Perform 2757
Proc_Cal_003: Save and Exit 2759
When to Perform 2759
Why Perform 2759
How to Perform 2759
Proc_Cal_004: Lift Valve Output Threshold 2760
When to Perform 2760
Calibration Order 2760
Why Perform 2760
How to Perform 2760
Proc_Cal_005: Lower Valve Output Threshold 2763
When to Perform 2763
Calibration Order 2763
Why Perform 2763
How to Perform 2763
Proc_Cal_006: Tilt Back Valve Output Threshold 2766
When to Perform 2766
Calibration Order 2766
Why Perform 2766
How to Perform 2766
Proc_Cal_007: Tilt Forward Valve Output Threshold 2769
When to Perform 2769
Calibration Order 2769
Why Perform 2769
How to Perform 2769
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2772
When to Perform 2772
Calibration Order 2772
Why Perform 2772
How to Perform 2772
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2775
When to Perform 2775
Calibration Order 2775
Why Perform 2775
How to Perform 2775
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2778
When to Perform 2778
Calibration Order 2778
Why Perform 2778
How to Perform 2778
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2781
When to Perform 2781
Calibration Order 2781
Why Perform 2781
How to Perform 2781
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2784
When to Perform 2784
Calibration Order 2784
Why Perform 2784
How to Perform 2784
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2787
When to Perform 2787
Calibration Order 2787
Why Perform 2787
How to Perform 2787
Proc_Cal_014: Load Weight Zero Point 2790
When to Perform 2790
Calibration Order 2790
Why Perform 2790
How to Perform 2790
Proc_Cal_015: Loaded Weight Calibration 2792
When to Perform 2792
Calibration Order 2792
Why Perform 2792
How to Perform 2792
Proc_Cal_016: Transmission Valve Calibration 2795
Applicable System/Option 2795
When to Perform 2795
Calibration Order 2795
Why Perform 2795
How to Perform 2795
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2797
Applicable System/Option 2797
When to Perform 2797
Calibration Order 2797
Why Perform 2797
How to Perform 2797
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2800
Applicable System/Option 2800
When to Perform 2800
Calibration Order 2800
Why Perform 2800
How to Perform 2800
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2803
Required Tools 2803
When to Perform 2803
Calibration Order 2803
Why Perform 2803
How to Perform 2803
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2805
When to Perform 2805
Why Perform 2805
How to Perform 2805
Proc_Cal_026: Travel Speed Calibration 2807
When to Perform 2807
Calibration Order 2807
Why Perform 2807
How to Perform 2807
550073240-1900YRM1620-(01-2023)-US-EN 2811
Proper Flushing after Major Hydraulic Repairs 2817
Introduction 2817
The Phases of Wear 2817
Causes of Hydraulic System Failure 2817
Progression of Contaminant Caused Hydraulic System Failure 2818
Hydraulic System Flushing Techniques 2818
Double Oil and Filter Change 2818
Mechanical Cleaning 2819
Cleaning of Components 2819
How to Clean Tubes and Hoses 2819
Filter Caddy 2819
Start-Up Procedure for Cleaned System 2820
Contaminated Oil Coolers 2820
Additional Filter Caddy Functions 2821
How to Handle Different Fluids 2821
Water Removal Filters 2821
Fluid Conditioning and System Flushing Procedures 2822
Operation of the Filter Caddy 2822
Filter Caddy operation 2822
Fluid Conditioning Procedure 2822
Filter Caddy Start-Up 2823
System Flushing Procedure 2823
Component Cleaning Procedure 2824
Reservoir Cleaning Procedure 2824
Cylinder Cleaning Procedure 2824
Hose and Tube Cleaning Procedure 2824
Valve Cleaning Procedure 2825
Front-End Attachment Cleaning Procedure 2826
System Flushing Procedure 2826
Filter Caddy Start-Up 2827
System Start-Up and Flushing 2827
Reservoir Fluid Cleaning Times 2828
Dealing With Different Fluid Types 2829
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2829
Filter Caddy Maintenance 2829
Servicing the Strainer 2829
DC Motor 2829
Hydraulic Oil Sampling Method and Procedure 2830
Hydraulic Oil Sampling Method 2830
Objective 2830
General Guidelines 2830
Synopsis 2831
Hydraulic Oil Analysis Report Guidelines 2832
Sampling Conditions 2832
Equipment 2832
Sampling Procedure 2833
Hydraulic Oil Sampling 2833
Sample Labeling 2833
Results Documentation 2833
550073240-1900YRM1620-(03-2020)-US-EN 2835
Proper Flushing after Major Hydraulic Repairs 2839
Introduction 2839
The Phases of Wear 2839
Causes of Hydraulic System Failure 2839
Progression of Contaminant Caused Hydraulic System Failure 2840
Hydraulic System Flushing Techniques 2840
Double Oil and Filter Change 2840
Mechanical Cleaning 2841
Cleaning of Components 2841
How to Clean Tubes and Hoses 2841
Filter Caddy 2841
Start-Up Procedure for Cleaned System 2842
Contaminated Oil Coolers 2842
Additional Filter Caddy Functions 2842
How to Handle Different Fluids 2842
Water Removal Filters 2843
Fluid Conditioning and System Flushing Procedures 2843
Operation of the Filter Caddy 2843
Filter Caddy operation 2843
Fluid Conditioning Procedure 2844
Filter Caddy Start-Up 2844
System Flushing Procedure 2845
Component Cleaning Procedure 2845
Reservoir Cleaning Procedure 2845
Cylinder Cleaning Procedure 2845
Hose and Tube Cleaning Procedure 2846
Valve Cleaning Procedure 2846
Front-End Attachment Cleaning Procedure 2847
System Flushing Procedure 2847
Filter Caddy Start-Up 2848
System Start-Up and Flushing 2848
Reservoir Fluid Cleaning Times 2849
Dealing With Different Fluid Types 2849
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2849
Filter Caddy Maintenance 2850
Servicing the Strainer 2850
DC Motor 2850
Hydraulic Oil Sampling Method and Procedure 2850
Hydraulic Oil Sampling Method 2850
Objective 2850
General Guidelines 2850
Synopsis 2851
Hydraulic Oil Analysis Report Guidelines 2852
Sampling Conditions 2853
Equipment 2853
Sampling Procedure 2853
Hydraulic Oil Sampling 2853
Sample Labeling 2854
Results Documentation 2854
550108490-0100YRM1735-(04-2015)-US-EN 2857
550108491-0600YRM1736-(10-2018)-US-EN 2915
General 2921
Engine Identification 2921
Major Engine Component Identification 2921
Location of Labels 2922
Engine Removal and Installation 2923
Cylinder Head Assembly Repair 2923
Drive Train and Lubrication System 2955
Remove 2956
Disassemble 2956
Oil Pan 2956
Oil Pump (Front Cover) 2958
Clean and Inspect 2959
Front Case 2959
Oil Seal 2959
Counterbalance Shaft 2959
Oil Pump 2959
Assemble 2960
Counterbalance Shaft Bearings 2960
Oil Pump (Front Cover) 2961
Oil Pan 2963
Install 2963
Crankshaft and Cylinder Block Repair 2963
Remove Major Attaching Components 2963
Crankshaft and Cylinder Block 2964
Remove 2964
Clean and Inspect 2965
Boring Cylinder 2966
Install 2967
Piston and Connecting Rod 2969
Remove 2969
Disassemble 2970
Clean and Inspect 2970
Assemble 2971
Install 2973
Piston 2973
Rod Bearing 2974
Install Major Attaching Components 2975
Fuel System Repair 2975
Cooling System Repair 2975
Electrical Equipment Repair 2975
Flywheel and Flywheel Housing 2975
Flywheel 2975
Remove 2975
Install 2976
Flywheel Housing 2976
Remove 2976
Install 2976
Engine Specifications 2976
Engine Data 2976
Engine Tuning 2977
Cylinder Head 2978
Intake/Exhaust Valve and Guide 2978
Valve Spring 2978
Gear Train and Camshaft 2978
Camshaft 2978
Idle Gear Shaft and Bushing 2979
Cylinder Block 2979
Crankshaft 2979
Piston 2979
Piston Ring 2980
Connecting Rod 2980
Oil Pump 2980
Engine Oil Pressure 2980
Drive Gear Clearance 2980
Driven Gear Clearance 2980
Torque Specifications 2981
Special Tools 2982
550108492-0700YRM1737-(12-2014)-US-EN 2989
550108494-0900YRM1739-(04-2018)-US-EN 3003
General 3007
LPG Tank and Bracket Replacement 3009
Remove LPG Tank 3009
Install LPG Tank 3012
Remove LPG Tank Bracket 3013
Install LPG Tank Bracket 3015
Remove LPG Tank Bracket Alignment Pin 3015
Install LPG Tank Bracket Alignment Pin 3017
LPG Fuel Filter Unit Repair 3018
LPG Fuel Filter Element 3018
Remove/Disassemble 3018
Clean/Inspect 3019
Assemble/Install 3019
Fuel Filter Housing 3020
Remove 3020
Disassemble 3022
Clean and Inspect 3023
Assemble 3023
Install 3024
Electronic Throttle Body Repair 3025
Remove 3025
Install 3026
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 3027
Remove 3028
Install 3029
Control System 3030
Engine Control Module (ECM) 3030
Remove 3030
Install 3030
Low LPG Pressure Switch 3031
Remove 3031
Install 3032
LPG Low Level Sensor 3033
Remove 3033
Install 3033
LPG Converter 3034
LPG Lock-Off Valve 3038
Remove 3038
Install 3039
Exhaust System 3040
Counterweight Exhaust System 3040
Lift Truck Models GLC030-035VX, GLC040SVX (D809) and GLP16-18VX, GLP20SVX (GLP030-035VX, GLP040SVX) (D810) 3042
Remove and Disassemble 3042
Inspect 3043
Assemble and Install 3044
Overhead Exhaust System 3044
Overhead Exhaust System With Catalytic Converter, Lift Truck Models GLP16-18VX, GLP20SVX (GLP030-035VX, GLP040SVX) (D810) 3046
Remove and Disassemble 3046
Inspect 3046
Assemble and Install 3046
Overhead Exhaust System Without Catalytic Converter, Lift Truck Models GLP16-18VX, GLP20SVX (D810) 3048
Remove and Disassemble 3048
Inspect 3048
Assemble and Install 3048
Exhaust Manifold 3050
Remove 3050
Clean and Inspect 3050
Install 3050
Oxygen (HEGO) Sensor 3051
Remove 3051
Install 3052
PCV Valve 3052
LPG Fuel Testing 3053
General 3053
Available Fuel Tests 3053
Composition Test (ASTM D-2163) 3053
Ammonia Test (ASTM D-4490) 3053
Basic Nitrogen Test (ASTM UOP269-90) 3053
Residues Test (ASTM D-2158) 3053
Vapor Pressure Test (ASTM D-2598) 3053
Sulfur Compounds Test (ASTM D-5623) 3053
Methanol Test (ASTM D-4864) 3054
Copper Corrosion (ASTM D-1838) 3054
Where To Send LPG Fuel Samples For Testing 3054
550108495-1300YRM1740-(06-2018)-US-EN 3057
General 3061
Serial Number 3061
Hydraulic Gear Pump 3061
Remove 3061
Install 3061
Housing Fittings Replacement 3062
Remove 3062
Install 3064
Charge Pump Repair 3064
Torque Converter Replacement 3067
Remove 3067
Clean and Inspect 3067
Install 3067
Stator Support Assembly Repair 3068
Remove 3068
Disassemble 3075
Clean 3076
Inspect 3076
Assemble 3077
Install 3077
Clutch Packs Repair 3079
Remove 3079
Disassemble 3081
Housings 3081
Clutch Packs 3084
Clean 3095
Inspect 3096
Assemble 3096
Clutch Packs 3096
Housings 3110
Install 3112
Drive Chains and Sprockets 3115
Remove 3115
Clean 3117
Inspect 3118
Install 3118
Proportional and Enable Solenoid Valves 3118
Proportional Valves 3118
Remove 3118
Disassemble 3120
Clean and Inspect 3121
Assemble 3121
Install 3121
Enable Solenoid Valve 3121
Remove 3121
Disassemble 3122
Clean and Inspect 3122
Assemble 3122
Install 3122
Pedal Repair Foot Directional Control 3123
Remove and Disassemble 3123
Clean and Inspect 3126
Assemble and Install 3127
550108496-1400YRM1741-(12-2014)-US-EN 3131
550108497-1600YRM1742-(12-2014)-US-EN 3179
550108498-1800YRM1743-(06-2018)-US-EN 3201
General 3205
Dry Brake System 3205
Wet Brake System 3205
Service Brakes Repair (Dry Brake) 3205
Remove and Disassemble 3206
Clean 3213
Inspect 3214
Assemble and Install 3214
Adjust 3222
Inching Overlap Adjustment 3222
Parking Brake Repair 3223
Remove and Disassemble 3223
Dry Brake System 3223
Wet Brake System 3225
Assemble and Install 3227
Dry Brake System 3227
Wet Brake System 3227
Adjust 3227
Master Cylinder Repair 3228
Remove (Dry Brake) 3228
Disassemble (Dry Brake) 3229
Clean and Inspect (Dry Brake) 3231
Assemble (Dry Brake) 3231
Bench Bleed Master Cylinder (Dry Brake) 3231
Install and Adjust (Dry Brake) 3231
Remove (Wet Brake) 3232
Disassemble (Wet Brake) 3233
Clean and Inspect (Wet Brake) 3234
Assemble (Wet Brake) 3235
Install and Adjust (Wet Brake) 3235
Service Brakes Adjustment (Dry Brake) 3236
Brake System Air Removal 3236
Using Pressure Bleed System 3236
Using Brake Pedal Pressure 3236
Brake Pedal Adjustment 3237
Free Pedal Adjustment 3238
Torque Specifications 3240
550108499-1900YRM1744-(06-2018)-US-EN 3243
General 3247
Hydraulic Gear Pump Assembly Repair 3248
Remove 3248
Disassemble 3252
Clean 3254
Inspect 3254
Assemble 3254
Install 3254
Quick-Lok™ Hydraulic Hose 3256
Hydraulic Gear Pump Specifications 3257
Variable Displacement Pump Repair 3259
Remove 3259
Disassemble 3264
Clean 3266
Inspect 3266
Assemble 3266
Install 3266
Variable Displacement Pump Checks and Adjustments 3269
Margin Pressure Check 3269
Flow Compensator Adjustment 3270
Pressure Compensator Adjustment 3270
Variable Displacement Pump Specifications 3271
Torque Specifications 3271
Hydraulic Gear Pump 3272
Variable Displacement Pump 3272
550108500-2000YRM1745-(06-2018)-US-EN 3275
General 3279
Electro-Hydraulic Main Control Valve 3279
Description 3279
Remove 3282
Electro-Hydraulic Control Valve Sections 3285
General 3285
Outlet Control Valve Section 3285
Remove 3285
Disassemble 3285
Clean 3287
Inspect 3287
Assemble 3287
Install 3288
Auxiliary Control Valve Sections 3288
Remove 3288
Disassemble 3290
Clean 3291
Inspect 3291
Assemble 3291
Install 3291
Tilt Control Valve Section 3292
Remove 3292
Disassemble 3292
Clean 3293
Inspect 3293
Assemble 3294
Install 3294
Lift/Lower Control Valve Section 3294
Remove 3294
Disassemble 3294
Clean 3296
Inspect 3296
Assemble 3297
Install 3297
Install 3297
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 3300
Lift Pilot Pin 3300
Lower Pilot Pin 3302
Abnormal/Erroneous EHPV Adjustment 3304
Manual Main Control Valve 3304
Description 3304
Remove 3307
OPS Solenoid Assembly 3313
General 3313
Remove 3314
Clean and Inspect 3316
Install 3316
Manual Control Valve Sections 3317
General 3317
Outlet Control Valve Section 3317
Remove 3317
Disassemble 3317
Clean 3320
Inspect 3320
Assemble 3320
Install 3321
Auxiliary Control Valve Sections 3321
Remove 3321
Disassemble 3321
Clean 3324
Inspect 3324
Assemble 3324
Install 3324
Lift/Tilt Control Valve Section 3325
Remove 3325
Disassemble 3325
Clean 3330
Inspect 3330
Assemble 3330
Install 3331
Install 3331
Pressure Relief Valve Check and Adjustment 3335
Primary Relief Valve 3336
Secondary Relief Valve 3337
Steering Control Unit Repair 3341
Steering Control Unit, Remove 3341
Steering Control Unit, Disassemble 3343
Steering Control Unit, Clean 3345
Steering Control Unit, Inspect 3345
Steering Control Unit, Assemble 3345
Relief Valve, Disassemble 3346
Relief Valve, Clean 3346
Relief Valve, Inspect 3347
Relief Valve, Assemble 3347
Steering Control Unit, Install 3347
550108501-2100YRM1746-(02-2018)-US-EN 3351
Safety Procedures When Working Near Mast 3355
General 3357
Tilt Cylinder Repair 3358
Remove 3359
Disassemble 3360
Clean 3362
Inspect 3362
Assemble 3362
Install 3363
Adjust Tilt Cylinders 3364
Lift Cylinder Repair 3365
Main Lift Cylinders 3365
Remove 3365
Disassemble 3367
Two-Stage FFL 3367
Three-Stage FFL 3369
Two-Stage LFL 3370
Clean 3370
Inspect 3370
Assemble 3371
Two-Stage FFL 3371
Three-Stage FFL 3371
Two-Stage LFL 3371
Install 3372
System Air Bleed Procedures 3372
Free-Lift Cylinder Repair 3373
Remove 3373
Two-Stage FFL 3373
Three-Stage FFL 3373
Disassemble 3375
Clean 3375
Inspect 3375
Assemble 3376
Install 3376
Two-Stage FFL 3376
Three-Stage FFL 3377
All Free-Lift Cylinders 3377
Sideshift Cylinder Repair Prior to December 2016 3378
Remove 3378
Disassemble 3379
Clean and Inspect 3379
Assemble 3379
Install 3380
Sideshift Cylinder Repair After December 2016 3380
Remove 3380
Disassemble 3382
Clean and Inspect 3382
Assemble 3382
Install 3383
Integral Side-Shift Cylinder Gland Leak Checks 3383
Fork Positioner Cylinder Repair Prior to December 2016 3384
Remove 3384
Disassemble 3384
Clean 3388
Inspect 3388
Assemble 3389
Install 3389
Fork Positioner Cylinder Adjustment 3389
Fork Positioner Cylinder Repair After December 2016 3390
Remove 3390
Disassemble 3390
Clean 3393
Inspect 3394
Assemble 3394
Install 3394
Fork Positioner Cylinder Adjustment 3394
Seal Kit Installation 3395
External Installation (Seal and Back-Up Ring) 3395
Internal Installation (Piston Rod Assembly) 3396
Torque Specifications 3396
Tilt Cylinders 3396
Main Lift Cylinder 3396
Free-Lift Cylinder 3396
Sideshift Cylinder 3396
Fork Positioner Cylinder 3396
550108502-2200YRM1747-(01-2020)-US-EN 3401
General 3407
Display Switch Cluster 3408
Remove 3408
Install 3410
Direction Control Lever 3410
Remove 3410
Install 3411
Key Switch 3411
Remove 3411
Install 3412
Display Switch Cluster Panel Bezel and Overlay 3412
Remove 3412
Install 3412
Steering Column Repair 3413
Remove 3413
Disassemble 3414
Assemble 3414
Install 3415
Sensors and Switches 3415
General 3415
Dash Panel, Kick Panel, and Seal Plate, Remove and Install 3415
Remove 3415
Install 3416
Accelerator Pedal Position Sensor 3416
Remove 3416
Install 3418
Brake Fluid Level Switch 3418
Remove 3418
Install 3419
Brake Pedal Position Sensor 3420
Remove 3420
Install 3421
Service Brake Pressure Sensor 3421
Remove 3421
Install 3421
Parking Brake Position Sensor 3421
Remove 3421
Install 3422
Seat Sensor (Operator Presence System) 3422
Non-Suspension Seat 3422
Remove 3422
Install 3423
Full Suspension Seats 3424
Remove 3424
Install 3424
Transmission Pressure Sensors (Transducers) 3424
Remove 3424
Install 3425
Transmission Temperature Sensor 3425
Remove 3425
Install 3425
Transmission Speed Sensor 3425
Remove 3425
Install 3425
Rear Horn Button Switch 3425
Remove 3425
Install 3426
Engine and Fuel Sensors and Switches, PSI 2 0L LPG Trucks 3426
Engine and Fuel Sensors, Yanmar 2 6L Diesel Trucks 3426
Engine Speed Sensor 3426
Remove 3426
Install 3428
Oil Pressure Sensor 3428
Remove 3428
Install 3428
Engine Coolant Temperature (ECT) Sensor 3428
Remove 3428
Install 3428
Fuel/Water Separator Sensor 3429
Remove 3429
Install 3429
Glow Plug Relay 3430
Remove 3430
Install 3432
Air Filter Restriction Switch 3432
Remove 3432
Install 3432
Throttle Position Sensor (TPS) 3432
Remove 3432
Install 3433
Sensor MicroswitchFoot Directional Control 3433
Remove 3433
Install 3435
Low Coolant Level Sensor 3435
Remove 3435
Install 3436
Fuel Level Sensor, Diesel Engine Only 3436
Remove 3436
Install 3436
Hydraulic Filter Pressure Switch 3437
Remove 3437
Install 3437
Return To Set Tilt (Tilt Angle) Sensor 3437
Remove 3437
Install 3438
Impact Sensor 3438
Remove 3438
Install 3439
Load Weight Sensor 3441
Remove 3441
Install 3441
Power Distribution Module (PDM) and Component Parts 3443
Power Distribution Module (PDM) as a Unit 3443
Remove 3443
Install 3445
Power Distribution Module (PDM) Components 3445
Remove and Install 3445
Battery 3446
Remove 3446
Install 3446
Lights 3446
Work Lights (Front and Rear) 3446
Remove 3446
Install 3446
Strobe Light 3447
Remove 3447
Install 3447
LED Tail, Backup, and Brake Lights 3448
Remove 3448
Install 3449
Front Marker/Turn Signal Lights 3449
Replacing Whole Front Marker/Turn Signal
Light Assembly 3449
Remove 3449
Install 3449
Replacing Just the Front Marker/Turn Signal
Light LED Light Lens 3449
Remove 3449
Install 3449
Vehicle System Manager (VSM) 3450
General 3450
VSM Replacement 3450
Remove 3450
Install 3451
Programming a New VSM and/or Display Switch Cluster 3452
Data Transferring 3452
New VSM 3452
New (Blank) Display Switch Cluster 3452
Used (Non-Blank) Display Switch Cluster 3452
PC Service Tool Software 3453
Electronic-Hydraulic Controls, Before January, 2020 3454
E-Hydraulic Controls – Test 3454
Mini-Levers 3454
Full Stroke Test 3454
Function Returns to Neutral Test 3455
Push (Override) Button 3455
General 3455
Mini-levers, Remove and Install 3456
Armrest Assembly 3457
Remove 3457
Install 3459
Horn Button 3459
Remove 3459
Install 3459
Direction Control Switch 3460
Remove 3460
Install 3460
Push (Override) Buttons and Toggle Switch 3460
Remove 3461
Install 3462
Electronic-Hydraulic Controls, After January, 2020 3463
E-Hydraulic Controls – TEST 3463
Mini-Levers 3463
Full Stroke Test 3463
Function Returns to Neutral Test 3463
Push (Override) Button 3464
General 3464
Mini-levers, Remove and Install 3464
Armrest Assembly 3465
Remove 3465
Install 3468
Horn Button 3468
Remove 3468
Install 3469
Direction Control Switch 3469
Remove 3469
Install 3469
Push (Override) Buttons 3470
Remove 3470
Install 3471
550108503-2200YRM1748-(05-2017)-US-EN 3473
General 3477
Ignition System 3477
Ignition Timing Adjustment 3477
Spark Plugs Check 3477
Coil Replacement 3478
Remove 3478
Inspect 3480
Install 3480
Starter Repair 3481
General 3481
Remove 3482
No-Load Test 3482
Magnetic Switch Test 3483
Pull-Out Test 3483
Holding Coil Test 3483
Return Test 3484
Pinion Movement Inspection 3484
Install 3484
Alternator Repair 3485
General 3485
Charging System Inspection 3486
Output Current Check 3486
No-Load Adjusted Voltage Check 3487
Remove 3487
Install 3487
Engine Sensors and Switches 3489
Oil Pressure Sensor 3489
Remove 3489
Install 3489
Air Filter Restriction Switch 3489
Remove 3489
Install 3489
Cam Angle Sensor 3490
Remove 3490
Install 3490
Crankshaft Position Sensor (CKP) 3490
Remove 3490
Install 3490
Temperature Manifold Absolute Pressure (TMAP) Sensor 3492
Remove 3492
Install 3492
Engine Coolant Temperature (ECT) Sensor 3492
Remove 3492
Install 3492
Battery Disconnect Switch, Safety Option 3493
Remove 3493
Install 3494
Electronic Control Module 3494
550108504-4000YRM1749-(10-2017)-US-EN 3497
General 3503
Safety Procedures When Working Near Mast 3505
Fork Replacement 3506
Remove 3507
Install 3507
Checks 3508
Fork Positioner Carriage 3510
Remove 3510
Install 3512
Checks 3512
Carriages Repair, Two-Stage LFL Mast 3514
Standard Carriage 3514
Remove 3514
Repair 3515
Install 3516
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3516
Remove 3516
Clean and Inspect 3519
Repair 3519
Install 3520
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3521
Remove 3521
Disassemble 3524
Clean and Inspect 3524
Assemble 3524
Install 3525
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 3526
Remove 3526
Disassemble and Assemble 3528
Clean and Inspect 3528
Install 3528
Fork Positioner Hydraulic Hose Adjustment 3530
Fork Positioner, Lift Trucks Manufactured After December, 2016 3531
Remove 3531
Disassemble and Assemble 3533
Clean and Inspect 3533
Install 3533
Fork Positioner Hydraulic Hose Adjustment 3535
Two-Stage LFL Mast Repair 3536
Mast With Serial Number B551 3536
Remove 3536
Disassemble 3538
Clean and Inspect 3539
Assemble 3542
Mast, Install 3543
Two-Stage LFL Mast, Header Hose Arrangement 3545
General 3545
Installation Procedures 3545
Adjustment 3552
Carriages Repair, Two-Stage FFL Mast 3552
Standard Carriage 3552
Remove 3552
Repair 3553
Install 3553
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3554
Remove 3554
Clean and Inspect 3557
Repair 3557
Install 3557
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3558
Remove 3558
Disassemble 3561
Clean and Inspect 3561
Assemble 3561
Install 3562
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 3563
Remove 3563
Clean and Inspect 3563
Disassemble and Assemble 3563
Install 3563
Fork Positioner Hydraulic Hose Adjustment 3567
Fork Positioner, Lift Trucks Manufactured After December, 2016 3568
Remove 3568
Disassemble and Assemble 3570
Clean and Inspect 3570
Install 3570
Fork Positioner Hydraulic Hose Adjustment 3571
Two-Stage FFL Mast Repair 3572
Mast With Serial Number B559 3572
Remove 3572
Disassemble 3575
Clean and Inspect 3578
Assemble 3579
Mast, Install 3580
Two-Stage FFL Mast, Header Hose Arrangement 3582
General 3583
Installation Procedure 3583
Adjustment 3587
Carriages Repair, Three-Stage FFL Mast 3591
Standard Carriage 3591
Remove 3591
Repair 3592
Install 3593
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3593
Remove 3593
Clean and Inspect 3596
Repair 3596
Install 3596
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3597
Remove 3597
Disassemble 3600
Clean and Inspect 3600
Assemble 3600
Install 3601
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 3602
Remove 3602
Clean and Inspect 3602
Disassemble and Assemble 3602
Install 3602
Fork Positioner Hydraulic Hose Adjustment 3605
Fork Positioner, Lift Trucks Manufactured After December, 2016 3606
Remove 3606
Disassemble and Assemble 3610
Clean and Inspect 3610
Install 3610
Fork Positioner Hydraulic Hose Adjustment 3611
Three-Stage FFL Mast Repair 3612
Mast With Serial Number B555 3612
Remove 3612
Disassemble 3614
Clean and Inspect 3615
Assemble 3618
Mast, Install 3619
Three-Stage FFL Mast, Header Hose Arrangement 3621
General 3622
Installation Procedures 3622
Adjustment 3629
Lift Chains Adjustment 3631
Carriage Adjustments 3632
Mast Adjustments 3634
Load Roller Adjustment 3634
Mast Side Kicking Adjustment 3634
550108505-8000YRM1750-(12-2018)-US-EN 3639
General 3645
Serial Number Data 3645
How to Move a Disabled Lift Truck 3645
How to Tow the Lift Truck 3645
How to Put a Lift Truck on Blocks 3646
How to Raise Drive Tires 3646
How to Raise the Steering Tires 3646
How To Clean A Lift Truck 3647
Maintenance Schedule 3648
Maintenance Procedures Every 8 Hours or Daily 3657
How to Make Checks With Engine Stopped 3657
Tires and Wheels 3657
Safety Labels 3658
Mast, Carriage, Lift Chains, Header Hoses, Attachment 3658
Operator Restraint System 3659
Emergency Locking Retractor (ELR) 3659
Adjust Seat – Full Suspension 3661
Adjust Seat – Internal Suspension 3662
Hood and Seat Latches 3662
Engine Compartment 3663
Paper Application 3663
Fuel, Oil, and Coolant Leaks, Check 3664
Direct Electronic Pressure Regulator (DEPR), Check 3664
Hydraulic Hoses 3664
Coolant Hoses 3664
Steering Column Gas Cylinder 3664
Transmission 3665
Hydraulic System Oil 3665
Engine Oil 3665
Air Filter 3666
Forks 3667
General 3667
Inspect 3667
Remove 3668
Install 3671
Adjust 3671
How to Make Checks With Engine Running 3672
Indicator Lights, Horn, Fuses, and Relays 3672
Service Brakes 3674
Brake Fluid Level 3674
Operation, Check 3674
Parking Brake 3675
Engine Oil Pressure 3675
Cooling System 3676
Steering System 3676
Control Levers and Pedals 3677
Lift System, Operate 3677
First Service After First 100 Hours of Operation 3677
PSI 2 0L LPG Engine Oil and Oil Filter 3677
Yanmar Engine Oil and Oil Filter 3678
Maintenance Procedures Every 250 Hours or 6 Months 3678
PSI 2 0L LPG Engine Oil and Oil Filter 3678
Drain Oil From LPG Vaporizer Regulator (LPG Converter) 3679
Cleaning Carbon Buildup From Intake Valves – PSI 2 0 LPG Engine 3681
Maintenance Procedures Every 500 Hours or 6 Months 3682
Hydraulic System Oil 3682
Battery 3684
Yanmar 2 6L Engine Oil and Oil Filter Change 3684
Yanmar 2 6L Engine Drive Belt 3684
Clean Debris From Radiator Core 3685
Transmission Oil Level 3685
Forks 3686
Inspect 3686
Mast Lubrication 3688
Header Hose Checks 3690
Lift Chain Lubrication 3690
Tilt Cylinder Lubrication 3690
Master Cylinder Rod End Pin Lubrication 3691
Manual Hydraulic Levers Lubrication 3692
Brake Fluid 3692
Parking Brake Adjustment 3692
Tie Rod Lubrication 3693
Differential and Drive Axle Oil 3693
Maintenance Procedures Every 1000 Hours or 6 Months 3694
Valve Clearance, Check and Adjust, Yanmar 2 6L Diesel Engine 3694
Drive Belt Check, PSI Engine 3694
LPG Fuel Filter Element Replace, PSI 2 0L LPG Engine 3694
Remove 3694
Install 3695
Fuel Filter Replacement, Yanmar Engine 3696
Priming the Fuel System (Yanmar) 3697
Lift Chains Wear Check 3698
Lift Chain Lubrication 3698
Integral Sideshift Carriage, Check Bearings 3699
Integral Sideshift Carriage, Check Lower Mounting Hooks 3700
Steering Axle 3700
Control Levers and Pedals 3700
Ignition System, PSI Engine 3700
PCV System, PSI 2 0L LPG Engine 3701
Maintenance Procedures Every 2000 Hours or 1 Year 3701
Hydraulic System 3701
Hydraulic Oil Filter Element, Replace 3701
Remove 3701
Clean and Inspect 3702
Install 3702
Hydraulic Tank Breather, Replace 3703
Air Filter 3704
Oxygen Sensor 3706
PCV System, PSI Engines 3707
Forks, Inspect 3707
Fuel Injector, Yanmar Engines 3709
Integral Sideshift Carriage 3709
Bearings, Replace 3709
Transmission Oil and Oil Filter, Replace 3709
Remove 3709
Clean and Inspect 3710
Install 3710
Brake Fluid Change 3710
Steering Axle Wheel Bearings 3712
Service Brakes 3712
Drive Axle and Differential Oil, Change 3713
Maintenance Procedures Every 4000 Hours or 2 Years 3716
Hydraulic Oil, Change 3716
Cooling System 3717
Maintenance Procedures Every 6000 Hours 3718
Timing Belt Change, PSI Engine 3719
Safety Procedures When Working Near Mast 3719
Hood Latch Check 3722
Lift Chain Adjustments 3723
Jump-Starting the Lift Truck 3724
Jump-Starting Using a Battery Charger 3725
Jump-Starting a Lift Truck Using Another Lift Truck 3725
Welding Repairs 3726
Overhead Guard Changes 3726
Wheel Repair 3726
General 3726
How to Change Solid Rubber Tire (GC Series) 3726
Remove and Install Tire on Wheel 3727
Pneumatic Tire With Tube, Repair 3728
Remove Wheels From Lift Truck 3728
Remove Tire From Wheel 3728
Install Wheel in Tire 3732
Add Air to Pneumatic Tires With Tube 3734
Wheels, Install 3735
Pneumatic Tubeless Tire, Repair 3736
Remove Wheels From Lift Truck 3736
Add Air to Pneumatic Tubeless Tire 3741
Wheels, Install 3741
Solid Rubber Tires on Pneumatic Wheels, Change 3741
Adhesives and Sealants 3745
550108506-8000YRM1751-(08-2018)-US-EN 3749
Lift Truck Lifting Capacity 3753
Counterweight Weights 3753
Tire Sizes 3753
Capacities 3754
Electrical System 3756
Transmission Oil Pressures 3757
Hydraulic System Relief Pressures 3757
Steering System 3758
Stall Speeds (in RPM ±100 rpm) 3759
PSI 2 0L Engine 3759
Yanmar 2 6L Engine 3759
Mast Speeds 3759
Tilt Angles 3760
Front End Equipment – Mast Creep 3760
Mast Creep 3761
Engine Specifications 3762
Torque Specifications 3763
Frame 3763
Mast 3763
Steering System, Cushion Tire Trucks 3763
Steering System, Pneumatic Tire Trucks 3763
Drive Axle 3763
Transmission 3764
Engine – PSI 2 0L LPG 3764
Engine – Yanmar 2 6L Diesel 3765
550108507-8000YRM1753-(03-2020)-US-EN 3769
General Information About Diagrams and Schematics 3773
Symbol Definitions 3773
Diagrams Manual Applications 3774
Diagrams and Schematics 3776
550108507-8000YRM1753-(05-2022)-US-EN 3869
General Information About Diagrams and Schematics 3875
Symbol Definitions 3875
Diagrams Manual Applications 3876
Diagrams and Schematics 3878

S.V 06/24