Yale D875 (GPGLPGDP040VX, GPGLPGDP050VX, GPGLPGDP060VX, GPGLPGDP070VX) Service Manual PDF

Yale Forklift D875 (GPGLPGDP040VX, GPGLPGDP050VX, GPGLPGDP060VX, GPGLPGDP070VX) Service Manual – PDF DOWNLOAD

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Yale Forklift D875 (GPGLPGDP040VX, GPGLPGDP050VX, GPGLPGDP060VX, GPGLPGDP070VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5328
Downloadable : Yes
File Type : PDF

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Yale Forklift D875 (GPGLPGDP040VX, GPGLPGDP050VX, GPGLPGDP060VX, GPGLPGDP070VX) 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
524223771 2200YRM1131 (03 2020) US EN 2465
Series Code / Model Designation Reference Table 2471
General 2473
Description 2473
Dash Display Menu Access 2473
Menu Navigation 2474
Main Menu 2474
Passwords 2475
Adding Passwords 2475
Hourmeters 2477
View Versions 2478
VSM Versions 2478
Dash Display Versions 2479
Engine Controller Version 2480
Transmission (Xmsn) Controller Version 2481
Truck Serial Number 2482
Truck Configuration 2483
Diagnostics 2484
Clear Fault Log 2484
View Fault Log 2485
No-Run Data Display 2486
Engine Accelerator and Throttle Data Display 2486
Engine Speeds and Governor Data Display 2487
Engine Fuel and Emissions Data Display 2488
Engine General Data Display 2490
XMSN/Brake Data Display 2491
Hydraulic Data Display 2494
General Truck Data Display 2496
Set Travel and Braking 2497
Speed Limit 2497
Acceleration Rate 2498
Auto-Deceleration Rate 2499
Set Power Reversal Rate 2499
Set Inching/Brake Overlap 2500
Setup Hydraulics 2500
Lift Maximum Speed 2501
Lower Maximum Speed 2501
Tilt Maximum Speed 2502
Auxiliary Function One, Direction A, Maximum Speed 2504
Auxiliary Function One, Direction B, Maximum Speed 2506
Auxiliary Function Two, Direction A, Maximum Speed 2506
Auxiliary Function Two, Direction B, Maximum Speed 2507
Auxiliary Function Three, Direction A, Maximum Speed 2508
Auxiliary Function Three, Direction B, Maximum Speed 2508
Lift/Lower Ramp Rate 2509
Hydraulic Auxiliary Ramp Rate 2509
Return to Set Tilt Delay/On/Off 2510
Hydraulic Input Device 2511
Auxiliary Solenoid 2511
Dual Function 2512
Setup Display 2513
Set Service Language 2513
Setup General Items 2513
Motion Alarm Activation Type 2514
Light Shutdown Time-Out 2515
Restore Default Settings 2515
Restore Engine Controller Default Calibration 2516
Impact Sensor – Enable/Disable 2516
Impact Sensor – Soft Impact Settings 2517
Impact Sensor – Hard Impact Settings 2518
Adjust Impact Sensor Settings 2519
Initial Adjustment of Soft and Hard Impact Settings 2521
Readjustment of Soft and Hard Impact Settings 2521
Impact Sensor – Impact Alarm/Shutdown Reset 2522
Impact Sensor – Alarm Time Duration and Deactivation 2523
Impact Sensor – View Impact Event Log 2524
Engine Mode Indicator 2524
Generation 1 (ECO-eLo ONLY) 2524
Generation 2 2525
Diesel Particulate Filter (DPF) Display 2526
General Description 2526
Passive Regeneration Only 2526
Regeneration Level 0 2526
Auto/Active Regeneration Inhibited 2527
Auto/Active Regeneration 2527
Regeneration Level 1 2527
Parked Regeneration Request 2528
Regeneration Level 2 2528
Warning Level 2528
Regeneration Level 3 2528
Service Level 2529
Regeneration Level 4 2529
Display, Diesel Particulate Filter (DPF), Revised 2529
Operator Interface 2529
Refer to Operator Manual 2529
CAN Communication Lost 2530
Passive Regeneration Only 2530
Regeneration Level 0 2530
Auto/Active Regeneration Inhibited 2530
Auto/Active Regeneration 2531
Regeneration Level 1 2531
Idle-up Auto/Active Regeneration 2531
Parked Regeneration Request 2531
Regeneration Level 2 2531
Warning Level 2533
Regeneration Level 3 2533
Service Level 2533
Regeneration Level 4 2533
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2533
Display, Diesel Particulate Filter (DPF), Stage V Engine 2533
Operator Interface 2534
Refer to Operator Manual 2534
CAN Communication Lost 2534
Passive Regeneration Only 2534
Regeneration Level 0 2534
Auto/Active Regeneration Inhibited 2535
Auto/Active Regeneration 2535
Regeneration Level 1 2535
Idle-up Auto/Active Regeneration 2536
Parked Regeneration Request 2536
Regeneration Level 2 2536
Warning Level 2537
Regeneration Level 3 2537
Service Level 2538
Regeneration Level 4 2538
Stage V Content 2538
Emissions System Malfunction 2538
Ash Load 2538
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2539
Operator Interface 2539
Refer to Operator Manual 2539
CAN Communication Lost 2540
Passive Regeneration Only 2540
Regeneration Level 0 2540
Auto/Active Regeneration Inhibited 2540
Auto/Active Regeneration 2541
Regeneration Level 1 2541
Idle-up Auto/Active Regeneration 2541
Parked Regeneration Request 2541
Regeneration Level 2 2541
Warning Level 2543
Regeneration Level 3 2543
Service Level 2543
Regeneration Level 4 2543
Calibrations 2544
Calibrate Transmission Valve 2546
Set Tilt Stop Point 2546
Calibrate Loaded Weight 2546
Calibrate Travel Speed Sensor 2547
Calibrate Mazda LP and Gas Accelerator Pedal 2547
524223780 8000YRM1134 (03 2020) US EN 2549
Series Code / Model Designation Reference Table 2555
Description 2557
Proc_Cal_001: Service Password Entry 2559
When to Perform 2559
Why Perform 2559
How to Perform 2559
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2560
When to Perform 2560
Calibration Order 2560
Why Perform 2560
How to Perform 2561
Proc_Cal_003: Save and Exit 2562
When to Perform 2562
Why Perform 2562
How to Perform 2562
Proc_Cal_004: Lift Valve Output Threshold 2563
When to Perform 2563
Calibration Order 2563
Why Perform 2563
How to Perform 2564
Proc_Cal_005: Lower Valve Output Threshold 2566
When to Perform 2566
Calibration Order 2566
Why Perform 2566
How to Perform 2566
Proc_Cal_006: Tilt Back Valve Output Threshold 2569
When to Perform 2569
Calibration Order 2569
Why Perform 2569
How to Perform 2569
Proc_Cal_007: Tilt Forward Valve Output Threshold 2572
When to Perform 2572
Calibration Order 2572
Why Perform 2572
How to Perform 2572
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2575
When to Perform 2575
Calibration Order 2575
Why Perform 2575
How to Perform 2575
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2578
When to Perform 2578
Calibration Order 2578
Why Perform 2578
How to Perform 2578
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2581
When to Perform 2581
Calibration Order 2581
Why Perform 2581
How to Perform 2581
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2584
When to Perform 2584
Calibration Order 2584
Why Perform 2584
How to Perform 2584
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2587
When to Perform 2587
Calibration Order 2587
Why Perform 2587
How to Perform 2587
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2590
When to Perform 2590
Calibration Order 2590
Why Perform 2590
How to Perform 2590
Proc_Cal_014: Load Weight Zero Point 2594
When to Perform 2594
Calibration Order 2594
Why Perform 2594
How to Perform 2594
Proc_Cal_015: Loaded Weight Calibration 2596
When to Perform 2596
Calibration Order 2596
Why Perform 2596
How to Perform 2596
Proc_Cal_016: Transmission Valve Calibration 2599
Applicable System/Option 2599
When to Perform 2599
Calibration Order 2599
Why Perform 2599
How to Perform 2599
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2601
Applicable System/Option 2601
When to Perform 2601
Calibration Order 2601
Why Perform 2601
How to Perform 2601
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2603
Applicable System/Option 2603
When to Perform 2603
Calibration Order 2603
Why Perform 2603
How to Perform 2604
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2605
Required Tools 2605
When to Perform 2605
Calibration Order 2605
Why Perform 2606
How to Perform 2606
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2607
When to Perform 2607
Why Perform 2607
How to Perform 2607
Proc_Cal_026: Travel Speed Calibration 2609
When to Perform 2609
Calibration Order 2609
Why Perform 2609
How to Perform 2609
524223780 8000YRM1134 (05 2022) US EN 2613
Series Code / Model Designation Reference Table 2619
Description 2622
Proc_Cal_001: Service Password Entry 2624
When to Perform 2624
Why Perform 2624
How to Perform 2624
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2625
When to Perform 2625
Calibration Order 2625
Why Perform 2625
How to Perform 2625
Proc_Cal_003: Save and Exit 2627
When to Perform 2627
Why Perform 2627
How to Perform 2627
Proc_Cal_004: Lift Valve Output Threshold 2628
When to Perform 2628
Calibration Order 2628
Why Perform 2628
How to Perform 2628
Proc_Cal_005: Lower Valve Output Threshold 2631
When to Perform 2631
Calibration Order 2631
Why Perform 2631
How to Perform 2631
Proc_Cal_006: Tilt Back Valve Output Threshold 2634
When to Perform 2634
Calibration Order 2634
Why Perform 2634
How to Perform 2634
Proc_Cal_007: Tilt Forward Valve Output Threshold 2637
When to Perform 2637
Calibration Order 2637
Why Perform 2637
How to Perform 2637
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2640
When to Perform 2640
Calibration Order 2640
Why Perform 2640
How to Perform 2640
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2643
When to Perform 2643
Calibration Order 2643
Why Perform 2643
How to Perform 2643
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2646
When to Perform 2646
Calibration Order 2646
Why Perform 2646
How to Perform 2646
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2649
When to Perform 2649
Calibration Order 2649
Why Perform 2649
How to Perform 2649
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2652
When to Perform 2652
Calibration Order 2652
Why Perform 2652
How to Perform 2652
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2655
When to Perform 2655
Calibration Order 2655
Why Perform 2655
How to Perform 2655
Proc_Cal_014: Load Weight Zero Point 2658
When to Perform 2658
Calibration Order 2658
Why Perform 2658
How to Perform 2658
Proc_Cal_015: Loaded Weight Calibration 2660
When to Perform 2660
Calibration Order 2660
Why Perform 2660
How to Perform 2660
Proc_Cal_016: Transmission Valve Calibration 2663
Applicable System/Option 2663
When to Perform 2663
Calibration Order 2663
Why Perform 2663
How to Perform 2663
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2665
Applicable System/Option 2665
When to Perform 2665
Calibration Order 2665
Why Perform 2665
How to Perform 2665
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2668
Applicable System/Option 2668
When to Perform 2668
Calibration Order 2668
Why Perform 2668
How to Perform 2668
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2671
Required Tools 2671
When to Perform 2671
Calibration Order 2671
Why Perform 2671
How to Perform 2671
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2673
When to Perform 2673
Why Perform 2673
How to Perform 2673
Proc_Cal_026: Travel Speed Calibration 2675
When to Perform 2675
Calibration Order 2675
Why Perform 2675
How to Perform 2675
524240453 0600YRM1205 (01 2017) US EN 2679
General 2685
Engine Identification 2685
Major Engine Component Identification 2685
Location of Labels 2686
Engine Removal and Installation 2687
Cylinder Head Assembly Repair 2687
Glow Plugs 2690
Remove 2690
Install 2690
Valve Cover 2690
Remove 2690
Clean and Inspect 2691
Install 2691
Rocker Arm Assembly 2691
Remove 2691
Disassemble 2692
Clean and Inspect 2693
Push Rods 2693
Rocker Arm Assembly 2693
Assemble 2693
Install 2694
Valve Clearance Adjustments 2694
Cylinder Head Assembly 2695
Remove 2695
Disassemble 2700
Valves and Valve Springs, Remove 2700
Valve Guides, Remove 2700
Clean and Inspect 2701
Cylinder Head 2701
Valve Guides 2702
Valves 2702
Valve Sink 2702
Valve Seat 2703
Valve Springs 2703
Assemble 2704
Valve Guides, Install 2704
Valves and Valve Springs, Install 2704
Install 2705
Timing Gear Case and Timing Gears Repair 2706
Timing Gear Case Cover 2707
Remove 2707
Clean and Inspect 2707
Install 2708
Timing Gears 2708
Crankshaft Gear 2709
Remove 2709
Install 2709
Idler Gear 2709
Remove 2709
Inspect 2710
Install 2710
Camshaft Gear 2710
Remove 2710
Install 2711
Timing Gear Case 2711
Remove 2711
Clean and Inspect 2712
Install 2712
Drive Train, Camshaft, and Cylinder Block Repair 2713
Remove 2713
Disassemble 2714
Pistons and Connecting Rods 2714
Crankshaft 2714
Camshaft 2717
Clean and Inspect 2718
Cylinder Block 2718
Honing and Boring 2721
Pistons 2722
Piston Pin 2722
Connecting Rod 2723
Tappets 2723
Crankshaft 2724
Camshaft 2725
Camshaft Bushing 2726
Assemble 2726
Camshaft 2726
Crankshaft 2726
Pistons and Connecting Rods 2727
Install 2728
Lubrication System Repair 2729
Engine Oil and Oil Filter Change 2729
Oil Pan 2729
Remove 2729
Install 2730
Oil Suction Tube 2730
Remove 2730
Clean 2731
Install 2731
Oil Pump 2731
Remove 2731
Clean and Inspect 2732
Outer Rotor Outside Clearance 2732
Outer Rotor to Inner Rotor Tip Clearance 2733
Outer Rotor Side Clearance 2733
Rotor Shaft Clearance 2733
Install 2734
Fuel System Repair 2734
Fuel Injectors 2735
Remove 2735
Inspect 2736
Clean 2736
Test 2736
Install 2739
Electronic Throttle System 2739
Remove 2739
Install 2742
Inspect 2743
Adjust 2744
Manual Throttle System 2745
Fuel Injection Pump 2745
Remove 2745
Clean and Inspect 2749
Install 2749
Check/Adjust Fuel Injection Timing 2750
Cooling System Repair 2752
V-Belt 2752
Remove 2752
Inspect 2752
Install 2752
Adjust 2752
Water Pump 2754
4TNE92-NMHA, 4TNE92-NMHA/580090035, 4TNE92-SNMU, and 4TNE98-SNMU Engines 2754
Remove 2754
Install 2755
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/580090036, and 4TNE98-BNMH Engines 2756
Remove 2756
Install 2757
Thermostat 2759
Remove 2759
Inspect 2760
Install 2760
Flywheel and Flywheel Housing 2760
Flywheel 2761
Remove 2761
Install 2762
Flywheel Housing 2762
Remove 2762
Install 2762
Electrical Equipment Repair 2764
Alternator 2764
Remove 2764
Bench Test 2766
Regulate Voltage Check 2766
No Load Test 2768
Output Test 2768
Install 2768
Starter 2769
Remove 2770
No Load Test 2770
Install 2771
Engine Specifications 2772
Engine Data 2772
Engine Tuning 2780
Cylinder Head 2780
Intake/Exhaust Valve and Guide 2781
Valve Spring 2781
Rocker Arm and Shaft 2781
Push Rod 2782
Gear Train and Camshaft 2782
Camshaft 2782
Idle Gear Shaft and Bushing 2782
Backlash of Each Gear 2783
Cylinder Block 2783
Crankshaft 2783
Thrust Bearing 2784
Piston 2784
Piston Ring 2784
Connecting Rod 2785
Rod Small End 2785
Tappet 2785
Oil Pump 2786
Engine Oil Pressure 2786
Outer Rotor Outside Clearance 2786
Outer Rotor Side Clearance 2786
Outer Rotor to Inner Rotor Tip Clearance 2786
Rotor Shaft Clearance 2786
Standard Torque Specifications 2787
Standard Torque Chart 2787
Special Torque Specifications 2788
Special Tools 2789
550073240 1900YRM1620 (01 2023) US EN 2797
Proper Flushing after Major Hydraulic Repairs 2803
Introduction 2803
The Phases of Wear 2803
Causes of Hydraulic System Failure 2803
Progression of Contaminant Caused Hydraulic System Failure 2804
Hydraulic System Flushing Techniques 2804
Double Oil and Filter Change 2804
Mechanical Cleaning 2805
Cleaning of Components 2805
How to Clean Tubes and Hoses 2805
Filter Caddy 2805
Start-Up Procedure for Cleaned System 2806
Contaminated Oil Coolers 2806
Additional Filter Caddy Functions 2807
How to Handle Different Fluids 2807
Water Removal Filters 2807
Fluid Conditioning and System Flushing Procedures 2808
Operation of the Filter Caddy 2808
Filter Caddy operation 2808
Fluid Conditioning Procedure 2808
Filter Caddy Start-Up 2809
System Flushing Procedure 2809
Component Cleaning Procedure 2810
Reservoir Cleaning Procedure 2810
Cylinder Cleaning Procedure 2810
Hose and Tube Cleaning Procedure 2810
Valve Cleaning Procedure 2811
Front-End Attachment Cleaning Procedure 2812
System Flushing Procedure 2812
Filter Caddy Start-Up 2813
System Start-Up and Flushing 2813
Reservoir Fluid Cleaning Times 2814
Dealing With Different Fluid Types 2815
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2815
Filter Caddy Maintenance 2815
Servicing the Strainer 2815
DC Motor 2815
Hydraulic Oil Sampling Method and Procedure 2816
Hydraulic Oil Sampling Method 2816
Objective 2816
General Guidelines 2816
Synopsis 2817
Hydraulic Oil Analysis Report Guidelines 2818
Sampling Conditions 2818
Equipment 2818
Sampling Procedure 2819
Hydraulic Oil Sampling 2819
Sample Labeling 2819
Results Documentation 2819
550073240 1900YRM1620 (03 2020) US EN 2821
Proper Flushing after Major Hydraulic Repairs 2825
Introduction 2825
The Phases of Wear 2825
Causes of Hydraulic System Failure 2825
Progression of Contaminant Caused Hydraulic System Failure 2826
Hydraulic System Flushing Techniques 2826
Double Oil and Filter Change 2826
Mechanical Cleaning 2827
Cleaning of Components 2827
How to Clean Tubes and Hoses 2827
Filter Caddy 2827
Start-Up Procedure for Cleaned System 2828
Contaminated Oil Coolers 2828
Additional Filter Caddy Functions 2828
How to Handle Different Fluids 2828
Water Removal Filters 2829
Fluid Conditioning and System Flushing Procedures 2829
Operation of the Filter Caddy 2829
Filter Caddy operation 2829
Fluid Conditioning Procedure 2830
Filter Caddy Start-Up 2830
System Flushing Procedure 2831
Component Cleaning Procedure 2831
Reservoir Cleaning Procedure 2831
Cylinder Cleaning Procedure 2831
Hose and Tube Cleaning Procedure 2832
Valve Cleaning Procedure 2832
Front-End Attachment Cleaning Procedure 2833
System Flushing Procedure 2833
Filter Caddy Start-Up 2834
System Start-Up and Flushing 2834
Reservoir Fluid Cleaning Times 2835
Dealing With Different Fluid Types 2835
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2835
Filter Caddy Maintenance 2836
Servicing the Strainer 2836
DC Motor 2836
Hydraulic Oil Sampling Method and Procedure 2836
Hydraulic Oil Sampling Method 2836
Objective 2836
General Guidelines 2836
Synopsis 2837
Hydraulic Oil Analysis Report Guidelines 2838
Sampling Conditions 2839
Equipment 2839
Sampling Procedure 2839
Hydraulic Oil Sampling 2839
Sample Labeling 2840
Results Documentation 2840
550093750 2100YRM1668 (02 2018) US EN 2843
General 2847
Safety Procedures When Working Near Mast 2848
Main Lift Cylinder Repair 2850
Remove 2850
Disassemble 2852
Clean 2854
Inspect 2854
Assemble 2854
Install 2855
Main Lift Cylinder Leak Check 2855
Free-Lift Cylinder 2856
Remove 2856
Disassemble 2857
Clean 2859
Inspect 2859
Assemble 2859
Install 2859
Tilt Cylinder Repair 2860
Remove 2860
Disassemble 2862
Clean 2864
Inspect 2864
Assemble 2864
Install 2865
Tilt Cylinder Adjustment 2866
Tilt Cylinder Leak Check 2867
Integral Sideshift Cylinder Repair Prior to December 2016 2869
Remove 2869
Disassemble 2870
Clean 2871
Inspect 2871
Assemble 2871
Install 2871
Integral Sideshift Cylinder Repair After December 2016 2872
General 2872
Remove 2872
Disassemble 2874
Clean 2874
Inspect 2874
Assemble 2874
Install 2875
Integral Side-Shift Cylinder Gland Leak Checks 2876
Fork Positioner Cylinder Repair Prior to December 2016 2877
Remove 2877
Disassemble 2877
Clean 2879
Inspect 2880
Assemble 2880
Install 2880
Fork Positioner Cylinder Adjustment 2880
Fork Positioner Cylinder Repair After December 2016 2881
General 2881
Remove 2881
Disassemble 2881
Clean 2884
Inspect 2885
Assemble 2885
Install 2885
Fork Positioner Cylinder Adjustment 2885
Seal Kit Installation 2886
External Installation (Seal and Backup Ring) 2886
Internal Installation (Piston Rod Assembly) 2886
Torque Specifications 2887
Main Lift Cylinders 2887
Free-Lift Cylinder 2887
Tilt Cylinders 2887
Integral Sideshift Cylinder 2887
Fork Positioner Cylinder 2887
550093750 2100YRM1668 (04 2023) US EN 2891
General 2897
Safety Procedures When Working Near Mast 2900
Main Lift Cylinder Repair 2902
Remove 2902
Disassemble 2904
Clean 2906
Inspect 2906
Assemble 2906
Install 2907
Main Lift Cylinder Leak Check 2907
Free-Lift Cylinder 2908
Remove 2908
Disassemble 2909
Clean 2911
Inspect 2911
Assemble 2911
Install 2911
Tilt Cylinder Repair 2913
Remove 2913
Disassemble 2915
Clean 2916
Inspect 2917
Assemble 2917
Install 2918
Tilt Cylinder Adjustment 2918
Tilt Cylinder Leak Check 2920
Integral Sideshift Cylinder Repair Prior to December 2016 2922
Remove 2922
Disassemble 2922
Clean 2923
Inspect 2923
Assemble 2923
Install 2924
Integral Sideshift Cylinder Repair After December 2016 2925
General 2925
Remove 2925
Disassemble 2926
Clean 2927
Inspect 2927
Assemble 2927
Install 2927
Integral Side-Shift Cylinder Gland Leak Checks 2928
Fork Positioner Cylinder Repair Prior to December 2016 2929
Remove 2929
Disassemble 2929
Clean 2932
Inspect 2932
Assemble 2933
Install 2933
Fork Positioner Cylinder Adjustment 2933
Fork Positioner Cylinder Repair After December 2016 2935
General 2935
Remove 2935
Disassemble 2935
Clean 2938
Inspect 2938
Assemble 2939
Install 2939
Fork Positioner Cylinder Adjustment 2939
Seal Kit Installation 2941
External Installation (Seal and Backup Ring) 2941
Internal Installation (Piston Rod Assembly) 2941
Torque Specifications 2942
Main Lift Cylinders 2942
Free-Lift Cylinder 2942
Tilt Cylinders 2942
Integral Sideshift Cylinder 2942
Fork Positioner Cylinder 2942
550093755 4000YRM1669 (04 2023) US EN 2945
General 2953
Safety Procedures When Working Near Mast 2955
Fork Replacement 2957
Standard Carriage and Integral Sideshift Carriage 2957
Remove 2957
Install 2958
Checks 2958
Fork Positioner Carriage 2960
Remove 2961
Install 2961
Checks 2963
Carriages Repair, Two-Stage LFL Mast 2966
Standard Carriage 2966
Remove 2966
Clean and Inspect 2967
Install 2967
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 2967
Remove 2967
Disassemble 2969
Clean and Inspect 2970
Assemble 2971
Install 2971
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 2972
Remove 2972
Disassemble 2975
Clean and Inspect 2975
Assemble 2976
Install 2977
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 2977
Remove 2977
Disassemble 2980
Clean and Inspect 2980
Assemble 2981
Install 2982
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 2982
Remove 2982
Install 2984
Fork Positioner Hydraulic Hose Adjustment 2986
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 2987
Remove 2987
Disassemble and Assemble 2991
Clean and Inspect 2991
Install 2991
Fork Positioner Hydraulic Hose Adjustment 2992
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 2993
Remove 2993
Disassemble and Assemble 2997
Clean and Inspect 2997
Install 2997
Fork Positioner Hydraulic Hose Adjustment 2998
Two-Stage LFL Mast Repair 3000
Mast With Serial Number F507 3000
Remove 3000
Disassemble 3004
Clean and Inspect 3011
Assemble 3013
Install 3014
Header Hoses 3016
Remove 3016
Installation 3016
Adjustment 3020
Mast With Serial Number F562 3021
Remove 3021
Disassemble 3025
Clean and Inspect 3032
Assemble 3034
Install 3035
Header Hose Installation and Adjustment 3036
Remove 3036
Installation 3037
Adjustment 3041
Carriages Repair, Three-Stage FFL Mast 3043
Standard Carriage 3043
Remove 3043
Clean and Inspect 3044
Install 3045
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3045
Remove 3045
Disassemble 3046
Clean and Inspect 3047
Assemble 3048
Install 3048
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3049
Remove 3049
Disassemble 3051
Clean and Inspect 3052
Assemble 3053
Install 3053
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 3054
Remove 3054
Disassemble 3056
Clean and Inspect 3057
Assemble 3058
Install 3058
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 3059
Remove 3059
Install 3061
Fork Positioner Hydraulic Hose Adjustment 3063
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3064
Remove 3064
Disassemble and Assemble 3066
Clean and Inspect 3066
Install 3066
Fork Positioner Hydraulic Hose Adjustment 3067
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 3068
Remove 3068
Disassemble and Assemble 3071
Clean and Inspect 3071
Install 3071
Fork Positioner Hydraulic Hose Adjustment 3072
Three-Stage FFL Mast Repair 3074
Mast With Serial Number F508 3074
Remove 3074
Disassemble 3077
Clean and Inspect 3087
Assemble 3090
Install 3091
Header Hose Installation and Adjustment 3093
Remove 3093
Installation 3093
Adjustment 3102
Mast With Serial Number F563 3102
Remove 3102
Disassemble 3106
Clean and Inspect 3116
Assemble 3119
Install 3120
Header Hose Installation and Adjustment 3122
Remove 3122
Installation 3122
Adjustment 3130
Mast Adjustments 3132
Load Roller, Adjust 3132
Mast Side Kicking, Adjust 3134
Carriage Adjustments 3135
Lift Chains Adjustment 3137
Hydraulic Quick Disconnect Hoses 3139
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) 3139
Lift Trucks Equipped With E-Hydraulic Controls 3139
Lift Trucks Equipped With Manual Hydraulic Controls 3139
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) 3140
Lift Trucks Equipped With E-Hydraulic Controls 3140
Lift Trucks Equipped With Manual Hydraulic Controls 3140
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 3140
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 3140
550093755 4000YRM1669 (06 2019) US EN 3143
General 3149
Safety Procedures When Working Near Mast 3150
Fork Replacement 3152
Standard Carriage and Integral Sideshift Carriage 3152
Remove 3152
Install 3154
Checks 3154
Fork Positioner Carriage 3156
Remove 3157
Install 3157
Checks 3159
Carriages Repair, Two-Stage LFL Mast 3161
Standard Carriage 3161
Remove 3161
Clean and Inspect 3162
Install 3163
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3163
Remove 3163
Disassemble 3164
Clean and Inspect 3165
Assemble 3166
Install 3166
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 3167
Remove 3167
Disassemble 3170
Clean and Inspect 3170
Assemble 3171
Install 3171
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 3172
Remove 3172
Disassemble 3175
Clean and Inspect 3175
Assemble 3176
Install 3176
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 3177
Remove 3177
Install 3179
Fork Positioner Hydraulic Hose Adjustment 3181
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3182
Remove 3182
Disassemble and Assemble 3186
Clean and Inspect 3186
Install 3186
Fork Positioner Hydraulic Hose Adjustment 3187
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 3188
Remove 3188
Disassemble and Assemble 3192
Clean and Inspect 3192
Install 3192
Fork Positioner Hydraulic Hose Adjustment 3193
Two-Stage LFL Mast Repair 3194
Mast With Serial Number F507 3194
Remove 3194
Disassemble 3198
Clean and Inspect 3205
Assemble 3207
Install 3208
Header Hoses 3210
Remove 3210
Installation 3210
Adjustment 3214
Mast With Serial Number F562 3215
Remove 3215
Disassemble 3219
Clean and Inspect 3226
Assemble 3228
Install 3229
Header Hose Installation and Adjustment 3230
Remove 3230
Installation 3231
Adjustment 3235
Carriages Repair, Three-Stage FFL Mast 3236
Standard Carriage 3236
Remove 3236
Clean and Inspect 3238
Install 3238
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3238
Remove 3238
Disassemble 3240
Clean and Inspect 3241
Assemble 3242
Install 3242
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3243
Remove 3243
Disassemble 3245
Clean and Inspect 3246
Assemble 3247
Install 3247
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 3248
Remove 3248
Disassemble 3250
Clean and Inspect 3251
Assemble 3252
Install 3252
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 3253
Remove 3253
Install 3255
Fork Positioner Hydraulic Hose Adjustment 3257
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3258
Remove 3258
Disassemble and Assemble 3260
Clean and Inspect 3260
Install 3260
Fork Positioner Hydraulic Hose Adjustment 3261
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 3262
Remove 3262
Disassemble and Assemble 3265
Clean and Inspect 3265
Install 3265
Fork Positioner Hydraulic Hose Adjustment 3266
Three-Stage FFL Mast Repair 3267
Mast With Serial Number F508 3267
Remove 3267
Disassemble 3271
Clean and Inspect 3281
Assemble 3284
Install 3285
Header Hose Installation and Adjustment 3287
Remove 3287
Installation 3287
Adjustment 3295
Mast With Serial Number F563 3296
Remove 3296
Disassemble 3299
Clean and Inspect 3309
Assemble 3312
Install 3313
Header Hose Installation and Adjustment 3315
Remove 3315
Installation 3315
Adjustment 3323
Mast Adjustments 3324
Load Roller, Adjust 3324
Mast Side Kicking, Adjust 3326
Carriage Adjustments 3326
Lift Chains Adjustment 3328
Hydraulic Quick Disconnect Hoses 3330
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) 3330
Lift Trucks Equipped With E-Hydraulic Controls 3330
Lift Trucks Equipped With Manual Hydraulic Controls 3331
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) 3331
Lift Trucks Equipped With E-Hydraulic Controls 3331
Lift Trucks Equipped With Manual Hydraulic Controls 3332
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 3332
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 3332
550096316 0600YRM1670 (07 2019) US EN 3335
General 3339
Fan Belt Installation 3339
Remove 3339
Inspect 3339
Installation 3340
Thermostat Repair 3340
Remove 3340
Thermostat Operation Check 3341
Install 3341
Water Pump Repair 3341
Remove 3341
Clean and Inspect 3341
Install 3342
Lubrication System Repair 3342
Oil Pan and Oil Pickup, Remove 3342
Oil Pan and Oil Pickup, Inspection 3342
Oil Pump, Remove 3343
Oil Pump, Inspection 3343
Rotor Lobe Clearance 3343
Rotor Cover Clearance 3344
Oil Pump, Assemble and Install 3344
Oil Pan and Oil Pickup, Assemble and Install 3344
Cylinder Head Repair 3345
Remove and Disassemble 3345
Clean and Inspect 3348
Valve Guides and Seats 3350
Valve Lapping 3350
Valve Guide, Replacement 3350
Valve Seats, Inspection and Repair 3351
Valve and Valve Seat Correction 3351
Valve Springs 3352
Assemble and Install 3353
Valve Clearance Adjustments 3356
Gear Case, Timing Gears, and Camshaft 3358
Gear Case 3358
Fan Drive Pulley, Remove 3358
Fan Drive Pulley, Install 3359
Gear Case, Remove 3359
Gear Case, Install 3359
Timing Gears 3359
Oil Pump, Remove 3359
Oil Pump, Install 3359
Crankshaft Oil Slinger, Remove 3359
Crankshaft Oil Slinger, Install 3360
Idler Gear, Remove 3360
Idler Gear, Install 3360
Camshaft 3360
Camshaft, Remove 3360
Camshaft, Install 3361
Piston and Connecting Rod Assemblies Repair 3361
Disassemble 3361
Piston, Clean and Inspect 3362
Piston Ring Gap 3362
Piston Ring Groove 3363
Connecting Rod and Piston Pin, Clean and Inspect 3363
Cylinder Bores, Clean and Inspect 3364
Cylinder Correction (Oversize) 3366
Assemble 3366
Piston Bore Preparation 3368
Cylinder Wear 3368
Cylinder Correction (Oversize) 3368
Flywheel and Bearing Case Cover 3369
Flywheel, Remove 3369
Bearing Case Cover, Remove 3369
Bearing Case Cover, Install 3370
Flywheel, Install 3370
Crankshaft Repair 3371
Crankshaft, Remove 3371
Inspect and Repair 3372
Crankshaft Journal Oil Clearance Bearing 1 3372
Crankshaft Journal Oil Clearance Bearing 2 3373
Crankshaft Bend 3374
Crankshaft, Install 3374
Crankshaft Side Clearance 3376
Engine Block Cleaning and Inspection 3377
Clean and Inspect 3377
Engine Removal and Installation 3378
Engine Specifications 3378
Engine Data 3378
Torque Specifications 3379
550096320 0900YRM1677 (04 2018) US EN 3381
General 3385
LPG Tank and Bracket Replacement 3385
Remove LPG Tank 3385
Install LPG Tank 3388
Remove LPG Bracket 3388
Install LPG Bracket 3391
Remove LPG Tank Bracket Alignment Pin 3391
Install LPG Tank Bracket Alignment Pin 3393
LPG Fuel Filter Unit Repair 3394
LPG Fuel Filter Element 3394
Remove/Disassemble 3394
Clean/Inspect 3395
Assemble/Install 3395
Fuel Filter Housing 3396
Remove 3396
Disassemble 3399
Clean and Inspect 3400
Assemble 3400
Install 3401
Electronic Throttle Body Repair 3401
Remove 3402
Install 3403
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 3404
Remove 3404
Install 3405
Control System 3406
Engine Control Unit (ECU) 3406
Remove 3406
Install 3407
Low LPG Pressure Switch 3407
Remove 3407
Install 3408
LPG Low Level Sensor 3408
Remove 3409
Install 3410
LPG Converter 3411
Remove 3411
Install 3414
LPG Lock-Off Valve 3415
Remove 3415
Install 3417
Exhaust System 3418
Counterweight Exhaust System 3418
Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (B910, C910) 3418
Remove and Disassemble 3418
Inspect 3419
Assemble and Install 3419
Lift Truck Models GLP20-35VX (GLP040-070VX) (C875, D875) 3420
Remove and Disassemble 3420
Inspect 3421
Assemble and Install 3422
Overhead Exhaust System 3422
Remove and Disassemble 3422
Inspect 3423
Assemble and Install 3424
Exhaust Manifold 3424
Remove 3424
Install 3425
Oxygen (HEGO) Sensor 3425
Remove 3425
Install 3426
PCV Valve 3426
LPG Fuel Testing 3427
General 3427
Available Fuel Tests 3427
Composition Test (ASTM D-2163) 3427
Ammonia Test (ASTM D-4490) 3427
Basic Nitrogen Test (ASTM UOP269-90) 3427
Residues Test (ASTM D-2158) 3427
Vapor Pressure Test (ASTM D-2598) 3427
Sulfur Compounds Test (ASTM D-5623) 3427
Methanol Test (ASTM D-4864) 3428
Copper Corrosion (ASTM D-1838) 3428
Where To Send LPG Fuel Samples For Testing 3428
550096322 1400YRM1679 (02 2018) US EN 3431
General 3435
Identification Plate 3435
Drive Axle Removal 3435
Reduction Gear Assembly 3441
Reduction Gear Assembly Repair 3441
Clean and Inspect 3451
Brake Repair 3464
Wet Disc Brake 3464
Clean and Inspect 3480
Wet Brake Noise Reduction 3493
General 3493
Adding Additive To Transmission 3494
Parking Brake Control Lever 3494
General 3494
Clean and Inspect 3497
Differential Repair 3501
Remove 3501
Disassemble 3515
Clean and Inspect 3517
Assemble 3518
Install 3523
Gear Set, Tooth Contact Pattern Check 3537
Drive Axle Installation 3541
Special Tools 3547
Torque Specifications 3550
550100651 2100YRM1692 (11 2016) US EN 3555
General 3561
Description 3563
Safety Procedures When Working Near Mast 3564
Tilt Cylinder Repair 3566
Remove 3566
Disassemble 3567
Clean 3568
Inspect 3568
Assemble 3569
Install 3569
Tilt Cylinders, Adjust 3570
Tilt Cylinders With Tilt Limit Spacers 3570
Tilt Cylinders Without Tilt Limit Spacers 3570
Tilt Cylinder Leak Check 3571
Main Lift And Free-Lift Cylinders Repair 3571
Main Lift Cylinders 3572
Remove 3572
Two-Stage FFL 3572
Four-Stage FFL 3572
Disassemble 3575
Two-Stage FFL 3575
Four-Stage FFL 3577
Clean 3579
Inspect 3579
Assemble 3579
Two-Stage FFL 3579
Four-Stage FFL 3579
Install 3580
Two-Stage FFL 3580
System Air Bleed Procedures 3580
Four-Stage FFL 3581
Free-Lift Cylinder 3581
Remove 3581
Two-Stage FFL 3581
Four-Stage FFL 3583
Disassemble 3585
Two-Stage FFL 3585
Four-Stage FFL 3586
Clean 3587
Inspect 3587
Assemble 3587
Two-Stage FFL 3587
Four-Stage FFL 3587
Install 3588
Two-Stage FFL 3588
Four-Stage FFL 3588
Lift Cylinder Leak Check 3589
Integral Sideshift Cylinder Repair
Prior to December 2016 3590
Remove 3590
Disassemble 3590
Clean and Inspect 3590
Assemble and Install 3591
Integral Sideshift Cylinder Repair
After December 2016 3593
Remove 3593
Disassemble 3593
Clean and Inspect 3593
Assemble and Install 3594
Fork Positioner Cylinder Repair Prior to December 2016 3596
Remove 3596
Disassemble 3596
Clean 3596
Inspect 3599
Assemble 3599
Install 3600
Fork Positioner Cylinder Adjustment 3600
Fork Positioner Cylinder Repair After December 2016 3601
Remove 3601
Disassemble 3601
Clean 3604
Inspect 3604
Assemble 3605
Install 3605
Fork Positioner Cylinder Adjustment 3605
Seal Kit Installation 3605
External Installation (Seal and Back-Up Ring) 3606
Internal Installation (Piston Rod Assembly) 3606
Torque Specifications 3606
Tilt Cylinders 3606
Piston Rod Nut 3606
Gland 3607
Tilt Cylinder Mounting Capscrew 3607
Tilt Cylinder Rod End Nut 3607
Main Lift and Free-Lift Cylinders 3607
Gland, Main Lift Cylinders 3607
Gland, Free-Lift Cylinder 3607
Piston, Main Lift Cylinders 3607
Main Lift Cylinder Mounting Nut To Outer
Mast 3607
Main Lift Cylinder Mounting Nut To Intermediate
Mast (Four-Stage FFL, Right Cylinder Only) 3607
Retainer Nuts 3607
Chain Guard Capscrew (Free-Lift Cylinder) 3607
Crosshead Mounting Capscrew (Free-Lift Cylinder) 3607
Free-Lift Cylinder Mounting Capscrews 3607
Cylinder Shell Capscrew, Main Lift Cylinders 3607
Fork Positioner 3607
Cylinder Rod Retainer 3607
Fork Positioner Cylinder Mounting Capscrews 3607
Cylinder Rod Anchor Plug 3608
Fork Carrier Capscrews 3608
Hose Guide Capscrews 3608
Integral Sideshift Cylinder 3608
Cylinder Rod Retainer 3608
Gland 3608
550100656 4000YRM1693 (10 2017) US EN 3611
General 3617
Safety Procedures When Working Near Mast 3619
Fork Replacement 3621
Standard Carriage and Integral Sideshift Carriage 3621
Remove 3621
Install 3622
Checks 3622
Fork Positioner Carriage 3624
Remove 3624
Install 3624
Checks 3626
Carriages Repair, Two-Stage FFL Mast 3627
Standard Carriage 3628
Remove 3628
Clean and Inspect 3629
Install 3629
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3630
Remove 3630
Disassemble 3630
Clean and Inspect 3633
Assemble 3634
Install 3634
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3635
Remove 3635
Disassemble 3638
Clean and Inspect 3638
Assemble 3638
Install 3639
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 3639
Remove 3639
Install 3640
Fork Positioner Hydraulic Hose Adjustment 3644
Fork Positioner Carriage, Lift Trucks Manufactured After December, 2016 3645
Remove 3645
Disassemble and Assemble 3648
Clean and Inspect 3648
Install 3648
Fork Positioner Hydraulic Hose Adjustment 3649
Two-Stage Mast With Full Free-Lift Repair 3650
Mast With Serial Number E509 3650
Remove 3650
Disassemble 3653
Clean and Inspect 3657
Assemble 3659
Install 3660
Header Hose Procedures 3661
Remove 3661
Installation 3662
Adjustment 3668
Mast With Serial Number E564 3668
Remove 3668
Disassemble 3672
Clean and Inspect 3677
Assemble 3679
Install 3680
Header Hose Procedures 3681
Remove 3681
Installation 3681
Adjustment 3688
Carriages Repair, Four-Stage FFL Mast 3688
Standard Carriage 3688
Remove 3688
Clean and Inspect 3689
Install 3690
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3691
Remove 3691
Disassemble 3693
Clean and Inspect 3693
Assemble 3694
Install 3694
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3695
Remove 3695
Disassemble 3695
Clean and Inspect 3698
Assemble 3698
Install 3698
Fork Positioner Carriage 3699
Four-Stage Mast With Full Free-Lift Repair 3700
Mast With Serial Number D515 3700
Remove 3700
Disassemble 3704
Clean and Inspect 3710
Assemble 3712
Install 3715
Header Hose Procedures 3716
Remove 3716
Installation 3716
Adjustment 3724
Carriage Adjustments 3724
Lift Chains Adjustment 3727
Mast Adjustments 3728
Load Roller, Adjust 3729
Mast Side Kicking, Adjust 3731
Hydraulic Quick Disconnect Hoses 3731
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3731
Lift Trucks Equipped With E-Hydraulic Controls 3731
Lift Trucks Equipped With Manual Hydraulic Controls 3732
Connecting Attachment Hydraulic Quick Disconnect Hoses 3732
Lift Trucks Equipped With E-Hydraulic Controls 3732
Lift Trucks Equipped With Manual Hydraulic Controls 3732
550108495 1300YRM1740 (06 2018) US EN 3735
General 3739
Serial Number 3739
Hydraulic Gear Pump 3739
Remove 3739
Install 3739
Housing Fittings Replacement 3740
Remove 3740
Install 3742
Charge Pump Repair 3742
Torque Converter Replacement 3745
Remove 3745
Clean and Inspect 3745
Install 3745
Stator Support Assembly Repair 3746
Remove 3746
Disassemble 3753
Clean 3754
Inspect 3754
Assemble 3755
Install 3755
Clutch Packs Repair 3757
Remove 3757
Disassemble 3759
Housings 3759
Clutch Packs 3762
Clean 3773
Inspect 3774
Assemble 3774
Clutch Packs 3774
Housings 3788
Install 3790
Drive Chains and Sprockets 3793
Remove 3793
Clean 3795
Inspect 3796
Install 3796
Proportional and Enable Solenoid Valves 3796
Proportional Valves 3796
Remove 3796
Disassemble 3798
Clean and Inspect 3799
Assemble 3799
Install 3799
Enable Solenoid Valve 3799
Remove 3799
Disassemble 3800
Clean and Inspect 3800
Assemble 3800
Install 3800
Pedal Repair Foot Directional Control 3801
Remove and Disassemble 3801
Clean and Inspect 3804
Assemble and Install 3805
550108498 1800YRM1743 (06 2018) US EN 3809
General 3813
Dry Brake System 3813
Wet Brake System 3813
Service Brakes Repair (Dry Brake) 3813
Remove and Disassemble 3814
Clean 3821
Inspect 3822
Assemble and Install 3822
Adjust 3830
Inching Overlap Adjustment 3830
Parking Brake Repair 3831
Remove and Disassemble 3831
Dry Brake System 3831
Wet Brake System 3833
Assemble and Install 3835
Dry Brake System 3835
Wet Brake System 3835
Adjust 3835
Master Cylinder Repair 3836
Remove (Dry Brake) 3836
Disassemble (Dry Brake) 3837
Clean and Inspect (Dry Brake) 3839
Assemble (Dry Brake) 3839
Bench Bleed Master Cylinder (Dry Brake) 3839
Install and Adjust (Dry Brake) 3839
Remove (Wet Brake) 3840
Disassemble (Wet Brake) 3841
Clean and Inspect (Wet Brake) 3842
Assemble (Wet Brake) 3843
Install and Adjust (Wet Brake) 3843
Service Brakes Adjustment (Dry Brake) 3844
Brake System Air Removal 3844
Using Pressure Bleed System 3844
Using Brake Pedal Pressure 3844
Brake Pedal Adjustment 3845
Free Pedal Adjustment 3846
Torque Specifications 3848
550108499 1900YRM1744 (06 2018) US EN 3851
General 3855
Hydraulic Gear Pump Assembly Repair 3856
Remove 3856
Disassemble 3860
Clean 3862
Inspect 3862
Assemble 3862
Install 3862
Quick-Lok™ Hydraulic Hose 3864
Hydraulic Gear Pump Specifications 3865
Variable Displacement Pump Repair 3867
Remove 3867
Disassemble 3872
Clean 3874
Inspect 3874
Assemble 3874
Install 3874
Variable Displacement Pump Checks and Adjustments 3877
Margin Pressure Check 3877
Flow Compensator Adjustment 3878
Pressure Compensator Adjustment 3878
Variable Displacement Pump Specifications 3879
Torque Specifications 3879
Hydraulic Gear Pump 3880
Variable Displacement Pump 3880
550108500 2000YRM1745 (06 2018) US EN 3883
General 3887
Electro-Hydraulic Main Control Valve 3887
Description 3887
Remove 3890
Electro-Hydraulic Control Valve Sections 3893
General 3893
Outlet Control Valve Section 3893
Remove 3893
Disassemble 3893
Clean 3895
Inspect 3895
Assemble 3895
Install 3896
Auxiliary Control Valve Sections 3896
Remove 3896
Disassemble 3898
Clean 3899
Inspect 3899
Assemble 3899
Install 3899
Tilt Control Valve Section 3900
Remove 3900
Disassemble 3900
Clean 3901
Inspect 3901
Assemble 3902
Install 3902
Lift/Lower Control Valve Section 3902
Remove 3902
Disassemble 3902
Clean 3904
Inspect 3904
Assemble 3905
Install 3905
Install 3905
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 3908
Lift Pilot Pin 3908
Lower Pilot Pin 3910
Abnormal/Erroneous EHPV Adjustment 3912
Manual Main Control Valve 3912
Description 3912
Remove 3915
OPS Solenoid Assembly 3921
General 3921
Remove 3922
Clean and Inspect 3924
Install 3924
Manual Control Valve Sections 3925
General 3925
Outlet Control Valve Section 3925
Remove 3925
Disassemble 3925
Clean 3928
Inspect 3928
Assemble 3928
Install 3929
Auxiliary Control Valve Sections 3929
Remove 3929
Disassemble 3929
Clean 3932
Inspect 3932
Assemble 3932
Install 3932
Lift/Tilt Control Valve Section 3933
Remove 3933
Disassemble 3933
Clean 3938
Inspect 3938
Assemble 3938
Install 3939
Install 3939
Pressure Relief Valve Check and Adjustment 3943
Primary Relief Valve 3944
Secondary Relief Valve 3945
Steering Control Unit Repair 3949
Steering Control Unit, Remove 3949
Steering Control Unit, Disassemble 3951
Steering Control Unit, Clean 3953
Steering Control Unit, Inspect 3953
Steering Control Unit, Assemble 3953
Relief Valve, Disassemble 3954
Relief Valve, Clean 3954
Relief Valve, Inspect 3955
Relief Valve, Assemble 3955
Steering Control Unit, Install 3955
550108507 8000YRM1753 (03 2020) US EN 3959
General Information About Diagrams and Schematics 3963
Symbol Definitions 3963
Diagrams Manual Applications 3964
Diagrams and Schematics 3966
550108507 8000YRM1753 (05 2022) US EN 4059
General Information About Diagrams and Schematics 4065
Symbol Definitions 4065
Diagrams Manual Applications 4066
Diagrams and Schematics 4068
550108590 0100YRM1752 (12 2014) US EN 4163
550108889 0100YRM1754 (12 2018) US EN 4217
General 4221
Description 4221
Hood, Seat, and Side Covers Replacement 4222
Remove 4222
Install 4229
Steering Column 4233
Description 4233
Steering Column Repair 4234
Remove 4234
Disassemble 4235
Clean 4236
Inspect 4237
Assemble 4237
Install 4237
LPG Tank and Bracket Assembly 4237
Counterweight Replacement 4237
Remove 4238
Install 4240
Tow Pin 4240
Overhead Guard Replacement 4241
Remove and Install 4241
LED Tail, Backup, and Brake Lights, Replace 4243
Operator Restraint System Replacement 4243
Description 4243
Emergency Locking Retractor (ELR) 4243
Engine Replacement 4245
Remove 4246
Install 4251
Transmission Replacement 4253
Remove Transmission with Iron Housing 4253
Install Transmission with Iron Housing 4255
Remove Transmission with Aluminum Housing 4256
Install Transmission with Aluminum Housing 4260
Throttle Pedal and Cable Adjustment 4262
Throttle Pedal Stop Adjustment 4262
Yanmar Diesel Engine With Basic Power Shift Transmission 4263
Yanmar Diesel Engine With Electronic Throttle 4264
Exhaust System Repair 4264
Lift Trucks With Counterweight Exhaust System 4265
PSI Gas and LPG Engines 4265
Kubota LPG Engines 4265
Yanmar Diesel Engine 4265
Remove and Disassemble 4265
Inspect 4265
Assemble and Install 4265
Lift Trucks With Overhead Exhaust System 4267
PSI Gas and LPG Engines 4267
Kubota LPG Engines 4267
Yanmar Diesel Engine 4267
Remove and Disassemble 4267
Inspect 4267
Assemble and Install 4268
Kubota 2 4L Diesel Engine With Diesel Oxidation Catalyst (DOC) 4270
Remove 4272
Inspect 4275
Install 4275
Diesel Oxidation Catalyst 4277
Disassemble 4277
Assemble 4278
Heavy Duty Pre-Cleaner, Kubota 2 4L Diesel Engine 4278
Remove 4278
Clean 4278
Inspect 4279
Install 4279
Kubota 2 4L Stage V Diesel Engine With Diesel Particulate Filter (DPF) 4280
Remove 4281
Inspect 4284
Install 4284
Cooling System 4285
Description 4285
Hydraulic Filter Assembly Repair 4285
Remove 4285
Clean and Inspect 4286
Install 4286
Fuel and Hydraulic Tanks Repair 4286
Inspect 4287
Clean 4287
Steam Method of Cleaning 4287
Chemical Solution Method of Cleaning 4288
Additional Preparations for Repair 4288
Small Leaks, Repair 4288
Large Leaks, Repair 4288
Preparations for Use After Repair 4289
Safety Labels 4289
550108890 0600YRM1755 (04 2019) US EN 4297
General 4303
Engine Removal and Installation 4306
Cylinder Head Assembly Repair 4306
Drive Train and Lubrication System 4345
Remove 4346
Disassemble 4346
Oil Pan 4346
Oil Pump (Front Cover) 4349
Clean and Inspect 4350
Front Case 4350
Oil Seal 4350
Counterbalance Shaft 4350
Oil Pump 4350
Assemble 4351
Counterbalance Shaft Bearings 4351
Oil Pump (Front Cover) 4352
Oil Pan 4354
Install 4354
Crankshaft and Cylinder Block Repair 4355
Remove Major Attaching Components 4355
Crankshaft and Cylinder Block 4355
Remove 4355
Clean and Inspect 4356
Boring Cylinder 4357
Install 4358
Piston and Connecting Rod 4360
Remove 4360
Disassemble 4361
Clean and Inspect 4362
Assemble 4363
Install 4365
Piston 4365
Rod Bearing 4366
Install Major Attaching Components 4367
Fuel System Repair 4367
Cooling System Repair 4367
Electrical Equipment Repair 4368
Flywheel and Flywheel Housing 4368
Flywheel 4368
Remove 4368
Install 4369
Flywheel Housing 4370
Remove 4370
Install 4370
Engine Specifications 4370
Engine Data 4370
Engine Tuning 4372
Cylinder Head 4372
Intake/Exhaust Valve and Guide 4372
Valve Spring 4373
Gear Train and Camshaft 4373
Camshaft 4373
Idle Gear Shaft and Bushing 4373
Cylinder Block 4373
Crankshaft 4373
Piston 4374
Piston Ring 4374
Connecting Rod 4374
Oil Pump 4374
Engine Oil Pressure 4374
Drive Gear Clearance 4374
Driven Gear Clearance 4375
Torque Specifications 4375
Special Tools 4376
550108890 0600YRM1755 (08 2023) US EN 4383
General 4391
Engine Removal and Installation 4395
Cylinder Head Assembly Repair 4396
Drive Train and Lubrication System 4437
Remove 4437
Disassemble 4437
Oil Pan 4437
Oil Pump (Front Cover) 4440
Clean and Inspect 4441
Front Case 4441
Oil Seal 4441
Counterbalance Shaft 4441
Oil Pump 4441
Assemble 4442
Counterbalance Shaft Bearings 4442
Oil Pump (Front Cover) 4443
Oil Pan 4445
Install 4445
Crankshaft and Cylinder Block Repair 4447
Remove Major Attaching Components 4447
Crankshaft and Cylinder Block 4447
Remove 4447
Clean and Inspect 4448
Boring Cylinder 4449
Install 4450
Piston and Connecting Rod 4452
Remove 4452
Disassemble 4453
Clean and Inspect 4453
Assemble 4454
Install 4456
Piston 4456
Rod Bearing 4457
Install Major Attaching Components 4458
Fuel System Repair 4459
Cooling System Repair 4460
Electrical Equipment Repair 4461
Flywheel and Flywheel Housing 4462
Flywheel 4462
Remove 4462
Install 4463
Flywheel Housing 4463
Remove 4463
Install 4463
POWER TAKE OFF (PTO), REMOVE AND INSTALL 4464
REMOVE COVER 4464
INSTALL COVER 4464
Engine Specifications 4466
Engine Data 4466
Engine Tuning 4467
Cylinder Head 4468
Intake/Exhaust Valve and Guide 4468
Valve Spring 4468
Gear Train and Camshaft 4469
Camshaft 4469
Idle Gear Shaft and Bushing 4469
Cylinder Block 4469
Crankshaft 4469
Piston 4469
Piston Ring 4470
Connecting Rod 4470
Oil Pump 4470
Engine Oil Pressure 4470
Drive Gear Clearance 4470
Driven Gear Clearance 4470
Torque Specifications 4471
Special Tools 4473
550108891 0700YRM1756 (06 2019) US EN 4477
General 4481
Cooling System Checks 4481
Exhaust Leaks Into Cooling System 4481
Water Flow Restrictions in Radiator 4481
Radiator Hoses 4481
Water Pump 4481
Flushing the Cooling System 4482
Cooling System, Clean 4482
Radiator Replacement 4483
Radiator, Remove 4483
Radiator, Install 4494
Fan Assembly Replacement 4495
Fan Removal 4495
Inspect 4499
Fan Installation 4500
550108892 0900YRM1757 (06 2018) US EN 4503
General 4509
Intake-Air System 4510
Intake-Air System Manifold Vacuum Check 4510
Throttle Body 4510
Remove 4511
Install 4512
Intake Manifold 4512
LPG Tank and Bracket Replacement Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (C910) and GLP20-35VX (GLP040-070VX) (D875) 4512
Remove LPG Tank 4512
Install LPG Tank 4515
Remove LPG Bracket 4515
Install LPG Bracket 4518
Remove LPG Tank Bracket Alignment Pin 4518
Install LPG Tank Bracket Alignment Pin 4520
LPG Tank and Bracket Replacement Lift Truck Models GLC050LX, GLC050LX2 (B967) and GLP20-25LX (GLP050LX) (B974) 4521
Remove LPG Tank 4521
LPG Tank Install 4523
Remove LPG Bracket 4523
Install LPG Bracket 4523
LPG Fuel Filter Unit Repair Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (C910) and GLP20-35VX (GLP040-070VX) (D875) 4524
Fuel Filter Element 4524
Remove 4524
Clean/Inspect 4524
Install 4525
Fuel Filter Housing 4525
Remove 4525
Disassemble 4526
Assemble 4527
Install 4527
LPG Fuel Filter Unit Repair Lift Truck Models GLC050LX, GLC050LX2 (B967) and GLP/GDP20-25LX (GLP/GDP050LX) (B974) 4528
Fuel Filter Element 4528
Remove 4528
Clean/Inspect 4529
Install 4529
Fuel Filter Housing 4529
Remove 4529
Disassemble 4529
Assemble 4530
Install 4530
Electronic Throttle Body Repair 4530
Remove 4531
Install 4532
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 4533
Remove 4534
Install 4536
Gasoline Fuel System 4537
Before Repair Procedure 4538
Fuel Line Safety Procedure 4538
After Repair Procedure 4540
Fuel Hose, Install 4540
Fuel Leakage Check 4540
Fuel Line Pressure Check 4541
Fuel Injectors 4541
Remove 4541
Install 4542
Pressure Regulator 4542
Remove 4542
Install 4543
Control System 4543
Engine Control Module (ECM) 4543
Remove 4543
Install 4545
Fuel Level Sensor 4545
Remove 4545
Install 4545
Low LPG Pressure Switch 4546
Remove 4546
Install 4546
LPG Low Level Sensor 4546
Remove 4547
Install 4547
LPG Converter 4548
LPG Lock-Off Valve 4553
Remove 4553
Install 4554
Exhaust System 4556
Counterweight Exhaust System 4556
Remove and Disassemble 4556
Inspect 4557
Assemble and Install 4558
Overhead Exhaust System 4558
Remove and Disassemble 4558
Inspect 4560
Assemble and Install 4560
Exhaust Manifold 4560
Positive Crankcase Ventilation (PCV) Valve 4560
Remove 4560
Inspect 4560
Install 4561
Oxygen Sensor 4561
Remove 4561
Install 4562
LPG Fuel Testing 4562
General 4562
Available Fuel Tests 4563
Composition Test (ASTM D-2163) 4563
Ammonia Test (ASTM D-4490) 4563
Basic Nitrogen Test (ASTM UOP269-90) 4563
Residues Test (ASTM D-2158) 4563
Vapor Pressure Test (ASTM D-2598) 4563
Sulfur Compounds Test (ASTM D-5623) 4563
Methanol Test (ASTM D-4864) 4563
Copper Corrosion (ASTM D-1838) 4563
Where To Send LPG Fuel Samples For Testing 4563
Technical Data 4564
550108893 1400YRM1758 (02 2018) US EN 4567
General 4571
Drive Axle Repair 4571
Remove and Disassemble 4571
Clean and Inspect 4574
Assemble and Install 4574
Differential Repair 4577
Remove 4577
Disassemble 4588
Clean and Inspect 4593
Install 4602
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 4602
Ring Gear Backlash, Adjust 4614
Ring Gear, Runout Check 4616
Gear Set, Tooth Contact Pattern Check 4616
Torque Specifications 4619
550108894 1600YRM1759 (12 2014) US EN 4623
550108895 2200YRM1760 (01 2020) US EN 4647
General 4655
Display Switch Cluster 4656
Remove 4656
Install 4658
Direction Control and Turn Signal Levers 4658
Remove 4658
Install 4659
Key Switch 4660
Remove 4660
Install 4660
Display Switch Cluster Panel Bezel and Overlay 4661
Remove 4661
Install 4661
Steering Column Repair 4661
Remove 4661
Disassemble 4663
Assemble 4663
Install 4664
Sensors and Switches 4664
General 4664
Dash and Kick Panel, Remove and Install 4664
Remove 4664
Install 4665
Accelerator Pedal Position Sensor 4665
Remove 4665
Install 4667
Brake Fluid Level Switch 4668
Remove 4668
Install 4668
Service Brake Pedal Position Sensor 4669
Remove 4669
Install 4670
Parking Brake Sensor 4670
Remove 4670
Install 4671
Service Brake Pressure Sensor 4671
Remove 4671
Install 4671
Sensor MicroswitchFoot Directional Control 4672
Remove 4672
Install 4674
Low Coolant Level Sensor 4674
Remove 4674
Install 4676
Fuel Level Sensor, Gas and Diesel Engines Only 4676
Remove 4676
Install 4676
Seat Sensor (Operator Presence System) 4677
Non-Suspension and Semi-Suspension Seats 4677
Remove 4677
Install 4678
Full Suspension And Swivel Seats 4678
Remove 4678
Install 4679
Hood Shut Off Switch 4679
Remove 4679
Install 4680
Hydraulic Filter Pressure Switch 4680
Remove 4680
Install 4681
Transmission Speed Sensor 4681
Remove 4681
Install 4682
Transmission Pressure Sensors 4682
Remove 4682
Install 4682
Transmission Temperature Sensor 4682
Remove 4682
Install 4683
Return to Set Tilt (Tilt Angle) Sensor 4683
Remove 4683
Install 4683
Rear Horn Button Switch 4683
Remove 4683
Install 4684
Impact Sensor 4684
Remove 4684
Install 4685
Load Weight Sensor 4686
Remove 4686
Install 4686
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with PSI 2 4L Dual Fuel Engine 4687
Engine and Fuel Sensors and Switches, Kubota 2 5L LPG Engine 4687
Crankshaft Position Sensor 4687
Remove 4687
Install 4687
Camshaft Position Sensor 4688
Remove 4688
Install 4688
Engine Coolant Temperature (ECT) Sensor 4688
Remove 4688
Install 4688
Manifold Absolute Pressure (MAP) Sensor 4689
Remove 4689
Install 4689
Oil Pressure Sensor 4689
Remove 4689
Install 4689
Knock Sensor 4690
Remove 4690
Install 4690
Oxygen Sensors 4690
Air Flow Restriction Switch 4690
Remove 4690
Install 4691
Engine and Fuel Sensors and Switches, Yanmar Diesel Engine 4691
Air Filter Restriction Switch 4691
Remove 4691
Install 4691
Oil Pressure Sensor 4691
Remove 4691
Install 4691
Engine Speed Sensor 4691
Remove 4691
Install 4691
Engine Coolant Temperature (ECT) Sensor 4692
Remove 4692
Install 4692
Throttle Position Sensor (TPS) 4694
Remove 4694
Install 4695
Fuel/Water Separator Sensor 4695
Remove 4695
Install 4695
Glow Plug Relay 4696
Remove 4696
Install 4698
Engine and Fuel Sensors and Switches, Kubota 2 4L Diesel Engine 4698
Crankshaft Position Sensor 4698
Remove 4698
Install 4698
Camshaft Position Sensor 4698
Remove 4698
Install 4698
Engine Coolant Temperature (ECT) Sensor 4699
Remove 4699
Install 4699
Engine Oil Pressure Sensor 4699
Remove 4699
Install 4700
Intake Air Pressure (Boost) Sensor 4700
Remove 4700
Install 4701
Air Filter Restriction Switch 4701
Remove 4701
Install 4701
Mass Airflow Sensor 4701
Remove 4701
Install 4701
Glow Plugs 4702
Remove 4702
Inspect 4703
Install 4703
Engine and Fuel Sensors and Switches, Kubota 2 4L Stage V Diesel Engine 4704
Crankshaft Position Sensor 4704
Remove 4704
Install 4704
Camshaft Position Sensor 4704
Remove 4704
Install 4704
Engine Coolant Temperature (ECT) Sensor 4705
Remove 4705
Install 4705
Engine Oil Pressure Sensor 4705
Remove 4705
Install 4706
Differential Pressure Sensor 4706
Remove 4706
Install 4706
Diesel Particulate Filter (DPF) Sensors 4706
Remove 4706
Install 4706
Intake Air Pressure (Boost) Sensor 4706
Remove 4706
Install 4706
Air Filter Restriction Switch 4707
Remove 4707
Install 4707
Mass Airflow Sensor 4707
Remove 4707
Install 4707
Glow Plugs 4708
Remove 4708
Inspect 4708
Install 4709
Vehicle System Manager (VSM) 4709
General 4709
VSM Replacement 4709
Remove 4709
Install 4710
Programming a New VSM and/or Display Switch Cluster 4710
General 4710
Data Transferring 4711
New VSM 4711
New (Blank) Display Switch Cluster 4711
Used (Non-Blank) Display Switch Cluster 4711
PC Service Tool Software 4712
Power Distribution Module (PDM) and Component Parts 4713
Remove 4713
PDM as a Unit 4713
Install 4715
PDM as a Unit 4715
Remove and Install 4715
PDM Component Parts 4715
Battery 4715
Remove 4715
Install 4715
Lights 4716
Work Lights (Front and Rear) 4716
Halogen Bulb Lights 4716
Remove 4716
Install 4716
LED Lights 4716
Remove 4716
Install 4717
Strobe Light 4717
Remove 4717
Install 4717
LED Tail, Backup, and Brake Lights 4718
Remove 4718
Install 4718
Front Marker/Turn Signal Lights 4719
Replacing Whole Front Marker/Turn Signal Light Assembly 4719
Remove 4719
Install 4719
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 4720
Remove 4720
Install 4720
Electronic-Hydraulic Controls, Before January, 2020 4720
E-Hydraulic Controls – TEST 4720
Mini-Levers 4720
Full Stroke Test 4721
Function Returns to Neutral Test 4721
Push (Override) Button 4721
General 4722
Mini-levers, Remove and Install 4722
Armrest Assembly 4723
Remove 4723
Install 4726
Horn Button 4726
Remove 4726
Install 4726
Direction Control Switch 4726
Remove 4726
Install 4727
Push (Override) Buttons 4727
Remove 4727
Install 4728
Electronic-Hydraulic Controls, After January, 2020 4728
E-Hydraulic Controls – TEST 4729
Mini-Levers 4729
Full Stroke Test 4729
Function Returns to Neutral Test 4729
Push (Override) Button 4729
General 4730
Mini-levers, Remove and Install 4730
Armrest Assembly 4731
Remove 4731
Install 4734
Horn Button 4734
Remove 4734
Install 4734
Direction Control Switch 4734
Remove 4734
Install 4735
Push (Override) Button 4735
Remove 4735
Install 4736
Diesel Particulate Filter (DPF) Display 4736
Remove 4736
Clean and Inspect 4737
Install 4737
550108896 2200YRM1761 (04 2020) US EN 4739
General 4743
Ignition System 4743
Ignition Timing Adjustment 4743
Spark Plugs Check 4743
Coil Replacement 4743
Remove 4743
Inspect 4745
Install 4745
Starter Repair 4746
General 4746
Remove 4746
No-Load Test 4747
Magnetic Switch Test 4748
Pull-Out Test 4748
Holding Coil Test 4748
Return Test 4749
Pinion Movement Inspection 4749
Install 4749
Alternator Repair 4750
General 4750
Charging System Inspection 4751
Output Current Check 4751
No-Load Adjusted Voltage Check 4751
Remove 4752
Install 4752
Engine Sensors and Switches 4753
Oil Pressure Sensor 4753
Remove 4753
Install 4753
Air Filter Restriction Switch 4753
Remove 4753
Install 4753
Cam Angle Sensor 4754
Remove 4754
Install 4754
Crankshaft Position Sensor (CKP) 4754
Remove 4754
Install 4754
Temperature Manifold Absolute Pressure (TMAP) Sensor 4755
Remove 4755
Install 4756
Engine Coolant Temperature (ECT) Sensor 4756
Remove 4756
Install 4756
Battery Disconnect Switch 4756
Remove 4756
Install 4758
Electronic Control Module 4759
550108897 8000YRM1762 (01 2022) US EN 4761
General 4767
Serial Number Data 4767
How to Move Disabled Lift Truck 4768
How to Tow Lift Truck 4768
How to Put Lift Truck on Blocks 4769
How to Raise Drive Tires 4769
How to Raise Steering Tires 4769
How to Clean a Lift Truck 4771
Maintenance Schedule 4772
Recommended Lubricants 4787
Lubricant Specifications 4787
Maintenance Procedures Every 8 Hours or Daily 4791
How to Make Checks With Engine Stopped 4791
Tires and Wheels 4791
Safety Labels 4791
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4791
Operator Restraint System 4792
Emergency Locking Retractor (ELR) 4793
Adjust Seat – Full Suspension 4794
Adjust Seat – Internal Suspension 4796
Hood and Seat Latches 4796
Engine Compartment 4796
Paper Application 4796
Fuel, Oil, and Coolant Leaks, Check 4797
Hydraulic Hoses 4797
Coolant Hoses 4797
Steering Column Gas Cylinder 4797
Transmission 4797
Hydraulic System Oil 4798
Engine Oil 4798
Air Filter 4800
Forks 4801
Inspect 4801
Remove 4802
Install 4805
Adjust 4805
How to Make Checks With Engine Running 4805
Indicator Lights, Horn, Fuses, and Relays 4806
Service Brakes 4808
Brake Fluid Level 4808
Operation, Check 4809
Parking Brake 4809
Engine Oil Pressure 4809
Cooling System 4810
Steering System 4811
Control Levers and Pedals 4811
Lift System, Operate 4811
First Service After First 100 Hours of Operation 4812
Kubota Engine Oil and Oil Filter 4812
Kubota 2 5L LPG Engine 4812
Kubota 2 4L Diesel Engine 4812
PSI Engine Oil and Oil Filter 4813
Yanmar Engine Oil and Oil Filter 4813
Maintenance Procedures Every 250 Hours or 6 Months 4814
PSI 2 4L Engine Oil and Oil Filter Change 4814
Drain Oil from LPG Vaporizer Regulator (LPG Converter) – PSI Engine 4814
Cleaning Carbon Buildup From Intake Valves – PSI 2 4L LPG Engine 4816
Maintenance Procedures Every 500 Hours or 6 Months 4818
Kubota Engine Oil and Oil Filter 4818
Kubota 2 5L LPG Engine 4818
Kubota 2 4L Diesel Engine 4818
Yanmar Engine Oil and Oil Filter Change 4819
Cleaning Carbon Buildup From Intake Valves – Kubota 2 5L LPG Engine 4819
Hydraulic System Oil 4821
Hydraulic Tank Breather 4821
Inspect 4821
Battery 4822
Drive Belt 4822
Yanmar Diesel Engine 4822
Fan and Alternator Drive Belt 4822
Kubota 2 4L Diesel Engine 4823
Fan and Alternator Drive Belt 4823
Kubota 2 5L LPG Engine 4824
Fan and Alternator Drive Belt 4824
Clean Debris From Radiator Core 4824
Transmission Oil Level 4825
Wet Brake Planetary Housing Oil Level Check 4826
Forks, Inspect 4828
Mast Lubrication 4830
Header Hose Checks 4833
Lift Chain Lubrication 4833
Tilt Cylinder Lubrication 4834
Master Brake Cylinder Rod End Pin Lubrication 4835
Manual Hydraulic Levers Lubrication 4836
Brake Fluid 4836
Tie Rod Lubrication (GP/GLP/GDP040-070VX) 4837
Differential and Drive Axle Oil (Dry Brake) 4837
Fuel/Water Separator, Kubota 2 4L Diesel Engine 4837
Drain 4838
Replace Filter 4838
Remove 4838
Install 4838
Priming the Fuel System (Kubota) 4839
Maintenance Procedures Every 1000 Hours or 6 Months 4840
Valve Clearance, Check and Adjust 4840
PCV Valve, Kubota Engine 4840
Drive Belt Check 4840
LPG Fuel Filter Element Replace, Kubota 2 5L Engine 4840
Remove 4840
Install 4841
LPG Fuel Filter Replace, PSI Engine 4841
Remove 4841
Clean/Inspect 4842
Install 4842
In-Line Fuel Filter Replacement, PSI 2 4L Engine 4843
Fuel Filter Replacement, Yanmar Engine 4843
Priming the Fuel System (Yanmar) 4845
Ignition System 4846
PSI 2 4L Engines 4846
Kubota 2 5L LPG Engine 4846
Lift Chains Wear Check 4846
Lift Chain Lubrication 4846
Integral Sideshift Carriage, Check Bearings 4847
Integral Sideshift Carriage, Check Lower Mounting Hooks 4847
Steering Axle 4848
Control Levers and Pedals 4848
Maintenance Procedures Every 1500 Hours 4849
Separator Element Replacement, Kubota 2 4L Diesel Engine 4849
Remove 4849
Install 4849
Maintenance Procedures Every 2000 Hours or 1 Year 4850
Hydraulic System 4850
Hydraulic Filter, Replace 4850
Hydraulic Tank Breather, Replace 4851
Air Filter 4851
Ignition System 4854
Kubota 2 5L LPG Engine 4854
PCV Valve 4854
Kubota 2 5L LPG Engine 4854
Oxygen Sensor 4854
Fuel Injector, Yanmar Engines 4855
Fuel Injector, Kubota 2 4L Diesel Engine 4855
Forks, Inspect 4855
Integral Sideshift Carriage 4856
Bearings, Replace 4856
Transmission Oil and Filter (Dry Brake), Replace 4856
Iron Transmission Housing 4856
Aluminum Transmission Housing 4857
Remove 4857
Clean and Inspect 4858
Install 4858
Transmission Oil Change, Wet Brake Drive Axle 4859
Iron Transmission Housing 4859
Aluminum Transmission Housing 4860
Wet Brake Axle Center Section and Planetary Housing, Oil Change 4864
Brake Fluid (Master Cylinder), Change 4866
Brake Fluid (Dry Brake), Remove 4868
Steer Axle Wheel Bearings Lubrication 4868
Service Brakes (Dry Brake) 4868
Differential (Dry Brake) 4869
Maintenance Procedures Every 4000 Hours or 2 Years 4870
Hydraulic Oil, Replace 4870
Cooling System 4871
Maintenance Procedures Every 6000 Hours 4873
Timing Belt Change, PSI Engine 4873
Diesel Particulate Filter (DPF), Kubota Diesel Engine 4873
Remove 4873
Install 4877
Safety Procedures When Working Near Mast 4878
Hood Latch Check 4881
Lift Chain Adjustments 4882
Jump-Starting the Lift Truck 4884
Jump-Starting Using a Battery Charger 4884
Jump-Starting a Lift Truck Using Another Lift Truck 4884
Welding Repairs 4885
Wheel and Tire Replacement 4886
General 4886
Solid Rubber Tire, Change (GC/GLC Series) 4886
Remove and Install Tire on Wheel 4886
Pneumatic Tire With Tube, Repair 4887
Remove Wheels From Lift Truck 4887
Remove Tire From Wheel 4888
Install Wheel in Tire 4890
Install Tire on Two-Piece Wheel 4892
Add Air to Pneumatic Tires With Tube 4893
Install the Wheels 4893
Dual Drive Wheels, Install 4894
Pneumatic Tubeless Tire, Repair 4894
Remove Wheels From Lift Truck 4894
Add Air to Pneumatic Tubeless Tire 4900
Wheels, Install 4900
Solid Rubber Tires on Pneumatic Wheels, Change 4900
Overhead Guard Changes 4904
Adhesives and Sealants 4905
550108897 8000YRM1762 (08 2019) US EN 4907
General 4913
Serial Number Data 4913
How to Move Disabled Lift Truck 4913
How to Tow Lift Truck 4913
How to Put Lift Truck on Blocks 4914
How to Raise Drive Tires 4914
How to Raise Steering Tires 4915
How to Clean a Lift Truck 4915
Maintenance Schedule 4916
Recommended Lubricants 4931
Lubricant Specifications 4931
Maintenance Procedures Every 8 Hours or Daily 4934
How to Make Checks With Engine Stopped 4934
Tires and Wheels 4934
Safety Labels 4935
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4935
Operator Restraint System 4936
Emergency Locking Retractor (ELR) 4936
Adjust Seat – Full Suspension 4938
Adjust Seat – Internal Suspension 4939
Hood and Seat Latches 4940
Engine Compartment 4940
Paper Application 4940
Fuel, Oil, and Coolant Leaks, Check 4941
Hydraulic Hoses 4941
Coolant Hoses 4941
Steering Column Gas Cylinder 4941
Transmission 4941
Hydraulic System Oil 4941
Engine Oil 4942
Air Filter 4944
Forks 4945
Inspect 4945
Remove 4946
Install 4949
Adjust 4949
How to Make Checks With Engine Running 4950
Indicator Lights, Horn, Fuses, and Relays 4950
Service Brakes 4952
Brake Fluid Level 4952
Operation, Check 4953
Parking Brake 4953
Engine Oil Pressure 4953
Cooling System 4954
Steering System 4954
Control Levers and Pedals 4955
Lift System, Operate 4955
First Service After First 100 Hours of Operation 4955
Kubota Engine Oil and Oil Filter 4955
Kubota 2 5L LPG Engine 4955
Kubota 2 4L Diesel Engine 4955
PSI Engine Oil and Oil Filter 4956
Yanmar Engine Oil and Oil Filter 4956
Maintenance Procedures Every 250 Hours or 6 Months 4957
PSI 2 4L Engine Oil and Oil Filter Change 4957
Drain Oil from LPG Vaporizer Regulator (LPG Converter) – PSI Engine 4958
Cleaning Carbon Buildup From Intake Valves – PSI 2 4L LPG Engine 4959
Maintenance Procedures Every 500 Hours or 6 Months 4961
Kubota Engine Oil and Oil Filter 4961
Kubota 2 5L LPG Engine 4961
Kubota 2 4L Diesel Engine 4962
Cleaning Carbon Buildup From Intake Valves – Kubota 2 5L LPG Engine 4963
Hydraulic System Oil 4964
Hydraulic Tank Breather 4965
Inspect 4965
Battery 4965
Yanmar Engine Oil and Oil Filter Change 4966
Drive Belt 4966
Yanmar Diesel Engine 4966
Fan and Alternator Drive Belt 4966
Kubota 2 4L Diesel Engine 4967
Fan and Alternator Drive Belt 4967
Kubota 2 5L LPG Engine 4968
Fan and Alternator Drive Belt 4968
Clean Debris From Radiator Core 4968
Transmission Oil Level 4969
Wet Brake Planetary Housing Oil Level Check 4970
Forks, Inspect 4972
Mast Lubrication 4973
Header Hose Checks 4977
Lift Chain Lubrication 4977
Tilt Cylinder Lubrication 4977
Master Brake Cylinder Rod End Pin Lubrication 4978
Manual Hydraulic Levers Lubrication 4979
Brake Fluid 4979
Tie Rod Lubrication (GP/GLP/GDP040-070VX) 4980
Differential and Drive Axle Oil (Dry Brake) 4980
Fuel/Water Separator, Kubota 2 4L Diesel Engine 4981
Drain 4981
Replace Filter 4982
Remove 4982
Install 4982
Priming the Fuel System (Kubota) 4982
Maintenance Procedures Every 1000 Hours or 6 Months 4983
Valve Clearance, Check and Adjust 4983
PCV Valve, Kubota Engine 4983
Drive Belt Check 4983
LPG Fuel Filter Element Replace, Kubota 2 5L Engine 4983
Remove 4983
Install 4983
LPG Fuel Filter Replace, PSI Engine 4984
Remove 4984
Clean/Inspect 4985
Install 4985
In-Line Fuel Filter Replacement, PSI 2 4L Engine 4986
Fuel Filter Replacement, Yanmar Engine 4986
Priming the Fuel System (Yanmar) 4988
Ignition System 4988
PSI 2 4L Engines 4988
Kubota 2 5L LPG Engine 4988
Lift Chains Wear Check 4989
Lift Chain Lubrication 4989
Integral Sideshift Carriage, Check Bearings 4989
Integral Sideshift Carriage, Check Lower Mounting Hooks 4990
Steering Axle 4990
Control Levers and Pedals 4991
Maintenance Procedures Every 1500 Hours 4991
Separator Element Replacement, Kubota 2 4L Diesel Engine 4991
Remove 4991
Install 4992
Maintenance Procedures Every 2000 Hours or 1 Year 4992
Hydraulic System 4992
Hydraulic Filter, Replace 4992
Hydraulic Tank Breather, Replace 4994
Air Filter 4994
Ignition System 4997
Kubota 2 5L LPG Engine 4997
PCV Valve 4997
Kubota 2 5L LPG Engine 4997
Oxygen Sensor 4997
Fuel Injector, Yanmar Engines 4997
Fuel Injector, Kubota 2 4L Diesel Engine 4998
Forks, Inspect 4998
Integral Sideshift Carriage 4999
Bearings, Replace 4999
Transmission Oil and Filter (Dry Brake), Replace 4999
Iron Transmission Housing 4999
Aluminum Transmission Housing 5000
Remove 5000
Clean and Inspect 5001
Install 5001
Transmission Oil Change, Wet Brake Drive Axle 5001
Iron Transmission Housing 5001
Aluminum Transmission Housing 5003
Wet Brake Axle Center Section and Planetary Housing, Oil Change 5006
Brake Fluid (Master Cylinder), Change 5008
Brake Fluid (Dry Brake), Remove 5010
Steer Axle Wheel Bearings Lubrication 5010
Service Brakes (Dry Brake) 5010
Differential (Dry Brake) 5010
Maintenance Procedures Every 4000 Hours or 2 Years 5011
Hydraulic Oil, Replace 5011
Cooling System 5013
Maintenance Procedures Every 6000 Hours 5014
Timing Belt Change, PSI Engine 5014
Diesel Particulate Filter (DPF), Kubota Diesel Engine 5014
Remove 5014
Install 5018
Safety Procedures When Working Near Mast 5019
Hood Latch Check 5021
Lift Chain Adjustments 5022
Jump-Starting the Lift Truck 5024
Jump-Starting Using a Battery Charger 5024
Jump-Starting a Lift Truck Using Another Lift Truck 5024
Welding Repairs 5024
Wheel and Tire Replacement 5025
General 5025
Solid Rubber Tire, Change (GC/GLC Series) 5025
Remove and Install Tire on Wheel 5025
Pneumatic Tire With Tube, Repair 5026
Remove Wheels From Lift Truck 5026
Remove Tire From Wheel 5027
Install Wheel in Tire 5030
Install Tire on Two-Piece Wheel 5032
Add Air to Pneumatic Tires With Tube 5033
Install the Wheels 5033
Dual Drive Wheels, Install 5033
Pneumatic Tubeless Tire, Repair 5034
Remove Wheels From Lift Truck 5034
Add Air to Pneumatic Tubeless Tire 5040
Wheels, Install 5040
Solid Rubber Tires on Pneumatic Wheels, Change 5040
Overhead Guard Changes 5044
Adhesives and Sealants 5044
550108898 8000YRM1763 (06 2022) US EN 5047
Lift Truck Lifting Capacity 5053
Counterweight Weights 5053
Tire Sizes 5053
Capacities 5054
Recommended Lubricants 5060
Lubricant Specifications 5060
Electrical System 5066
Transmission Oil Pressures 5068
Hydraulic System Relief Pressures 5070
Steering System 5071
Stall Speeds (in RPM ±100 rpm) 5072
PSI 2 4L 5072
Kubota 2 5L 5072
Yanmar 2 6L 5072
Yanmar 3 0L 5072
Yanmar 3 3L 5072
Kubota 2 4L 5072
Mast Speeds 5073
Tilt Angles 5087
Front End Equipment – Mast Creep 5088
Mast Creep 5088
Engine Specifications 5089
Diesel Fuel Cleanliness Levels 5092
Torque Specifications 5093
Frame 5093
Mast 5093
Steering System, Cushioned Tire Trucks 5093
Steering System, Pneumatic Tire Trucks 5093
Drive Axle (Dry Brake) 5093
Drive Axle (Wet Brake) 5094
Transmission – Iron Housing 5094
Transmission – Aluminum Housing 5095
Engine – PSI 2 4L Dual Fuel 5095
Engine – Yanmar 2 6L, 3 0L, and 3 3L Diesel 5096
Engine – Kubota 2 5L LPG 5097
Kubota 2 4L Diesel 5098
550108898 8000YRM1763 (08 2019) US EN 5101
Lift Truck Lifting Capacity 5105
Counterweight Weights 5105
Tire Sizes 5106
Capacities 5106
Recommended Lubricants 5112
Lubricant Specifications 5112
Electrical System 5115
Transmission Oil Pressures 5117
Hydraulic System Relief Pressures 5118
Steering System 5119
Stall Speeds (in RPM ±100 rpm) 5120
PSI 2 4L 5120
Kubota 2 5L 5120
Yanmar 2 6L 5120
Yanmar 3 0L 5120
Yanmar 3 3L 5121
Kubota 2 4L 5121
Mast Speeds 5122
Tilt Angles 5136
Front End Equipment – Mast Creep 5137
Mast Creep 5137
Engine Specifications 5138
Diesel Fuel Cleanliness Levels 5141
Torque Specifications 5141
Frame 5141
Mast 5141
Steering System, Cushioned Tire Trucks 5141
Steering System, Pneumatic Tire Trucks 5141
Drive Axle (Dry Brake) 5142
Drive Axle (Wet Brake) 5142
Transmission – Iron Housing 5143
Transmission – Aluminum Housing 5143
Engine – PSI 2 4L Dual Fuel 5143
Engine – Yanmar 2 6L, 3 0L, and 3 3L Diesel 5145
Engine – Kubota 2 5L LPG 5145
Kubota 2 4L Diesel 5146
550109083 1300YRM1764 (12 2014) US EN 5149
550120852 0600YRM1921 (11 2017) US EN 5215
General 5221
Engine Identification 5221
Major Engine Component Identification 5221
Location of Labels 5221
Engine Removal and Installation 5222
Cylinder Head Assembly Repair 5222
Valve Covers and Fuel Injectors 5222
Remove 5222
Clean and Inspect 5227
Install 5227
Rocker Arm Assembly 5228
Remove 5228
Disassemble 5228
Clean and Inspect 5229
Push Rods 5229
Rocker Arm Assembly 5229
Assemble 5230
Install 5230
Valve Clearance Adjustments 5230
Compression Test 5231
Cylinder Head Assembly 5231
Remove 5231
Disassemble 5240
Valves and Valve Springs, Remove 5240
Valve Guides, Remove 5241
Clean and Inspect 5241
Cylinder Head 5242
Valve Guides 5242
Valves 5242
Valve Sink 5243
Valve Seat 5243
Valve Springs 5244
Assemble 5244
Valve Guides, Install 5244
Valves and Valve Springs, Install 5245
Install 5246
Timing Gear Case and Timing Gears Repair 5248
Timing Gear Case Cover 5249
Remove 5249
Clean and Inspect 5250
Install 5250
Timing Gears 5251
Oil Pump Driven Gear 5251
Remove 5251
Install 5251
Crankshaft Gear 5251
Remove 5251
Install 5251
Idler Gear 5252
Remove 5252
Inspect 5252
Install 5252
Camshaft Gear 5253
Remove 5253
Install 5253
Drive Train, Camshaft, and Cylinder Block Repair 5253
Remove 5254
Disassemble 5254
Pistons and Connecting Rods 5254
Crankshaft 5255
Camshaft 5257
Remove 5257
Install 5257
Clean and Inspect 5257
Cylinder Block 5258
Honing and Boring 5258
Cylinder Correction (Oversize) 5259
Pistons 5260
Piston Ring Gap 5260
Piston Ring Groove 5261
Connecting Rod and Piston Pin 5261
Crankshaft 5262
Camshaft 5264
Assemble 5265
Camshaft 5265
Crankshaft 5265
Pistons and Connecting Rods 5265
Install 5266
Lubrication System Repair 5267
Engine Oil and Oil Filter Change 5267
Oil Pan 5268
Remove 5268
Install 5268
Oil Suction Tube 5268
Remove 5268
Clean 5268
Install 5269
Oil Pump 5269
Remove 5269
Clean and Inspect 5269
Outer Rotor Outside Clearance 5270
Outer Rotor to Inner Rotor Tip Clearance 5270
Rotor Cover Clearance 5270
Install 5270
Fuel System Repair 5271
Fuel Injectors 5271
Remove 5271
Inspect 5271
Clean 5271
Replace 5271
Install 5272
Test 5272
Fuel Injection Pump/Supply Pump 5272
Remove 5272
Clean and Inspect 5274
Install 5274
Cooling System Repair 5275
Accessory Drive Belt 5275
Remove 5275
Inspect 5275
Install 5276
Accessory Drive Belt, Adjustment 5276
Water Pump 5277
Remove 5277
Install 5277
Thermostat 5279
Remove 5279
Inspect 5279
Install 5279
Flywheel and Flywheel Housing 5280
Flywheel 5281
Remove 5281
Install 5281
Flywheel Housing 5281
Remove 5281
Install 5281
Electrical Equipment Repair 5281
Alternator 5282
Remove 5282
Install 5282
Starter 5283
Remove 5283
Install 5283
Engine Specifications 5283
Engine Data 5284
Engine Tuning 5285
Cylinder Head 5285
Intake/Exhaust Valve and Guide 5285
Valve Spring 5285
Rocker Arm and Shaft 5286
Push Rod 5286
Gear Train and Camshaft 5286
Camshaft 5286
Idle Gear Shaft and Bushing 5286
Backlash of Each Gear 5287
Cylinder Block 5287
Crankshaft 5287
Piston 5288
Piston Ring 5288
Connecting Rod 5288
Rod Small End 5288
Tappet 5289
Oil Pump 5289
Engine Oil Pressure 5289
Outer Rotor Outside Clearance 5289
Outer Rotor Side Clearance 5289
Inner Rotor to Cover 5289
Standard Torque Specifications 5289
Standard Torque Chart 5290
Special Torque Specifications 5290
Special Tools 5291
550158688 2040YRM2075 (06 2017) US EN 5299
General 5303
Description 5303
Precautions 5303
Clamp Assembly Installation 5303
Hydraulic Hose Flush 5304
Clamp Installation (With Lifting Device) 5304
Clamp Installation (Without Lifting Device) 5306
Hose Connections 5306
Clamp Series 5306
Connecting The Hoses 5307
Operating Checks 5307
Clamping Force Test 5307
Troubleshooting 5309
General 5309
Hydraulic Schematics 5311
550158693 2040YRM2081 (09 2017) US EN 5315
General 5319
Description 5319
Precautions 5319
Rotator Assembly Installation 5320
Removing Rotator From Skid 5321
Rotator Attachment Installation 5322
Hydraulic Hose Flush And Connection 5324
Fork Installation 5325