Yale Forklift A964 (GP30MX) Service Manual – PDF DOWNLOAD

Yale Forklift A964 (GP30MX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A964 (GP30MX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1518
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A964 (GP30MX) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) UK EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524223769 2200YRM1128 (01 2023) UK EN 23
Series Code / Model Designation Reference Table 31
General 33
Deutsch Crimping Tool 34
How to Strip a Wire for Use With Deutsch Crimping Tool 34
How to Crimp With the Deutsch Crimping Tool 35
Calibration Test for the Deutsch Crimping Tool 37
Deutsch Connectors 39
DT, DTM, and DTP Series Connectors 39
HD Series Connectors 82
Metri-Pack Connectors 104
Remove and Install 104
Micro-Pack Connectors 107
Weather-Pack Connectors 108
AMPSEAL Crimping Tools 110
AMP Hand Crimping Tool With Certi-Crimp 110
Description 110
Stripping Wire for Use with AMP Hand Crimping Tool 111
Insulation Crimp Adjustment 112
Maintenance and Inspection for AMP Hand Crimping Tool 112
AMP Hand Crimping Tool 112
Crimp Height Inspection 112
How to use AMP Hand Crimping Tool 113
AMP Pro-Crimper II Tool 113
Description 113
Remove and Install Die Set and Locator Assembly 114
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 114
Contact Support Adjustment 115
Crimp Height Adjustment 116
Maintenance and Inspection Procedures 116
PRO-CRIMPER II Tool 116
Crimp Height Inspection 116
How to Use AMP PRO-CRIMPER II Tool 117
AMPSEAL Connector Assemblies 118
Description for Plug Connector Assembly 118
Seal Plug 119
Contact Crimping 119
Description for Plug Connector and Header Assembly 124
Voltage Reading 127
Seal Plug 127
Contact Crimping 127
AMP Superseal 1 5 Crimping Tools 134
Mini Mic Receptacle and Tab Contacts 134
Description 134
Crimping Conditions and Measurements 134
Insertion of Rubber Seal on Cable 136
AMP Hand Application Tool 141
Description 141
Maintenance and Inspection 141
Crimp Height Inspection 141
Crimp Height Adjustment 142
How to Use AMP Hand Application Tool 142
AMP Pro-Crimper II Tool 143
Description 143
Remove and Install Die Set and Locator Assembly 143
Adjustments 144
Contact Support 144
Crimp Height 145
Inspections and Maintenance 146
Crimp Height Inspection 146
Visual Inspection 146
Maintenance 147
How to Use Pro-Crimper II Tool 147
AMP Superseal 1 5 Connector Assemblies 148
Description 148
Repair and Maintenance 155
Panel Mount Option 155
AMP Fastin-Faston Hand Tools 156
Description – AMP Double Action Hand Tool 156
Maintenance and Inspection Procedures 156
Daily Maintenance 156
Periodic Tool Inspection 157
Lubrication 157
Visual Inspection 157
Crimp Height Inspection 157
Certi-Crimp Ratchet Inspection 158
How to Use AMP Double Action Hand Tool 159
Description – AMP Extraction Tool 160
Maintenance and Inspection 161
How to Use AMP Extraction Tool 161
AMP Fastin-Faston Receptacles and Housings 163
Description 163
Wire Repair 171
Wire Splicing Requirements 171
Deutsch Jiffy Splice 172
Twisted/Shielded Cable and Leads Repair 178
Special Tools 180
550073240 1900YRM1620 (01 2023) UK EN 189
Proper Flushing after Major Hydraulic Repairs 195
Introduction 195
The Phases of Wear 195
Causes of Hydraulic System Failure 195
Progression of Contaminant Caused Hydraulic System Failure 196
Hydraulic System Flushing Techniques 196
Double Oil and Filter Change 196
Mechanical Cleaning 197
Cleaning of Components 197
How to Clean Tubes and Hoses 197
Filter Caddy 197
Start-Up Procedure for Cleaned System 198
Contaminated Oil Coolers 198
Additional Filter Caddy Functions 199
How to Handle Different Fluids 199
Water Removal Filters 199
Fluid Conditioning and System Flushing Procedures 200
Operation of the Filter Caddy 200
Filter Caddy operation 200
Fluid Conditioning Procedure 200
Filter Caddy Start-Up 201
System Flushing Procedure 201
Component Cleaning Procedure 202
Reservoir Cleaning Procedure 202
Cylinder Cleaning Procedure 202
Hose and Tube Cleaning Procedure 202
Valve Cleaning Procedure 203
Front-End Attachment Cleaning Procedure 204
System Flushing Procedure 204
Filter Caddy Start-Up 205
System Start-Up and Flushing 205
Reservoir Fluid Cleaning Times 206
Dealing With Different Fluid Types 207
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 207
Filter Caddy Maintenance 207
Servicing the Strainer 207
DC Motor 207
Hydraulic Oil Sampling Method and Procedure 208
Hydraulic Oil Sampling Method 208
Objective 208
General Guidelines 208
Synopsis 209
Hydraulic Oil Analysis Report Guidelines 210
Sampling Conditions 210
Equipment 210
Sampling Procedure 211
Hydraulic Oil Sampling 211
Sample Labeling 211
Results Documentation 211
550141724 9000YRM2004 (03 2021) UK EN 213
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 219
Group 05 – Operational Checkout 221
SECTION 9020 ENGINE 233
Group 10 – Principles of Operation 235
Group 40 – Tests and Adjustments 283
Group 30 – Observed Symptoms 291
SECTION 9030 ELECTRICAL SYSTEM 295
Group 03 – General Maintenance and Diagnostic Data 299
Group 10 – Principles of Operation 327
Group 20 – Diagnostic Trouble Codes 337
Group 30 – Observed Symptoms 421
SECTION 9040 DRIVE TRAIN 427
Group 10 – Principles of Operation 429
Group 30 – Observed Symptoms 441
Group 40 – Tests and Adjustments 473
SECTION 9050 HYDRAULIC SYSTEM 479
Group 10 – Principles of Operation 483
Group 30 – Observed Symptoms 511
Group 33 – Observed Symptoms-Gear Pump 527
Group 43 – Tests and Adjustments-Gear Pump 613
Group 40 – Tests and Adjustments 629
SECTION 9060 OPERATORS STATION 631
Group 10 – Principles of Operation 633
SECTION 9070 FRONT END (MAST) AND CHASSIS 653
Group 10 – Principles of Operation 655
Group 30 – Observed Symptoms 671
SECTION 9080 SUPPLEMENTARY DATA 715
Group 50 – Abbreviations and Acronyms 717
Group 60 – Special Tools List 725
Group 70 – Fault Mode Indicator Reference 729
Group 80 – Supplier Specification Data 731
550188057 0100YRM2111 (04 2019) UK EN 735
General 739
Description 739
Hood, Seat, and Side Covers Replacement 741
Remove 741
Install 745
Steering Column 746
Description 746
Steering Column Repair 747
Remove 747
Disassemble 748
Clean 750
Inspect 751
Assemble 751
Install 751
LPG Tank and Bracket Assembly 751
Counterweight Replacement 751
Remove 752
Install 752
Tow Pin 753
Overhead Guard Replacement 753
Remove and Install 753
LED Tail, Backup, and Brake Lights, Replace 755
Operator Restraint System Replacement 755
Description 755
Emergency Locking Retractor (ELR) 755
Engine Replacement 755
Remove 756
Install 759
Transmission Replacement 760
Remove 761
Install Transmission with Aluminum Housing 762
Throttle Pedal and Cable Adjustment 763
Yanmar Diesel Engine With Manual Throttle Cable 763
Traction Speed Limit (TSL) Group 765
Remove 766
Install 769
Adjustment Procedure 769
Exhaust System Repair 770
Lift Trucks With Counterweight Exhaust System 771
Yanmar Diesel Engine 771
Remove and Disassemble 771
Inspect 771
Assemble and Install 771
Lift Trucks With Overhead Exhaust System 772
Yanmar Diesel Engine 772
Remove and Disassemble 772
Inspect 775
Assemble and Install 775
Cooling System 775
Description 775
Diesel Fuel Level Sender 776
Remove 776
Install 776
Hydraulic Filter Assembly Repair 776
Remove 777
Clean and Inspect 778
Install 778
Fuel and Hydraulic Tanks Repair 779
Inspect 779
Clean 779
Steam Method of Cleaning 780
Chemical Solution Method of Cleaning 780
Additional Preparations for Repair 780
Small Leaks, Repair 781
Large Leaks, Repair 781
Preparations for Use After Repair 781
Safety Labels 781
550188058 0100YRM2112 (12 2017) UK EN 787
General 791
Cab Replacement 791
Remove 792
Install 798
Cab Doors 799
Remove 799
Disassemble 799
Right Cab Door 799
Left Cab Door 801
Clean 802
Inspect 802
Assemble 802
Right Cab Door 802
Left Cab Door 802
Install 802
Window Wipers Replacement 802
General 803
Front Wiper and Motor Assembly 803
Remove 803
Clean 803
Inspect 803
Install 803
Rear Wiper and Motor Assembly 805
Remove 805
Clean 805
Inspect 805
Install 805
Window Replacement 806
General 807
Front Window 807
Remove 807
Clean 807
Inspect 807
Install 808
Rear Window 808
Remove 808
Clean 809
Inspect 809
Install 809
Door Window 810
Remove and Disassemble 810
Clean 812
Inspect 812
Assemble and Install 812
Top Window 812
PVC Top Window 812
Remove 812
Clean 813
Inspect 813
Install 813
Glass Top Window 813
Remove 813
Clean 814
Inspect 814
Install 814
Cab Heater Replacement 814
Remove 815
Install 816
Cab Heater Filter 817
Remove 817
Install 817
Cab Heater Operation 817
Lights Replacement 818
Optional Equipment 818
Heavy Duty Pre-Cleaner 818
Remove 818
Clean 818
Inspect 818
Install 819
Mirror 820
Remove 820
Install 820
Rear Horn Button and Handle 820
Label Replacement 820
Electrical Schematics 820
Dash Display Panel and Switches 820
550188059 0600YRM2113 (12 2017) UK EN 825
General 831
Engine Removal and Installation 832
Cylinder Head Assembly Repair 832
Drive Train and Lubrication System 864
Remove 865
Disassemble 865
Oil Pan 865
Oil Pump (Front Cover) 867
Clean and Inspect 868
Front Case 868
Oil Seal 868
Counterbalance Shaft 868
Oil Pump 868
Assemble 868
Counterbalance Shaft Bearings 868
Oil Pump (Front Cover) 870
Oil Pan 871
Install 871
Crankshaft and Cylinder Block Repair 871
Remove Major Attaching Components 872
Crankshaft and Cylinder Block 872
Remove 872
Clean and Inspect 872
Boring Cylinder 874
Install 875
Piston and Connecting Rod 877
Remove 877
Disassemble 878
Clean and Inspect 879
Assemble 880
Install 882
Piston 882
Rod Bearing 883
Install Major Attaching Components 883
Fuel System Repair 884
Cooling System Repair 884
Electrical Equipment Repair 884
Flywheel and Flywheel Housing 884
Flywheel 884
Remove 884
Install 884
Flywheel Housing 885
Remove 885
Install 885
Engine Specifications 885
Engine Data 885
Engine Tuning 886
Cylinder Head 887
Intake/Exhaust Valve and Guide 887
Valve Spring 887
Gear Train and Camshaft 887
Camshaft 887
Idle Gear Shaft and Bushing 888
Cylinder Block 888
Crankshaft 888
Piston 888
Piston Ring 889
Connecting Rod 889
Oil Pump 889
Engine Oil Pressure 889
Drive Gear Clearance 889
Driven Gear Clearance 889
Torque Specifications 889
Special Tools 891
550188060 0600YRM2114 (04 2018) UK EN 897
General 903
Engine Identification 903
Major Engine Component Identification 903
Location of Labels 903
Engine Removal and Installation 904
Cylinder Head Assembly Repair 904
Glow Plugs 906
Remove 906
Install 906
Valve Cover 907
Remove 907
Clean and Inspect 907
Install 907
Rocker Arm Assembly 907
Remove 907
Disassemble 908
Clean and Inspect 909
Push Rods 909
Rocker Arm Assembly 909
Assemble 909
Install 910
Valve Clearance Adjustments 910
Cylinder Head Assembly 911
Remove 911
Disassemble 915
Valves and Valve Springs, Remove 915
Valve Guides, Remove 916
Clean and Inspect 916
Cylinder Head 917
Valve Guides 917
Valves 917
Valve Sink 917
Valve Seat 918
Valve Springs 918
Assemble 919
Valve Guides, Install 919
Valves and Valve Springs, Install 919
Install 920
Timing Gear Case and Timing Gears Repair 922
Timing Gear Case Cover 922
Remove 922
Clean and Inspect 922
Install 923
Timing Gears 923
Crankshaft Gear 923
Remove 923
Install 924
Idler Gear 924
Remove 924
Inspect 924
Install 925
Camshaft 925
Remove 925
Install 925
Timing Gear Case 925
Remove 925
Clean and Inspect 926
Install 926
Drive Train, Camshaft, and Cylinder Block Repair 926
Remove 927
Disassemble 927
Pistons and Connecting Rods 927
Crankshaft 928
Camshaft 930
Clean and Inspect 932
Cylinder Block 932
Honing and Boring 935
Pistons 936
Piston Pin 936
Connecting Rod 936
Tappets 937
Crankshaft 937
Camshaft 938
Camshaft Bushing 939
Assemble 939
Camshaft 939
Crankshaft 940
Pistons and Connecting Rods 940
Install 942
Lubrication System Repair 942
Engine Oil and Oil Filter Change 942
Oil Pan 942
Remove 942
Install 943
Oil Suction Tube 943
Remove 943
Clean 943
Install 944
Oil Pump 944
Remove 944
Clean and Inspect 944
Outer Rotor Outside Clearance 945
Outer Rotor to Inner Rotor Tip Clearance 945
Outer Rotor Side Clearance 945
Rotor Shaft Clearance 945
Install 946
Fuel System Repair 946
Fuel Injectors 946
Remove 946
Inspect 948
Clean 948
Test 948
Install 951
Electronic Throttle System 951
Remove 951
Install 954
Inspect 955
Adjust 955
Manual Throttle System 956
Fuel Injection Pump 956
Remove 956
Clean and Inspect 959
Install 960
Check/Adjust Fuel Injection Timing 960
Cooling System Repair 962
V-Belt 962
Remove 962
Inspect 962
Install 962
Adjust 962
Water Pump 963
Remove 963
Install 965
Thermostat 966
Remove 966
Inspect 966
Install 967
Flywheel and Flywheel Housing 967
Flywheel 968
Remove 968
Install 969
Flywheel Housing 970
Remove 970
Install 970
Electrical Equipment Repair 970
Alternator 971
Remove 971
Bench Test 972
Regulate Voltage Check 973
No Load Test 975
Output Test 975
Install 975
Starter 976
Remove 977
No Load Test 977
Install 978
Engine Specifications 979
Engine Data 979
Engine Tuning 980
Cylinder Head 980
Intake/Exhaust Valve and Guide 981
Valve Spring 981
Rocker Arm and Shaft 981
Push Rod 981
Gear Train and Camshaft 982
Camshaft 982
Idle Gear Shaft and Bushing 982
Backlash of Each Gear 983
Cylinder Block 983
Crankshaft 983
Thrust Bearing 983
Piston 984
Piston Ring 984
Connecting Rod 985
Rod Small End 985
Tappet 985
Oil Pump 985
Engine Oil Pressure 985
Outer Rotor Outside Clearance 985
Outer Rotor Side Clearance 986
Outer Rotor to Inner Rotor Tip Clearance 986
Rotor Shaft Clearance 986
Standard Torque Specifications 986
Standard Torque Chart 986
Special Torque Specifications 987
Special Tools 988
550188061 0700YRM2115 (04 2018) UK EN 995
General 999
Cooling System Checks 999
Exhaust Leaks Into Cooling System 999
Water Flow Restrictions in Radiator 999
Radiator Hoses 999
Water Pump 999
Flushing the Cooling System 999
Cooling System, Clean 1000
Radiator Replacement 1001
Radiator, Remove 1001
Radiator, Install 1004
Fan Assembly Replacement 1006
Fan Removal 1006
Inspect 1006
Fan Installation 1006
550188062 0900YRM2116 (12 2017) UK EN 1009
General 1013
Intake-Air System 1013
Intake-Air System Manifold Vacuum Check 1013
Throttle Body 1014
Remove 1014
Install 1015
Intake Manifold 1015
LPG Tank and Bracket Replacement with Swing-Out Bracket 1015
Remove LPG Tank 1015
Install LPG Tank 1017
Remove LPG Bracket 1017
Install LPG Bracket 1018
Remove LPG Tank Bracket Alignment Pin 1019
Install LPG Tank Bracket Alignment Pin 1020
LPG Tank and Bracket Replacement with Fixed Bracket 1020
Remove LPG Tank 1021
LPG Tank Install 1021
Remove LPG Bracket 1023
Install LPG Bracket 1023
LPG Fuel Filter Unit Repair 1023
Fuel Filter Element 1023
Remove 1023
Clean/Inspect 1024
Install 1024
Fuel Filter Housing 1024
Remove 1024
Disassemble 1026
Assemble 1026
Install 1026
Electronic Throttle Body Repair 1027
Remove 1027
Install 1027
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 1029
Remove 1030
Install 1032
Control System 1032
Engine Control Module (ECM) 1033
Remove 1033
Install 1033
Fuel Level Sensor 1035
Remove 1035
Install 1035
Low LPG Pressure Switch 1035
Remove 1035
Install 1036
LPG Converter 1036
LPG Lock-Off Valve 1039
Remove 1039
Install 1041
Exhaust System 1041
Counterweight Exhaust System 1042
Remove and Disassemble 1042
Inspect 1042
Assemble and Install 1042
Overhead Exhaust System 1044
Remove and Disassemble 1044
Inspect 1044
Assemble and Install 1046
Exhaust Manifold 1046
Positive Crankcase Ventilation (PCV) Valve 1046
Remove 1046
Inspect 1046
Install 1046
Oxygen Sensor 1047
Remove 1047
Install 1048
550188063 1300YRM2117 (05 2018) UK EN 1051
General 1055
Serial Number 1055
Torque Converter Repair 1056
Remove 1056
Clean and Inspect 1061
Install 1061
Gear Pump Replacement 1063
Remove 1063
Clean 1064
Inspect 1064
Install 1064
Clutch Packs Repair 1065
Remove 1065
Disassemble 1066
Clean 1078
Inspect 1078
Assemble 1079
Install 1090
Control Valve and Solenoid Valve Repair 1093
Remove 1093
Disassemble 1094
Clean 1096
Inspect 1096
Assemble 1096
Install 1096
Pedal Repair – Foot Directional Control 1097
Remove and Disassemble 1097
Clean and Inspect 1101
Assemble and Install 1101
550188064 1400YRM2118 (04 2018) UK EN 1105
General 1109
Drive Axle Repair 1109
Remove and Disassemble 1109
Clean and Inspect 1110
Assemble and Install 1111
Differential Repair 1113
Remove 1113
Disassemble 1120
Clean and Inspect 1127
Install 1134
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 1134
Ring Gear Backlash, Adjust 1144
Ring Gear, Runout Check 1146
Gear Set, Tooth Contact Pattern Check 1146
Torque Specifications 1149
550188065 1600YRM2119 (04 2018) UK EN 1153
General 1157
Steering Axle Assembly Repair 1157
Remove 1158
Disassemble 1158
Clean 1159
Inspect 1159
Assemble 1160
Install 1160
Spindles, Bearings, and Tie Rods Repair 1160
Spindles and Bearings 1161
Tie Rods 1163
Steering Cylinder Repair 1165
Remove and Disassemble 1166
Clean and Inspect 1166
Assemble and Install 1166
Torque Specifications 1167
550188066 1800YRM2120 (04 2018) UK EN 1171
General 1175
Dry Brake System 1175
Service Brakes Repair 1175
Remove and Disassemble 1175
Clean 1180
Inspect 1181
Assemble and Install 1181
Adjust 1186
Parking Brake Repair 1186
Remove and Disassemble 1186
Assemble and Install 1187
Adjust 1187
Master Cylinder Repair 1188
Remove 1188
Disassemble 1189
Clean and Inspect 1190
Assemble 1190
Bench Bleed Master Cylinder 1190
Install and Adjust 1190
Service Brakes Adjustment 1190
Brake System Air Removal 1191
Using Pressure Bleed System 1191
Using Brake Pedal Pressure 1191
Brake Pedal Adjustment with Single Pedal Option 1191
Brake Pedal Adjustment with Dual Pedal Option 1192
550188067 1900YRM2121 (05 2018) UK EN 1197
General 1201
Hydraulic Gear Pump Repair 1202
Remove 1202
Gear Pump With Rear Ports 1202
Disassemble 1204
Clean 1205
Inspect 1205
Assemble 1206
Install 1207
Gear Pump With Rear Ports 1207
Hydraulic Gear Pump Specifications 1207
Torque Specifications 1207
Hydraulic Gear Pump 1207
550188069 2100YRM2123 (04 2018) UK EN 1211
General 1215
Safety Procedures When Working Near Mast 1216
Main Lift Cylinder Repair 1219
Remove 1219
Disassemble 1221
Clean 1223
Inspect 1223
Assemble 1223
Install 1224
Main Lift Cylinder Leak Check 1224
Free-Lift Cylinder 1225
Remove 1225
Disassemble 1226
Clean 1227
Inspect 1228
Assemble 1228
Install 1228
Tilt Cylinder Repair 1228
Remove 1229
Disassemble 1230
Clean 1231
Inspect 1231
Assemble 1231
Install 1232
Tilt Cylinder Adjustment 1232
Tilt Cylinder Leak Check 1233
Integral Sideshift Cylinder Repair 1234
Remove 1234
Disassemble 1235
Clean 1235
Inspect 1236
Assemble 1236
Install 1236
Fork Positioner Cylinder Repair 1236
Remove 1236
Disassemble 1236
Clean 1239
Inspect 1239
Assemble 1240
Install 1240
Fork Positioner Cylinder Adjustment 1240
Seal Kit Installation 1240
External Installation (Seal and Backup Ring) 1241
Internal Installation (Piston Rod Assembly) 1241
Torque Specifications 1242
Main Lift Cylinders 1242
Free-Lift Cylinder 1242
Tilt Cylinders 1242
Integral Sideshift Cylinder 1242
Fork Positioner Cylinder 1242
550188070 2200YRM2124 (04 2019) UK EN 1245
General 1249
Description 1249
Dash Display Menu Access 1249
Menu Navigation 1250
Standard Display 1250
Main Menu 1250
Passwords 1250
Adding Passwords 1250
Hourmeters 1251
Instrument Panel Display Functions 1252
Digital Clock 1252
Speedometer 1253
Lift Truck Controller 1254
Load Meter 1254
Truck Configuration 1255
Diagnostics 1255
View Fault Log 1255
Controller Error Code 1255
Display Error Code 1255
Clear Error Codes 1256
Speed Settings 1257
Speed Limit 1257
Setup Display Menu 1257
Setup General Items 1257
Seat Belt Alarm 1258
Parking Alarm 1258
Leaving Seat Warning Function 1258
Key Switch OFF Reminder 1258
Calibrations 1258
550188071 2200YRM2125 (05 2018) UK EN 1261
General 1267
Display Panel 1267
Remove 1268
Install 1269
Direction Control and Turn Signal Levers 1269
Remove 1269
Install 1271
Key Switch 1271
Remove 1271
Install 1272
Steering Column Repair 1274
Remove 1274
Disassemble 1275
Assemble 1276
Install 1276
Sensors and Switches 1277
General 1277
Dash and Kick Panel, Remove and Install 1277
Remove 1277
Install 1277
Brake Fluid Level Switch 1278
Remove 1278
Install 1279
Stop Lamp Switch 1280
Remove 1280
Parking Brake Sensor 1280
Remove 1280
Install 1281
Service Brake Pressure Switch 1281
Remove 1281
Install 1282
Drive Axle Speed Sensor 1282
Yanmar Diesel Engine 1282
Remove 1282
Install 1283
Sensor MicroswitchFoot Directional Control 1283
Remove 1283
Install 1285
Seat Sensor (Operator Presence System) 1285
Non-Suspension Seat 1285
Remove 1285
Install 1286
Seat Belt Interlock Control Module 1287
Remove 1287
Install 1287
Transmission Temperature Switch 1288
Remove 1288
Install 1288
Remote Key Switch 1288
Remove 1288
Install 1288
Load Weight Sensor 1289
Remove 1289
Install 1289
Rear Horn Button Switch 1290
Remove 1290
Install 1290
Engine and Fuel Sensors and Switches, Yanmar 3 3L Diesel Engines 1291
Engine Oil Pressure Switch 1291
Remove 1291
Install 1291
Engine Coolant Temperature (ECT) Sensor 1291
Remove 1291
Install 1291
Fuel/Water Separator 1291
Remove 1291
Install 1291
Glow Plugs 1292
Dash Panel Rocker Switches 1292
Remove 1292
Install 1292
Power Distribution Module (PDM) and Component Parts (Fuses and Relays) 1293
Remove 1293
PDM as a Unit 1293
Install 1294
PDM as a Unit 1294
Remove and Install 1294
PDM Component Parts 1294
Battery 1295
Remove 1296
Install 1296
Lights 1296
Work Lights (Front and Rear) 1296
Halogen Bulb Lights 1296
Remove 1296
Install 1297
LED Lights 1297
Remove 1297
Install 1297
Strobe Light 1297
Remove 1297
Install 1298
LED Tail, Backup, and Brake Lights 1299
Remove 1299
Install 1299
LED Front Marker/Turn Signal Lights 1300
Remove 1300
Install 1300
Blue Spot Light (LED) 1301
Remove 1301
Install 1301
Vehicle Electronic Control Unit (VECU) 1302
General 1302
Remove 1302
Install 1303
Horn, Alarms, and Buzzers 1303
Horn 1303
Remove 1303
Install 1303
Audible Alarm 1304
Remove 1304
Install 1304
Telemetry Wireless Asset Management System 1304
General 1305
Level 1 – Wireless Monitoring (WIFI Group) 1306
Communication Module 1308
Remove 1308
Install 1309
Antenna 1310
Remove 1310
Install 1310
Level 2 – Wireless Access 1311
Communication Module 1313
Antenna 1313
RF-ID Reader 1313
Remove 1314
Install 1314
Buzzer 1315
Remove 1315
Install 1315
Level 3 – Wireless Verification 1316
Communication Module 1317
Antenna 1318
RF-ID Reader 1318
Buzzer 1318
Display Panel (Checklist) 1318
Remove 1318
Install 1318
550188073 4000YRM2127 (04 2018) UK EN 1321
General 1325
Safety Procedures When Working Near Mast 1326
Fork Replacement 1328
Standard Carriage and Integral Sideshift Carriage 1328
Remove 1328
Install 1330
Checks 1330
Carriages Repair, Two-Stage LFL Mast 1332
Standard Carriage 1332
Remove 1332
Clean and Inspect 1333
Install 1334
Integral Sideshift Carriage 1334
Remove 1334
Disassemble 1336
Clean and Inspect 1337
Assemble 1338
Install 1338
Two-Stage LFL Mast Repair 1339
Mast With Serial Numbers A389 and A399 1339
Remove 1341
Disassemble 1344
Clean and Inspect 1348
Assemble 1350
Install 1351
Header Hoses 1352
Remove 1352
Installation 1352
Adjustment 1356
Carriages Repair, Three-Stage FFL Mast 1357
Standard Carriage 1357
Remove 1357
Clean and Inspect 1359
Install 1359
Integral Sideshift Carriage 1359
Remove 1359
Disassemble 1362
Clean and Inspect 1363
Assemble 1364
Install 1364
Three-Stage FFL Mast Repair 1365
Mast With Serial Numbers A387 And A397 1365
Remove 1367
Disassemble 1369
Clean and Inspect 1377
Assemble 1380
Install 1381
Header Hose Installation and Adjustment 1382
Remove 1382
Installation 1383
Adjustment 1390
Carriage Adjustments 1391
Lift Chains Adjustment 1392
Mast Adjustments 1393
Load Roller, Adjust 1393
Mast Side Kicking, Adjust 1395
Hydraulic Quick Disconnect Hoses 1395
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 1395
Lift Trucks Equipped With E-Hydraulic Controls 1395
Lift Trucks Equipped With Manual Hydraulic Controls 1396
Connecting Attachment Hydraulic Quick Disconnect Hoses 1396
Lift Trucks Equipped With E-Hydraulic Controls 1396
Lift Trucks Equipped With Manual Hydraulic Controls 1397
550188074 8000YRM2128 (10 2019) UK EN 1401
General 1407
Serial Number Data 1407
How to Move Disabled Lift Truck 1407
How to Tow Lift Truck 1407
How to Put Lift Truck on Blocks 1408
How to Raise Drive Tires 1408
How to Raise Steering Tires 1408
How to Clean a Lift Truck 1409
Maintenance Schedule 1410
Maintenance Procedures Every 8 Hours or Daily 1418
How to Make Checks With Engine Stopped 1418
Tires and Wheels 1418
Safety Labels 1419
Mast, Carriage, Lift Chains, Header Hoses, Attachment 1419
Operator Restraint System 1420
Emergency Locking Retractor (ELR) 1420
Hood and Seat Latches 1421
Ground Static Strap 1421
Engine Compartment 1422
Fuel, Oil, and Coolant Leaks, Check 1422
Hydraulic Hoses 1422
Coolant Hoses 1422
Steering Column 1422
Transmission 1422
Hydraulic System Oil 1422
Engine Oil 1423
Air Filter 1423
Forks 1424
General 1424
Inspect 1424
Remove 1424
Install 1426
Adjust 1427
Brake Fluid 1427
How to Make Checks With Engine Running 1428
Indicator Lights, Horn, Fuses, and Relays 1428
Service Brakes 1430
Operation, Check 1430
Parking Brake 1430
Engine Oil Pressure 1431
Cooling System 1431
Steering System 1432
Control Levers and Pedals 1432
Lift System, Operate 1432
First Service After First 100 Hours of Operation 1433
Yanmar Engine Oil and Oil Filter 1433
Maintenance Procedures Every 300 Hours 1433
Tie Rod Lubrication 1433
King Pin Lubrication 1434
Maintenance Procedures Every 500 Hours or 1 Year 1434
Hydraulic System Oil 1434
Battery 1435
Yanmar Engine Oil and Oil Filter Change 1435
Drive Belt 1435
Yanmar Diesel Engine 1435
Fan and Alternator Drive Belt 1435
Clean Debris From Radiator Core 1436
Transmission Oil Level 1437
Forks 1437
Inspect 1437
Mast Lubrication 1438
Header Hose Checks 1440
Lift Chain Lubrication 1440
Tilt Cylinder Lubrication 1440
Master Brake Cylinder Rod End Pin Lubrication 1442
Manual Hydraulic Levers Lubrication 1442
Brake Fluid 1442
Differential and Drive Axle Oil 1443
Maintenance Procedures Every 1000 Hours or 1 Year 1444
Valve Clearance, Check and Adjust, Yanmar Engines 1444
Fuel Filter Replacement, Yanmar Engines 1444
Priming the Fuel System, Yanmar 1446
Lift Chains Wear Check 1446
Lift Chain Lubrication 1447
Integral Sideshift Carriage, Check Bearings 1447
Integral Sideshift Carriage, Check Lower Mounting Hooks 1448
Control Levers, Pedals, and Parking Brake 1448
Maintenance Procedures Every 2000 Hours or 1 Year 1448
Hydraulic System 1448
Return Filter, Replace 1448
Air Filter Element, Replace 1450
Air Filter Without Silencer 1450
Air Filter With Silencer 1452
Fuel Injector, Yanmar Engines 1453
Forks, Inspect 1453
Integral Sideshift Carriage 1454
Bearings, Replace 1454
Service Brakes (Dry Brake) 1454
Differential 1455
Transmission Oil and Filter, Replace 1456
Brake Fluid Change, Master Cylinder 1457
Brake Fluid, Remove 1458
Maintenance Procedures Every 4000 Hours or 2 Years 1459
Hydraulic Oil, Replace 1459
Cooling System 1460
Replace Throttle (Accelerator) Cable, Yanmar Diesel Engine 1461
Safety Procedures When Working Near Mast 1462
Hood Lock Assembly Check 1464
Lift Chain Adjustments 1466
Jump-Starting the Lift Truck 1467
Jump-Starting Using a Battery Charger 1467
Jump-Starting a Lift Truck Using Another Lift Truck 1467
Welding Repairs 1468
Wheel and Tire Replacement 1468
General 1468
Pneumatic Tire With Tube, Repair 1468
Remove Wheels From Lift Truck 1468
Remove Tire From Wheel 1469
Install Wheel in Tire 1470
Install Tire on Two-Piece Wheel 1471
Add Air to Pneumatic Tires With Tube 1472
Install the Wheels 1472
Pneumatic Tubeless Tire, Repair 1472
Remove Wheels From Lift Truck 1472
Add Air to Pneumatic Tubeless Tire 1478
Wheels, Install 1478
Overhead Guard Changes 1478
Adhesives and Sealants 1479
550188075 8000YRM2129 (04 2018) UK EN 1481
Lift Truck Lifting Capacity 1485
Counterweight Weights 1485
Capacities 1485
Tire Sizes 1486
Electrical System 1486
Transmission Oil Pressures 1487
Hydraulic System Relief Pressures 1488
Steering System 1489
Stall Speeds (in RPM ±100 rpm) 1489
Yanmar 3 3L 1489
Mast Speeds 1489
Tilt Angles 1490
Front End Equipment – Mast Creep 1490
Mast Creep 1490
Engine Specifications 1491
Torque Specifications 1492
Frame 1492
Mast 1492
Steering System 1492
Drive Axle 1492
Transmission 1493
Engine – Yanmar 3 3L Diesel 1493
550188077 8000YRM2131 (04 2018) UK EN 1497
Enter Service Mode 1501
Exit Service Mode 1501
Turn Options ON and OFF 1502
Controller Settings 1503
Configure Settings When Replacing the Display 1504
Configure Settings When Replacing the Controller 1504
Set Up the Load Weight Sensor 1504
Set the Truck Speed Limit (Yanmar Engines With Manual Throttle) 1505
Turn on Password Requirements 1505
Clear the System Memory 1506
Flowcharts 1506
Top Level Menu 1506
Software Version Sub Menus 1507
Maintenance Record Sub Menu 1507
Setting Adjustment 1 Sub Menus 1507
Controller Adjustment Sub Menus 1508
Controller Adjustment – Speed Settings Sub Menus 1508
Controller Adjustment – Operator Compartment Sub Menus 1509
Password Sub Menu 1509
Password Creation Sub Menu 1509
Password ID Sub Menus 1509
Setting Adjustment 4 Sub Menu 1510
Option Adjustment Sub Menus 1510
Maintenance Sub Menus 1511
Controller Error Code Sub Menu 1511
Display Error Code Sub Menu 1512
Error Memory Sub Menus 1512
Display Switch Monitor Sub Menus 1513
Controller Switch Monitor Sub Menus 1513
Output Settings Sub Menu 1514
Data Copy Sub Menus 1515
Copy From Controller to Display Sub Menu 1516
Copy From Display to Controller Sub Menu 1516
Reset Sub Menus 1516
Serial Number Sub Menu 1516