Yale Forklift A974 (GLP050LX, GDP50LX) Service Manual – PDF DOWNLOAD

Yale Forklift A974 (GLP050LX, GDP50LX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A974 (GLP050LX, GDP50LX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2188
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift A974 (GLP050LX, GDP50LX) 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
524223756 0600YRM1122 (03 2020) US EN 43
General 47
Serial Number 48
Engine Removal and Installation 48
Cylinder Head, Camshaft, and Valve Mechanism Repair 48
Remove 48
Clean 51
Inspect and Repair 51
Cylinder Head 51
Rocker Shaft Assembly 51
Camshaft 52
Valve Guides 53
Valve Seats 53
Valves 54
Valve Springs 54
Install 55
Crankshaft and Main Bearings Repair 59
Remove 59
Inspect and Repair 60
Crankshaft 60
Main Bearings 60
Install 61
Pistons and Connecting Rods Repair 62
Remove and Disassemble 62
Clean 62
Inspect and Repair 62
Pistons 62
Piston Rings 62
Connecting Rods and Bearings 63
Assemble and Install 63
Cylinder Block Repair 65
Oil Pump Repair 66
Remove 66
Disassemble 67
Clean 67
Inspect 67
Assemble 68
Install 68
Cooling System Repair 70
Thermostat 70
Replace 70
Fan Assembly 70
Remove and Disassemble 70
Assemble and Install 71
Water Pump 71
Remove 71
Install 72
Flywheel and Ring Gear Repair 73
Remove 73
Install 73
Valve Adjustment 73
Compression Pressure Check 75
Engine Timing Adjustment 76
Engine Specifications 76
Engine Data 76
Engine Speeds 76
2007, and Later, Emission Compliant Engines 76
All Engines Except 2007, and Later, Emission Compliant Engines 77
Thermostat 77
Cylinder Head 77
Valve Mechanism 77
Camshaft 78
Crankshaft 78
Connecting Rods 78
Cylinder Block 79
Pistons 79
Oil Pump 79
Torque Specifications 80
524223757 0700YRM1123 (06 2016) US EN 83
General 87
Cooling System Checks 87
Exhaust Leaks Into Cooling System 87
Water Flow Restrictions in Radiator 87
Radiator Hoses 87
Water Pump 88
Flushing the Cooling System 88
Cooling System, Clean 88
Radiator Replacement 89
Radiator, Remove GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 90
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 105
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 108
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 111
Radiator, Install for Lift Truck Models GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 118
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 123
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 125
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 128
Fan Assembly Replacement 140
Fan Removal 140
Inspect 155
Fan Installation 155
524223765 1800YRM1135 (09 2018) US EN 161
General 165
Dry Brake System 165
Wet Brake System 165
Service Brakes Repair (Dry Brake) 165
Remove and Disassemble 166
Clean 174
Inspect 174
Assemble and Install 175
Adjust 182
Inching Overlap Adjustment 182
Parking Brake Repair 183
Remove and Disassemble 183
Assemble and Install 186
Adjust 186
Master Cylinder Repair 187
Remove (Dry Brake) 187
Disassemble (Dry Brake) 188
Clean and Inspect (Dry Brake) 190
Assemble (Dry Brake) 190
Bench Bleed Master Cylinder (Dry Brake) 190
Install and Adjust (Dry Brake) 190
Remove (Wet Brake) 191
Disassemble (Wet Brake) 193
Clean and Inspect (Wet Brake) 194
Assemble (Wet Brake) 195
Install and Adjust (Wet Brake) 195
Service Brakes Adjustment (Dry Brake) 196
Brake System Air Removal 196
Using Pressure Bleed System 196
Using Brake Pedal Pressure 197
Brake Pedal Adjustment 197
Free Pedal Adjustment 198
Torque Specifications 200
524223766 1900YRM1136 (11 2017) US EN 203
General 207
Hydraulic Gear Pump Assembly 208
Variable Displacement Pump Assembly 209
Single Gear Pump Assembly Repair 209
Remove 209
Disassemble 216
Clean 216
Inspect 218
Assemble 218
Install 218
Tandem Gear Pump Assembly 222
Remove 223
Disassemble 225
Clean 227
Inspect 227
Assemble 227
Install 228
Gear Pump Specifications 228
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 234
Remove 234
Disassemble 244
Clean 247
Inspect 247
Assemble 247
Install 248
63 0 cc/rev – Variable Displacement Pump Repair 251
Remove 251
Disassemble 254
Clean 254
Inspect 254
Assemble 256
Install 256
Variable Displacement Pump Checks and Adjustments (Single Pump) 258
Margin Pressure Check 258
Flow Compensator Adjustment 259
Pressure Compensator Adjustment 259
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 260
Variable Displacement Pump Specifications 263
Torque Specifications 264
Hydraulic Gear Pump 265
Variable Displacement Pump 266
Special Tools 266
524223767 2000YRM1137 (01 2017) US EN 271
General 277
Electro-Hydraulic Main Control Valve 278
Description 278
Remove 286
Electro-Hydraulic Control Valve Sections 291
General 291
Outlet Control Valve Section 291
Remove 291
Disassemble 292
Clean 294
Inspect 294
Assemble 294
Install 295
Auxiliary Control Valve Sections 295
Remove 295
Disassemble 302
Clean 303
Inspect 304
Assemble 304
Install 306
Tilt Control Valve Section 307
Remove 307
Disassemble 307
Clean 313
Inspect 313
Assemble 313
Install 314
Lift/Lower Control Valve Section 315
Remove 315
Disassemble 315
Clean 324
Inspect 324
Assemble 324
Install 325
Mid-Inlet Section 325
Remove 325
Clean 326
Inspect 326
Install 326
Install 326
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 331
Lift Pilot Pin 331
Lower Pilot Pin 335
Abnormal/Erroneous EHPV Adjustment 337
Manual Main Control Valve 338
Description 338
Remove 342
OPS Solenoid Assembly 350
General 350
Remove 351
Clean and Inspect 354
Install 354
Manual Control Valve Sections 355
General 355
Outlet Control Valve Section 355
Remove 355
Disassemble 355
Clean 358
Inspect 358
Assemble 358
Install 359
Auxiliary Control Valve Sections 359
Remove 359
Disassemble 359
Clean 362
Inspect 362
Assemble 362
Install 363
Lift/Tilt Control Valve Section 363
Remove 363
Disassemble 363
Clean 370
Inspect 370
Assemble 371
Install 372
Mid-Inlet Section 373
Remove 373
Clean 373
Inspect 373
Install 373
Install 374
Pressure Relief Valve Check and Adjustment 380
Primary Relief Valve 381
Secondary Relief Valve 385
Steering Control Unit Repair 392
Steering Control Unit, Remove 392
Steering Control Unit, Disassemble 396
Steering Control Unit, Clean 398
Steering Control Unit, Inspect 398
Steering Control Unit, Assemble 398
Relief Valve, Disassemble 399
Relief Valve, Clean 399
Relief Valve, Inspect 400
Relief Valve, Assemble 400
Steering Control Unit, Install 400
524223768 2100YRM1139 (02 2014) US EN 405
524223769 2200YRM1128 (01 2023) US EN 453
Series Code / Model Designation Reference Table 461
General 463
Deutsch Crimping Tool 464
How to Strip a Wire for Use With Deutsch Crimping Tool 464
How to Crimp With the Deutsch Crimping Tool 465
Calibration Test for the Deutsch Crimping Tool 467
Deutsch Connectors 469
DT, DTM, and DTP Series Connectors 469
HD Series Connectors 512
Metri-Pack Connectors 534
Remove and Install 534
Micro-Pack Connectors 537
Weather-Pack Connectors 538
AMPSEAL Crimping Tools 540
AMP Hand Crimping Tool With Certi-Crimp 540
Description 540
Stripping Wire for Use with AMP Hand Crimping Tool 541
Insulation Crimp Adjustment 542
Maintenance and Inspection for AMP Hand Crimping Tool 542
AMP Hand Crimping Tool 542
Crimp Height Inspection 542
How to use AMP Hand Crimping Tool 543
AMP Pro-Crimper II Tool 543
Description 543
Remove and Install Die Set and Locator Assembly 544
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 544
Contact Support Adjustment 545
Crimp Height Adjustment 546
Maintenance and Inspection Procedures 546
PRO-CRIMPER II Tool 546
Crimp Height Inspection 546
How to Use AMP PRO-CRIMPER II Tool 547
AMPSEAL Connector Assemblies 548
Description for Plug Connector Assembly 548
Seal Plug 549
Contact Crimping 549
Description for Plug Connector and Header Assembly 554
Voltage Reading 557
Seal Plug 557
Contact Crimping 557
AMP Superseal 1 5 Crimping Tools 564
Mini Mic Receptacle and Tab Contacts 564
Description 564
Crimping Conditions and Measurements 564
Insertion of Rubber Seal on Cable 566
AMP Hand Application Tool 571
Description 571
Maintenance and Inspection 571
Crimp Height Inspection 571
Crimp Height Adjustment 572
How to Use AMP Hand Application Tool 572
AMP Pro-Crimper II Tool 573
Description 573
Remove and Install Die Set and Locator Assembly 573
Adjustments 574
Contact Support 574
Crimp Height 575
Inspections and Maintenance 576
Crimp Height Inspection 576
Visual Inspection 576
Maintenance 577
How to Use Pro-Crimper II Tool 577
AMP Superseal 1 5 Connector Assemblies 578
Description 578
Repair and Maintenance 585
Panel Mount Option 585
AMP Fastin-Faston Hand Tools 586
Description – AMP Double Action Hand Tool 586
Maintenance and Inspection Procedures 586
Daily Maintenance 586
Periodic Tool Inspection 587
Lubrication 587
Visual Inspection 587
Crimp Height Inspection 587
Certi-Crimp Ratchet Inspection 588
How to Use AMP Double Action Hand Tool 589
Description – AMP Extraction Tool 590
Maintenance and Inspection 591
How to Use AMP Extraction Tool 591
AMP Fastin-Faston Receptacles and Housings 593
Description 593
Wire Repair 601
Wire Splicing Requirements 601
Deutsch Jiffy Splice 602
Twisted/Shielded Cable and Leads Repair 608
Special Tools 610
524223769 2200YRM1128 (07 2020) US EN 619
Series Code / Model Designation Reference Table 625
General 628
Deutsch Crimping Tool 628
How to Strip a Wire for Use With Deutsch Crimping Tool 628
How to Crimp With the Deutsch Crimping Tool 629
Calibration Test for the Deutsch Crimping Tool 631
Deutsch Connectors 633
DT, DTM, and DTP Series Connectors 633
HD Series Connectors 675
Metri-Pack Connectors 698
Remove and Install 698
Micro-Pack Connectors 700
Weather-Pack Connectors 701
AMPSEAL Crimping Tools 703
AMP Hand Crimping Tool With Certi-Crimp 703
Description 703
Stripping Wire for Use with AMP Hand Crimping Tool 703
Insulation Crimp Adjustment 704
Maintenance and Inspection for AMP Hand Crimping Tool 704
AMP Hand Crimping Tool 704
Crimp Height Inspection 704
How to use AMP Hand Crimping Tool 705
AMP Pro-Crimper II Tool 705
Description 705
Remove and Install Die Set and Locator Assembly 706
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 707
Contact Support Adjustment 707
Crimp Height Adjustment 708
Maintenance and Inspection Procedures 708
PRO-CRIMPER II Tool 708
Crimp Height Inspection 708
How to Use AMP PRO-CRIMPER II Tool 709
AMPSEAL Connector Assemblies 710
Description for Plug Connector Assembly 710
Seal Plug 711
Contact Crimping 711
Description for Plug Connector and Header Assembly 716
Voltage Reading 718
Seal Plug 718
Contact Crimping 718
AMP Superseal 1 5 Crimping Tools 725
Mini Mic Receptacle and Tab Contacts 725
Description 725
Crimping Conditions and Measurements 725
Insertion of Rubber Seal on Cable 727
AMP Hand Application Tool 732
Description 732
Maintenance and Inspection 732
Crimp Height Inspection 732
Crimp Height Adjustment 733
How to Use AMP Hand Application Tool 733
AMP Pro-Crimper II Tool 734
Description 734
Remove and Install Die Set and Locator Assembly 735
Adjustments 735
Contact Support 735
Crimp Height 736
Inspections and Maintenance 737
Crimp Height Inspection 737
Visual Inspection 737
Maintenance 738
How to Use Pro-Crimper II Tool 738
AMP Superseal 1 5 Connector Assemblies 739
Description 739
Repair and Maintenance 746
Panel Mount Option 746
AMP Fastin-Faston Hand Tools 747
Description – AMP Double Action Hand Tool 747
Maintenance and Inspection Procedures 747
Daily Maintenance 747
Periodic Tool Inspection 748
Lubrication 748
Visual Inspection 748
Crimp Height Inspection 748
Certi-Crimp Ratchet Inspection 749
How to Use AMP Double Action Hand Tool 750
Description – AMP Extraction Tool 751
Maintenance and Inspection 751
How to Use AMP Extraction Tool 752
AMP Fastin-Faston Receptacles and Housings 753
Description 753
Wire Repair 760
Wire Splicing Requirements 760
Deutsch Jiffy Splice 761
Twisted/Shielded Cable and Leads Repair 766
Special Tools 769
524240453 0600YRM1205 (01 2017) US EN 777
General 783
Engine Identification 783
Major Engine Component Identification 783
Location of Labels 784
Engine Removal and Installation 785
Cylinder Head Assembly Repair 785
Glow Plugs 788
Remove 788
Install 788
Valve Cover 788
Remove 788
Clean and Inspect 789
Install 789
Rocker Arm Assembly 789
Remove 789
Disassemble 790
Clean and Inspect 791
Push Rods 791
Rocker Arm Assembly 791
Assemble 791
Install 792
Valve Clearance Adjustments 792
Cylinder Head Assembly 793
Remove 793
Disassemble 798
Valves and Valve Springs, Remove 798
Valve Guides, Remove 798
Clean and Inspect 799
Cylinder Head 799
Valve Guides 800
Valves 800
Valve Sink 800
Valve Seat 801
Valve Springs 801
Assemble 802
Valve Guides, Install 802
Valves and Valve Springs, Install 802
Install 803
Timing Gear Case and Timing Gears Repair 804
Timing Gear Case Cover 805
Remove 805
Clean and Inspect 805
Install 806
Timing Gears 806
Crankshaft Gear 807
Remove 807
Install 807
Idler Gear 807
Remove 807
Inspect 808
Install 808
Camshaft Gear 808
Remove 808
Install 809
Timing Gear Case 809
Remove 809
Clean and Inspect 810
Install 810
Drive Train, Camshaft, and Cylinder Block Repair 811
Remove 811
Disassemble 812
Pistons and Connecting Rods 812
Crankshaft 812
Camshaft 815
Clean and Inspect 816
Cylinder Block 816
Honing and Boring 819
Pistons 820
Piston Pin 820
Connecting Rod 821
Tappets 821
Crankshaft 822
Camshaft 823
Camshaft Bushing 824
Assemble 824
Camshaft 824
Crankshaft 824
Pistons and Connecting Rods 825
Install 826
Lubrication System Repair 827
Engine Oil and Oil Filter Change 827
Oil Pan 827
Remove 827
Install 828
Oil Suction Tube 828
Remove 828
Clean 829
Install 829
Oil Pump 829
Remove 829
Clean and Inspect 830
Outer Rotor Outside Clearance 830
Outer Rotor to Inner Rotor Tip Clearance 831
Outer Rotor Side Clearance 831
Rotor Shaft Clearance 831
Install 832
Fuel System Repair 832
Fuel Injectors 833
Remove 833
Inspect 834
Clean 834
Test 834
Install 837
Electronic Throttle System 837
Remove 837
Install 840
Inspect 841
Adjust 842
Manual Throttle System 843
Fuel Injection Pump 843
Remove 843
Clean and Inspect 847
Install 847
Check/Adjust Fuel Injection Timing 848
Cooling System Repair 850
V-Belt 850
Remove 850
Inspect 850
Install 850
Adjust 850
Water Pump 852
4TNE92-NMHA, 4TNE92-NMHA/580090035, 4TNE92-SNMU, and 4TNE98-SNMU Engines 852
Remove 852
Install 853
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/580090036, and 4TNE98-BNMH Engines 854
Remove 854
Install 855
Thermostat 857
Remove 857
Inspect 858
Install 858
Flywheel and Flywheel Housing 858
Flywheel 859
Remove 859
Install 860
Flywheel Housing 860
Remove 860
Install 860
Electrical Equipment Repair 862
Alternator 862
Remove 862
Bench Test 864
Regulate Voltage Check 864
No Load Test 866
Output Test 866
Install 866
Starter 867
Remove 868
No Load Test 868
Install 869
Engine Specifications 870
Engine Data 870
Engine Tuning 878
Cylinder Head 878
Intake/Exhaust Valve and Guide 879
Valve Spring 879
Rocker Arm and Shaft 879
Push Rod 880
Gear Train and Camshaft 880
Camshaft 880
Idle Gear Shaft and Bushing 880
Backlash of Each Gear 881
Cylinder Block 881
Crankshaft 881
Thrust Bearing 882
Piston 882
Piston Ring 882
Connecting Rod 883
Rod Small End 883
Tappet 883
Oil Pump 884
Engine Oil Pressure 884
Outer Rotor Outside Clearance 884
Outer Rotor Side Clearance 884
Outer Rotor to Inner Rotor Tip Clearance 884
Rotor Shaft Clearance 884
Standard Torque Specifications 885
Standard Torque Chart 885
Special Torque Specifications 886
Special Tools 887
524289374 0900YRM1326 (04 2018) US EN 895
General 901
LPG Tank and Bracket Replacement 901
Remove LPG Tank for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 901
Install LPG Tank for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 903
Remove LPG Tank for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 904
LPG Tank Install for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 906
Remove LPG Bracket for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 907
Install LPG Bracket for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 909
Remove LPG Tank Bracket Alignment Pin, Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 910
Install LPG Tank Bracket Alignment Pin, Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 912
Remove LPG Bracket for Lift Truck Models and GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 913
Install LPG Bracket for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 913
Fuel Filter Unit Repair 913
Fuel Filter Element 913
Remove 913
Clean/Inspect 914
Install 914
Fuel Filter Housing 914
Remove 914
Disassemble 917
Assemble 919
Install 920
Electronic Throttle Body Repair 920
Remove 920
Install 922
Electronic Pressure Regulator (EPR) Repair 922
Remove 923
Disassemble 927
Assemble 929
Install 930
LPG Shutoff Valve Assembly 930
Remove 930
Install 934
Fuel Mixer Repair 936
Remove 936
Install 939
Control System 939
Engine Control Unit (ECU) 939
Remove 939
Install 941
Low LPG Pressure Switch 941
Remove 941
Install 942
LPG Low Level Sensor 942
Remove 943
Install 946
Exhaust System 947
Counterweight Exhaust System 947
Remove and Disassemble 947
Inspect 949
Assemble and Install 949
Overhead Exhaust System 949
Remove and Disassemble 950
Inspect 952
Assemble and Install 952
Exhaust Manifold 953
Remove 953
Install 954
Positive Crankcase Ventilation (PCV) Valve 955
Remove 955
Inspect 955
Install 955
Oxygen Sensor 955
Remove 955
Install 957
LPG Fuel Testing 958
General 958
Available Fuel Tests 958
Composition Test (ASTM D-2163) 958
Ammonia Test (ASTM D-4490) 958
Basic Nitrogen Test (ASTM UOP269-90) 958
Residues Test (ASTM D-2158) 958
Vapor Pressure Test (ASTM D-2598) 958
Sulfur Compounds Test (ASTM D-5623) 959
Methanol Test (ASTM D-4864) 959
Copper Corrosion (ASTM D-1838) 959
Where To Send LPG Fuel Samples For Testing 959
524289375 2200YRM1327 (09 2012) US EN 963
General 967
Ignition System 967
General 967
Ignition Timing Adjustment, Gasoline and LPG 967
Spark Plugs Check 972
Spark Plug Wires Check 972
Coil Replacement 973
Remove 973
Inspect 974
Install 974
Starter Repair 975
General 975
Remove 975
No-Load Test 976
Magnetic Switch Test 977
Pull-Out Test 977
Holding Coil Test 977
Return Test 977
Pinion Movement Inspection 978
Install 978
Alternator Repair 978
General 978
Charging System Inspection 980
Output Current Check 980
No-Load Adjusted Voltage Check 981
Remove 982
Inspect 982
Rectifier Check 982
Install 983
Engine Sensors and Switches 984
Oil Pressure Sensor, Gas and LPG Engines 984
Remove 984
Install 984
Air Filter Restriction Switch, Gas and LPG Engines 984
Remove 984
Install 984
Cam Angle Sensor, Gas and LPG Engines 985
Remove 985
Install 986
Voltage Check 986
Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Engines 987
Remove 987
Install 988
Intake Air Temperature (IAT) Sensor, LPG Engines 989
Remove 989
Install 989
Intake Air Temperature (IAT) Sensor, Gas Engines 989
Remove 989
Install 989
Fuel Temperature Sensor, LPG Engines 992
Remove 992
Install 992
Engine Coolant Temperature (ECT) Sensor 993
2007 Emissions Compliant Gas Engines 993
Remove 993
Install 993
2007 and 2010 Emissions Compliant LPG Engines 994
Remove 994
Install 994
2010 Emissions Compliant Gas and LPG Engines 996
Remove 996
Install 996
550010194 1300YRM1421 (08 2013) US EN 1001
toc 1001
Single Speed PowerShift 1001
Safety Precautions Maintenance and Repair 1002
General 1005
Serial Number 1005
Hydraulic Gear Pump 1006
Remove 1006
Install 1006
Charge Pump Repair 1007
Original Charge Pump 1007
Remove 1007
Disassemble 1008
Clean 1008
Inspect 1008
Assemble 1008
Install 1008
New Charge Pump, Manufactured After July, 2013 1009
Remove 1009
Clean 1010
Inspect 1010
Install 1011
Torque Converter Replacement 1013
Remove 1013
Clean and Inspect 1013
Install 1013
Stator Support Assembly Repair 1014
Remove 1014
Disassemble 1019
Clean 1020
Inspect 1020
Assemble 1021
Install 1021
Clutch Packs Repair 1023
Remove 1023
Engine, Torque Converter, and Transmission Assembly 1023
Transmission Components 1024
Disassemble 1026
Transmission 1026
Housings 1026
Forward Clutch Pack 1029
Reverse Clutch Pack 1034
Clean 1040
Inspect 1040
Assemble 1041
Transmission 1041
Reverse Clutch Pack 1041
Forward Clutch Pack 1048
Housings 1054
Install 1056
Transmission Components 1056
Engine, Torque Converter, and Transmission Assembly 1059
Inching Overlap Adjustment 1059
Proportional and Enable Solenoid Valves 1060
Proportional Valves 1060
Remove 1060
Disassemble 1062
Clean and Inspect 1062
Assemble 1062
Install 1062
Enable Solenoid Valve 1062
Remove 1062
Disassemble 1062
Clean and Inspect 1062
Assemble 1063
Install 1063
Foot Directional Control Pedal Repair 1063
Remove and Disassembly 1063
Clean and Inspect 1067
Assemble and Install 1067
550013974 0100YRM1423 (03 2012) US EN 1071
toc 1071
Frame 1071
Safety Precautions Maintenance and Repair 1072
General 1075
Hood, Seat, and Side Covers Replacement 1076
Remove 1076
Install 1082
Belly Pan (Optional) 1083
Remove 1083
Clean and Inspect 1083
Install 1083
Steering Column 1084
Description 1084
Steering Column Repair 1084
Remove 1084
Disassemble 1085
Clean 1088
Inspect 1088
Assemble 1088
Install 1088
Counterweight Replacement 1089
Remove 1089
Install 1091
Overhead Guard Replacement 1091
Remove 1091
Install 1092
Rain Top (Optional) 1092
Remove 1092
Clean and Inspect 1092
Install 1092
Operator Restraint System Replacement 1093
Description 1093
Emergency Locking Retractor (ELR) 1093
Engine Replacement 1095
Remove 1095
LPG Engine 1095
Diesel Engine 1103
Install 1108
LPG Engine 1108
Diesel Engine 1109
Transmission Replacement 1110
Remove 1110
Install 1112
Throttle Pedal and Cable Adjustment 1113
Mazda LPG Engine 1113
Throttle Pedal Stop Adjustment 1113
Yanmar Diesel Engine 1113
Yanmar Diesel Engine With Electronic Throttle 1115
Cooling System 1115
Description 1115
Hydraulic Filter Repair 1115
Remove 1115
Clean and Inspect 1116
Install 1116
Tank Repair 1116
LPG Tank Repair 1116
Hydraulic and Diesel Tanks 1116
Inspect 1116
Clean 1117
Steam Method of Cleaning 1117
Chemical Solution Method of Cleaning 1118
Additional Preparations for Repair 1118
Small Leaks, Repair 1118
Large Leaks, Repair 1118
Preparations for Use After Repair 1119
Label Replacement 1119
tables 1071
Table 1 Weight of Counterweights 1090
550013975 1400YRM1426 (07 2011) US EN 1127
toc 1127
Drive Axle and Differential Assembly Repair 1127
Safety Precautions Maintenance and Repair 1128
General 1131
Identification Plate 1131
Drive Axle Repair 1132
Remove and Disassemble 1132
Clean and Inspect 1135
Assemble and Install 1135
Differential Repair 1138
Remove 1138
Differential Assembly From Drive Axle Center Section Assembly 1138
Drive Pinion, Pinion Gear, and Bearings From Drive Axle Center S 1140
Disassemble 1145
Differential Assembly 1145
Drop Box Housing 1149
Differential Assembly Cover 1150
Drive Axle Center Section 1151
Clean and Inspect 1152
Assemble 1153
Drive Axle Center Section 1153
Differential Assembly Cover 1155
Drop Box Housing 1156
Differential Assembly 1157
Install 1161
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 1161
Drive Pinion, Pinion Gear, and Bearings Into Drive Axle Center S 1163
Differential Assembly Into Drive Axle Center Section 1167
Hypoid Gear Backlash, Adjust 1170
Hypoid Gear, Runout Check 1171
Gear Set, Tooth Contact Pattern Check 1171
Torque Specifications 1174
tables 1127
Table 1 Pinion Variation Numbers Examples 1162
Table 2 Ring and Pinion Tooth Contact Adjustment 1172
Table 3 Correct Tooth Contact 1172
Table 4 Incorrect Tooth Contact 1173
550013976 1600YRM1425 (07 2011) US EN 1177
toc 1177
Steering Axle 1177
Safety Precautions Maintenance and Repair 1178
General 1181
Steering Axle Assembly Repair 1182
Remove 1182
Disassemble 1182
Clean 1184
Inspect 1184
Assemble 1185
Install 1186
Spindles, Bearings, and Tie Rods Repair 1188
Spindles and Bearings 1188
Remove 1188
Disassemble 1188
Clean 1189
Inspect 1189
Assemble 1189
Install 1190
Tie Rods 1190
Remove 1190
Disassemble 1191
Clean 1191
Inspect 1191
Assemble 1191
Install 1192
Steering Cylinder Repair 1192
Remove 1192
Disassemble 1192
Clean 1193
Inspect 1194
Assemble 1194
Install 1194
Torque Specifications 1194
550013977 2200YRM1427 (03 2012) US EN 1197
toc 1197
Electrical System 1197
Safety Precautions Maintenance and Repair 1198
General 1201
Engine Control Module (ECM), Yanmar Diesel Engine 1202
Remove 1202
Install 1202
Display Switch Cluster 1203
Remove 1203
Install 1204
Direction Control Lever 1205
Remove 1205
Install 1205
Key Switch 1206
Remove 1206
Install 1206
Display Switch Cluster Panel Bezel and Overlay 1207
Remove 1207
Install 1207
Steering Column Repair 1207
Remove 1207
Disassemble 1207
Assemble 1208
Install 1208
Sensors and Switches 1209
General 1209
Dash Panel, Kick Panel, and Seal Plate, Remove and Install 1209
Remove 1209
Install 1209
Accelerator Pedal Position Sensor 1210
Remove 1210
Install 1211
Brake Fluid Level Switch 1212
Remove 1212
Install 1213
Brake Pedal Position Sensor 1213
Remove 1213
Install 1213
Parking Brake Position Sensor 1214
Remove 1214
Install 1215
Seat Sensor (Operator Presence System) 1215
Non-Suspension Seat 1215
Remove 1215
Install 1216
Full Suspension Seats 1216
Remove 1216
Install 1216
Transmission Pressure Sensors (Transducers) 1217
Remove 1217
Install 1217
Transmission Temperature Sensor 1217
Remove 1217
Install 1218
Rear Horn Button Switch 1218
Remove 1218
Install 1218
Engine and Fuel Sensors and Switches, Mazda 2 0L LPG Trucks 1219
Engine and Fuel Sensors, Yanmar 2 6L Diesel Trucks 1219
Engine Speed Sensor 1219
Remove 1219
Install 1219
Oil Pressure Sensor 1219
Remove 1219
Install 1220
Engine Coolant Temperature (ECT) Sensor 1220
Remove 1220
Install 1220
Fuel/Water Separator Sensor 1221
Remove 1221
Install 1221
Glow Plug Relay 1222
Remove 1222
Install 1222
Power Distribution Module (PDM) and Component Parts 1224
Power Distribution Module (PDM) as a Unit 1224
Remove 1224
Install 1224
Power Distribution Module (PDM) Components 1226
Remove and Install 1226
Battery 1226
Remove 1226
Install 1226
Lights 1227
Work Lights (Front and Rear) 1227
Remove 1227
Install 1227
Strobe Light 1227
Remove 1227
Install 1227
LED Tail, Backup, and Brake Lights 1228
Remove 1228
Install 1228
Reflectors 1228
Remove 1228
Install 1228
550013978 4000YRM1431 (02 2014) US EN 1233
550013979 8000YRM1424 (08 2013) US EN 1301
toc 1301
Periodic Maintenance 1301
Safety Precautions Maintenance and Repair 1302
General 1307
Serial Number Data 1307
How to Move Disabled Lift Truck 1307
How to Tow Lift Truck 1307
How to Put Lift Truck on Blocks 1308
How to Raise Drive Tires 1308
How to Raise Steering Tires 1309
How to Clean a Lift Truck 1310
Maintenance Schedule 1310
Maintenance Procedures Every 8 Hours or Daily 1321
How to Make Checks With Engine Stopped 1321
Tires and Wheels 1321
Safety Labels 1321
Mast, Carriage, Lift Chains, Header Hoses, Attachment 1322
Operator Restraint System 1323
Emergency Locking Retractor (ELR) 1325
Hood and Seat Latches 1325
Engine Compartment 1325
Ground Static Strap 1325
Fuel, Oil, and Coolant Leaks, Check 1326
Hydraulic Hoses 1326
Coolant Hoses 1327
Steering Column Gas Cylinder 1327
Transmission 1327
Hydraulic System Oil 1327
Engine Oil 1328
Air Filter 1331
Forks 1331
Remove 1331
Inspect 1332
Install 1332
Adjust 1333
How To Make Checks With Engine Running 1333
Indicator Lights, Horn, Fuses, and Relays 1333
Service Brakes 1336
Brake Fluid Level 1336
Operation, Check 1336
Parking Brake 1336
Engine Oil Pressure 1336
Cooling System 1337
Steering System 1337
Control Levers and Pedals 1337
Lift System, Operate 1338
First Service After First 100 Hours of Operation 1339
Mazda FE and F2 Engine Oil and Oil Filter Change 1339
Yanmar 2 6L Engine Oil and Oil Filter Change 1339
Hydraulic System 1339
Hydraulic Filter Element, Replace 1339
Remove 1339
Install 1340
Maintenance Procedures Every 250 Hours or 6 Months 1342
Mazda FE and F2 Engine Oil and Oil Filter Change 1342
Mazda FE and F2 Engine Drive Belt Check 1342
Fan and Alternator Drive Belt 1342
Drain Tar From Electronic Pressure Regulator (EPR) 1343
Maintenance Procedures Every 500 Hours or 6 Months 1344
Hydraulic System Oil 1344
Hydraulic Tank Breather 1344
Inspect 1344
Battery 1346
Yanmar 2 6L Engine Oil and Oil Filter Change 1346
Yanmar 2 6L Engine Drive Belt 1346
PCV Valve 1347
Clean Debris From Radiator Core 1347
Transmission Oil Level 1347
Forks 1348
Mast Lubrication 1348
Header Hose Checks 1352
Lift Chain Lubrication 1352
Tilt Cylinder Lubrication 1352
Master Cylinder Rod End Pin Lubrication 1352
Manual Hydraulic Levers Lubrication 1352
Brake Fluid 1352
Parking Brake Adjustment 1353
Tie Rod Lubrication 1356
Differential and Drive Axle Oil 1356
Maintenance Procedures Every 1000 Hours or 6 Months 1357
Valve Clearance, Check and Adjust 1357
Ignition System – Mazda FE and F2 Engine 1357
LPG Fuel Filter Replace – Mazda FE and F2 Engine 1357
Remove 1357
Clean/Inspect 1357
Install 1357
Fuel Filter Replacement – Yanmar 2 6L Engine 1358
Priming the Fuel System (Yanmar) 1360
Lift Chains Wear Check 1360
Lift Chain Lubrication 1360
Integral Sideshift Carriage, Check Bearings 1360
Steering Axle 1361
Control Levers and Pedals 1361
Maintenance Procedures Every 2000 Hours or Annually 1363
Hydraulic System 1363
Hydraulic Oil Filter Element, Replace 1363
Remove 1363
Clean and Inspect 1363
Install 1363
Hydraulic Tank Breather, Replace 1364
Air Filter 1365
PCV Valve 1367
Oxygen Sensor 1367
Timing Belt 1367
Forks 1367
Fuel Injector, Yanmar Engines 1367
Integral Sideshift Carriage 1367
Bearings, Replace 1367
Transmission Oil and Oil Filter, Replace 1369
Remove 1369
Clean and Inspect 1372
Install 1372
Brake Fluid Change 1373
Service Brakes 1374
Drive Axle and Differential Oil, Change 1374
Wheel Bearings 1375
Steer Wheels, Lubrication 1375
Maintenance Procedures Every 4000 Hours or 2 Years 1377
Hydraulic Oil, Change 1377
Cooling System 1379
Safety Procedures When Working Near Mast 1381
Hood Latch Check 1383
Lift Chain Adjustments 1384
Jump-Starting the Lift Truck 1386
Jump-Starting Using a Battery Charger 1386
Jump-Starting a Lift Truck Using Another Lift Truck 1386
Welding Repairs 1386
Overhead Guard Changes 1387
Wheels and Tires Replacement 1387
General 1387
How to Change Solid Rubber Tire 1387
Remove and Install Tire on Wheel 1387
Pneumatic Tire With Tube, Repair 1388
Remove Wheels From Lift Truck 1388
Remove Tire From Wheel 1389
Remove Tire From Two-Piece Wheel 1389
Remove Tire From Three- and Four-Piece Wheels 1390
Install Wheel in Tire 1391
Install Two-Piece Wheel in Tire 1392
Install Three- or Four-Piece Wheel in Tire 1393
Add Air to Pneumatic Tires With Tube 1394
Wheels, Install 1394
Pneumatic Tubeless Tire, Repair 1395
Remove Wheels From Lift Truck 1395
Remove Tire From Wheel 1395
Install Tire on Wheel 1397
Add Air to Pneumatic Tubeless Tire 1399
Wheels, Install 1400
Solid Rubber Tires on Pneumatic Wheels, Change 1400
Remove Tire From Wheel 1400
Install Tire on Wheel 1402
Adhesives and Sealants 1404
tables 1301
Table 1 Maintenance Schedule 1315
Table 2 V-Belt Deflection Table 1346
Table 3 Carriage Chain Adjustment, Forks Not Installed 1385
550013980 8000YRM1428 (10 2015) US EN 1407
Lift Truck Lifting Capacity 1411
Counterweight Weights 1411
Tire Sizes 1411
Capacities 1412
Electrical System 1413
Transmission Oil Pressures 1414
Hydraulic System Relief Pressures 1416
Steering System 1416
Stall Speeds 1416
Mast Speeds 1417
Tilt Angles 1418
Front End Equipment 1418
Mast Creep 1418
Engine Specifications 1419
Torque Specifications 1420
Frame 1420
Mast 1420
Steering System 1420
Drive Axle 1420
Transmission 1421
Engine – Mazda FE and F2 LPG 1421
550013981 8000YRM1429 (09 2017) US EN 1425
Diagrams and Schematics 1429
550022929 9000YRM1434 (02 2018) US EN 1451
SECTION 9010 Operational Diagnostic Procedures 1457
Group 05 – Operational Checkout 1459
SECTION 9020 Engine 1469
Group 10 – Principles of Operation 1473
Group 30 – Observed Symptoms 1529
Group 40 – Tests and Adjustments 1583
SECTION 9030 Electrical System 1595
Group 03 – General Maintenance and Diagnostic Data 1601
Group 10 – Principles of Operation 1623
Group 20 – Diagnostic Trouble Codes 1633
Group 30 – Observed Symptoms 1819
SECTION 9040 Drive Train 1855
Group 10 – Principles of Operation 1857
Group 30 – Observed Symptoms 1871
Group 40 – Tests and Adjustments 1901
SECTION 9050 Hydraulic Systems 1905
Group 10 – Principles of Operation 1907
Group 33 – Observed Symptoms-Gear Pump 1923
Group 43 – Tests and Adjustments-Gear Pump 1957
SECTION 9060 Operators Station 1973
Group 10 – Principles of Operation 1975
SECTION 9070 Front End (Mast) and Chassis 1985
Group 10 – Principles of Operation 1987
Group 30 – Observed Symptoms 1997
SECTION 9080 Supplementary Data 2039
Group 50 – Abbreviations and Acronyms 2041
Group 60 – Special Tools List 2049
Group 70 – Fault Mode Indicator Reference 2051
Group 80 – Supplier Specification Data 2053
550030170 1300YRM1447 (08 2013) US EN 2057
toc 2057
Single Speed Powershift 2057
Safety Precautions Maintenance and Repair 2058
General 2061
Serial Number 2061
Hydraulic Gear Pump 2062
Remove 2062
Install 2062
Housing Fittings Replacement 2062
Remove 2062
Disassemble 2063
Assemble 2063
Install 2063
Charge Pump Repair 2063
Lift Trucks Manufactured Before July, 2013 2063
Remove 2063
Disassemble 2065
Clean 2065
Inspect 2065
Assemble 2065
Install 2065
Lift Trucks Manufactured After July, 2013 2067
Remove 2067
Clean 2067
Inspect 2067
Install 2068
Torque Converter Replacement 2071
Remove 2071
Clean and Inspect 2071
Install 2071
Stator Support Assembly Repair 2073
Remove 2073
Disassemble 2078
Clean 2082
Inspect 2082
Assemble 2083
Install 2083
Clutch Packs Repair 2086
Remove 2086
Disassemble 2087
Housings 2087
Clutch Packs 2092
Forward Clutch Pack 2092
Reverse Clutch Pack 2097
Clean 2103
Inspect 2103
Assemble 2104
Clutch Packs 2104
Reverse Clutch Pack 2104
Forward Clutch Pack 2111
Housings 2118
Install 2118
Drive Chains and Sprockets 2124
Remove 2124
Clean 2126
Inspect 2126
Install 2126
Proportional and Enable Solenoid Valves 2127
Proportional Valves 2127
Remove 2127
Disassemble 2127
Clean and Inspect 2127
Assemble 2130
Install 2130
Enable Solenoid Valve 2130
Remove 2130
Disassemble 2131
Clean and Inspect 2131
Assemble 2131
Install 2131
Foot Directional Control Pedal Repair 2133
Remove and Disassemble 2133
Clean and Inspect 2137
Assemble and Install 2137
550073240 1900YRM1620 (01 2023) US EN 2143
Proper Flushing after Major Hydraulic Repairs 2149
Introduction 2149
The Phases of Wear 2149
Causes of Hydraulic System Failure 2149
Progression of Contaminant Caused Hydraulic System Failure 2150
Hydraulic System Flushing Techniques 2150
Double Oil and Filter Change 2150
Mechanical Cleaning 2151
Cleaning of Components 2151
How to Clean Tubes and Hoses 2151
Filter Caddy 2151
Start-Up Procedure for Cleaned System 2152
Contaminated Oil Coolers 2152
Additional Filter Caddy Functions 2153
How to Handle Different Fluids 2153
Water Removal Filters 2153
Fluid Conditioning and System Flushing Procedures 2154
Operation of the Filter Caddy 2154
Filter Caddy operation 2154
Fluid Conditioning Procedure 2154
Filter Caddy Start-Up 2155
System Flushing Procedure 2155
Component Cleaning Procedure 2156
Reservoir Cleaning Procedure 2156
Cylinder Cleaning Procedure 2156
Hose and Tube Cleaning Procedure 2156
Valve Cleaning Procedure 2157
Front-End Attachment Cleaning Procedure 2158
System Flushing Procedure 2158
Filter Caddy Start-Up 2159
System Start-Up and Flushing 2159
Reservoir Fluid Cleaning Times 2160
Dealing With Different Fluid Types 2161
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2161
Filter Caddy Maintenance 2161
Servicing the Strainer 2161
DC Motor 2161
Hydraulic Oil Sampling Method and Procedure 2162
Hydraulic Oil Sampling Method 2162
Objective 2162
General Guidelines 2162
Synopsis 2163
Hydraulic Oil Analysis Report Guidelines 2164
Sampling Conditions 2164
Equipment 2164
Sampling Procedure 2165
Hydraulic Oil Sampling 2165
Sample Labeling 2165
Results Documentation 2165
550073240 1900YRM1620 (03 2020) US EN 2167
Proper Flushing after Major Hydraulic Repairs 2171
Introduction 2171
The Phases of Wear 2171
Causes of Hydraulic System Failure 2171
Progression of Contaminant Caused Hydraulic System Failure 2172
Hydraulic System Flushing Techniques 2172
Double Oil and Filter Change 2172
Mechanical Cleaning 2173
Cleaning of Components 2173
How to Clean Tubes and Hoses 2173
Filter Caddy 2173
Start-Up Procedure for Cleaned System 2174
Contaminated Oil Coolers 2174
Additional Filter Caddy Functions 2174
How to Handle Different Fluids 2174
Water Removal Filters 2175
Fluid Conditioning and System Flushing Procedures 2175
Operation of the Filter Caddy 2175
Filter Caddy operation 2175
Fluid Conditioning Procedure 2176
Filter Caddy Start-Up 2176
System Flushing Procedure 2177
Component Cleaning Procedure 2177
Reservoir Cleaning Procedure 2177
Cylinder Cleaning Procedure 2177
Hose and Tube Cleaning Procedure 2178
Valve Cleaning Procedure 2178
Front-End Attachment Cleaning Procedure 2179
System Flushing Procedure 2179
Filter Caddy Start-Up 2180
System Start-Up and Flushing 2180
Reservoir Fluid Cleaning Times 2181
Dealing With Different Fluid Types 2181
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2181
Filter Caddy Maintenance 2182
Servicing the Strainer 2182
DC Motor 2182
Hydraulic Oil Sampling Method and Procedure 2182
Hydraulic Oil Sampling Method 2182
Objective 2182
General Guidelines 2182
Synopsis 2183
Hydraulic Oil Analysis Report Guidelines 2184
Sampling Conditions 2185
Equipment 2185
Sampling Procedure 2185
Hydraulic Oil Sampling 2185
Sample Labeling 2186
Results Documentation 2186