Yale Forklift C810 (GDPGLP16-18VX, GDPGLP20SVX Europe) Service Manual PDF

Yale Forklift C810 (GDPGLP16-18VX, GDPGLP20SVX Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift C810 (GDPGLP16-18VX, GDPGLP20SVX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4662
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift C810 (GDPGLP16-18VX, GDPGLP20SVX Europe) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (03 2020) UK EN 1
General 5
Threaded Fasteners 5
Nomenclature, Threads 5
Strength Identification 6
Cotter (Split) Pins 7
Fastener Torque Tables 12
Conversion Table 14
524221866 9000YRM1112 (10 2020) UK EN 21
SECTION 9010 Operational Diagnostic Procedures 37
Group 05 – Operational Checkout 39
SECTION 9020 Engine 57
Group 10 – Principles of Operation 67
Group 30 – Observed Symptoms 265
Group 40 – Tests and Adjustments 367
SECTION 9030 Electrical System 399
Group 03 – General Maintenance and Diagnostic Data 423
Group 10 – Principles of Operation 517
Group 20 – Diagnostic Trouble Codes 541
Group 30 – Observed Symptoms 1513
SECTION 9040 Drive Train 1569
Group 10 – Principles of Operation 1573
Group 30 – Observed Symptoms 1629
Group 40 – Tests and Adjustments 1679
SECTION 9050 Hydraulic Systems 1689
Group 10 – Principles of Operation 1693
Group 30 – Observed Symptoms 1751
Group 33 – Observed Symptoms-Gear Pump 1753
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1841
Group 40 – Tests and Adjustments 1885
Group 43 – Tests and Adjustments-Gear Pump 1887
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1911
SECTION 9060 Operators Station 1929
Group 10 – Principles of Operation 1931
SECTION 9070 Front End (Mast) and Chassis 1967
Group 10 – Principles of Operation 1969
Group 30 – Observed Symptoms 1991
SECTION 9080 Supplementary Data 2049
Group 50 – Abbreviations and Acronyms 2051
Group 60 – Special Tools List 2059
Group 70 – Fault Mode Indicator Reference 2069
Group 80 – Supplier Specification Data 2071
524223754 0100YRM1120 (12 2012) UK EN 2075
toc 2075
Frame 2075
Safety Precautions Maintenance and Repair 2076
General 2079
Description 2079
Hood, Seat, and Side Covers Replacement 2080
Remove 2080
Install 2086
Steering Column 2091
Description 2091
Steering Column Repair 2091
Remove 2091
Disassemble 2093
Clean 2093
Inspect 2093
Assemble 2093
Install 2096
LPG Tank and Bracket Assembly 2096
Counterweight Replacement 2097
Remove 2097
Install 2100
Tow Pin, Remove and Install 2101
Overhead Guard Replacement 2101
Remove and Install 2101
LED Tail, Backup, and Brake Lights, Replace 2102
Operator Restraint System Replacement 2103
Description 2103
Automatic Locking Retractor (ALR) 2103
Emergency Locking Retractor (ELR) 2103
Engine Replacement 2105
Remove 2105
Install 2110
Transmission Replacement 2112
Remove Transmission with Iron Housing 2112
Install Transmission with Iron Housing 2114
Remove Transmission with Aluminum Housing 2114
Install Transmission with Aluminum Housing 2119
Throttle Pedal and Cable Adjustment 2122
Mazda Gas/LPG Engines With Basic Power Shift Transmission and El 2122
Mazda Gasoline Engine With Electronic Transmission 2124
Throttle Pedal Stop Adjustment 2125
Yanmar Diesel Engine With Basic Power Shift Transmission 2126
Yanmar Diesel Engine With Electronic Throttle 2126
Exhaust System Repair 2127
Lift Trucks With Counterweight Exhaust System 2127
Mazda Gas and LPG Engines 2127
Remove and Disassemble 2127
Inspect 2127
Assemble and Install 2127
Yanmar Diesel Engine 2129
Remove and Disassemble 2129
Inspect 2129
Assemble and Install 2129
Lift Trucks With Overhead Exhaust System 2131
Yanmar Diesel Engine 2131
Remove and Disassemble 2131
Inspect 2131
Assemble and Install 2132
Mazda Gas and LPG Engines 2134
Remove and Disassemble 2134
Inspect 2134
Assemble and Install 2134
Cooling System 2136
Description 2136
Hydraulic Filter Assembly Repair 2136
Remove 2136
Clean and Inspect 2137
Install 2137
Fuel and Hydraulic Tanks Repair 2138
Inspect 2138
Clean 2138
Steam Method of Cleaning 2138
Chemical Solution Method of Cleaning 2139
Additional Preparations for Repair 2139
Small Leaks, Repair 2139
Large Leaks, Repair 2139
Preparations for Use After Repair 2140
Safety Labels 2140
tables 2075
Table 1 Gas Spring Installation, Lift Truck Models GLP/GDP16VX, 2087
Table 2 Gas Spring Installation, Lift Truck Models GLP/GDP20-35 2089
Table 3 Weight of Counterweights, Lift Truck Models GLC20-35VX 2099
Table 4 Weight of Counterweights, Lift Truck Models GC/GLC030VX 2099
Table 5 Weight of Counterweights, Lift Truck Models GLP/GDP16-1 2099
Table 6 Weight of Counterweights, Lift Truck Models GLP/GDP20-3 2099
524223756 0600YRM1122 (03 2020) UK EN 2147
General 2151
Serial Number 2152
Engine Removal and Installation 2152
Cylinder Head, Camshaft, and Valve Mechanism Repair 2152
Remove 2152
Clean 2155
Inspect and Repair 2155
Cylinder Head 2155
Rocker Shaft Assembly 2155
Camshaft 2156
Valve Guides 2157
Valve Seats 2157
Valves 2158
Valve Springs 2158
Install 2159
Crankshaft and Main Bearings Repair 2163
Remove 2163
Inspect and Repair 2164
Crankshaft 2164
Main Bearings 2164
Install 2165
Pistons and Connecting Rods Repair 2166
Remove and Disassemble 2166
Clean 2166
Inspect and Repair 2166
Pistons 2166
Piston Rings 2166
Connecting Rods and Bearings 2167
Assemble and Install 2167
Cylinder Block Repair 2169
Oil Pump Repair 2170
Remove 2170
Disassemble 2171
Clean 2171
Inspect 2171
Assemble 2172
Install 2172
Cooling System Repair 2174
Thermostat 2174
Replace 2174
Fan Assembly 2174
Remove and Disassemble 2174
Assemble and Install 2175
Water Pump 2175
Remove 2175
Install 2176
Flywheel and Ring Gear Repair 2177
Remove 2177
Install 2177
Valve Adjustment 2177
Compression Pressure Check 2179
Engine Timing Adjustment 2180
Engine Specifications 2180
Engine Data 2180
Engine Speeds 2180
2007, and Later, Emission Compliant Engines 2180
All Engines Except 2007, and Later, Emission Compliant Engines 2181
Thermostat 2181
Cylinder Head 2181
Valve Mechanism 2181
Camshaft 2182
Crankshaft 2182
Connecting Rods 2182
Cylinder Block 2183
Pistons 2183
Oil Pump 2183
Torque Specifications 2184
524223757 0700YRM1123 (06 2016) UK EN 2187
General 2191
Cooling System Checks 2191
Exhaust Leaks Into Cooling System 2191
Water Flow Restrictions in Radiator 2191
Radiator Hoses 2191
Water Pump 2192
Flushing the Cooling System 2192
Cooling System, Clean 2192
Radiator Replacement 2193
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) 2194
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 2209
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2212
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) 2215
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) 2222
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 2227
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2229
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) 2232
Fan Assembly Replacement 2244
Fan Removal 2244
Inspect 2259
Fan Installation 2259
524223759 0900YRM1125 (10 2005) UK EN 2265
toc 2265
LPG Fuel System 2265
Safety Precautions Maintenance and Repair 2266
General 2269
Hoses Replacement 2269
LPG Tank Replacement 2269
Remove 2269
Install 2271
Fuel Filter 2272
Remove 2272
Clean and Inspect 2272
Install 2273
Relief Valve Replacement 2274
Remove and Install 2274
Carburetor Repair 2274
Remove 2274
Disassemble 2274
Clean 2276
Assemble 2276
Install 2276
Fuel Injector Repair 2277
Remove 2277
Clean and Inspect 2277
Install 2277
Governor Repair 2277
Remove 2277
Install 2277
Regulator Repair 2278
Remove 2278
Install 2278
Control System 2279
Engine Control Unit (ECU) 2279
Remove 2279
Install 2280
Engine Coolant Temperature (ECT) Sensor 2280
Remove 2280
Install 2280
Camshaft Position (CMP) Sensor 2280
Voltage Check 2280
Intake Air Temperature (IAT) Sensor 2281
Remove 2281
Install 2281
Manifold Absolute Pressure (MAP) Sensor 2282
Remove 2282
Install 2282
Oxygen Sensor 2282
Remove 2282
Install 2282
Throttle Position (TP) Sensor 2283
Remove 2283
Install 2283
524223762 1300YRM1129 (11 2018) UK EN 2287
General 2291
Serial Number 2291
Charge Pump Repair 2291
Remove 2291
Inspect 2292
Install 2292
Torque Converter Replace 2292
Remove 2292
Install 2300
Front Cover Housing and Chain Drive Repair 2306
Remove 2306
Clean 2315
Inspect 2315
Install 2315
Clutch Packs Repair 2324
Remove and Disassemble 2324
Transmission, Remove and Disassemble 2324
Clean 2343
Inspect 2343
Assemble and Install 2344
Transmission, Assemble and Install 2352
Control Valve Repair 2358
Remove and Disassemble 2358
Clean 2362
Inspect 2362
Assemble and Install 2362
Foot Directional Control Pedal Repair 2363
Remove and Disassemble 2363
Assemble and Install 2367
Direction Control Lever 2368
Remove 2368
Install 2368
524223764 1600YRM1133 (07 2013) UK EN 2373
toc 2373
Steering Axle 2373
Safety Precautions Maintenance and Repair 2374
General 2377
Steering Axle Assembly Repair 2379
Remove 2379
Disassemble 2380
Clean 2388
Inspect 2388
Assemble 2388
Install 2394
Spindles, Bearings, and Tie Rods Repair 2396
Spindles and Bearings 2396
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2396
Remove 2396
Disassemble 2398
Clean 2399
Inspect 2399
Assemble 2399
Install 2400
Spindles and Bearings 2403
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2403
Remove and Disassemble 2403
Assemble and Install 2404
Tie Rods 2404
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2404
Remove 2404
Install 2405
Tie Rods 2406
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2406
Remove 2406
Install 2412
Steering Cylinder Repair 2412
Remove and Disassemble 2412
Clean and Inspect 2413
Assemble and Install 2413
Torque Specifications 2414
524223765 1800YRM1135 (09 2018) UK EN 2419
General 2423
Dry Brake System 2423
Wet Brake System 2423
Service Brakes Repair (Dry Brake) 2423
Remove and Disassemble 2424
Clean 2432
Inspect 2432
Assemble and Install 2433
Adjust 2440
Inching Overlap Adjustment 2440
Parking Brake Repair 2441
Remove and Disassemble 2441
Assemble and Install 2444
Adjust 2444
Master Cylinder Repair 2445
Remove (Dry Brake) 2445
Disassemble (Dry Brake) 2446
Clean and Inspect (Dry Brake) 2448
Assemble (Dry Brake) 2448
Bench Bleed Master Cylinder (Dry Brake) 2448
Install and Adjust (Dry Brake) 2448
Remove (Wet Brake) 2449
Disassemble (Wet Brake) 2451
Clean and Inspect (Wet Brake) 2452
Assemble (Wet Brake) 2453
Install and Adjust (Wet Brake) 2453
Service Brakes Adjustment (Dry Brake) 2454
Brake System Air Removal 2454
Using Pressure Bleed System 2454
Using Brake Pedal Pressure 2455
Brake Pedal Adjustment 2455
Free Pedal Adjustment 2456
Torque Specifications 2458
524223766 1900YRM1136 (11 2017) UK EN 2461
General 2465
Hydraulic Gear Pump Assembly 2466
Variable Displacement Pump Assembly 2467
Single Gear Pump Assembly Repair 2467
Remove 2467
Disassemble 2474
Clean 2474
Inspect 2476
Assemble 2476
Install 2476
Tandem Gear Pump Assembly 2480
Remove 2481
Disassemble 2483
Clean 2485
Inspect 2485
Assemble 2485
Install 2486
Gear Pump Specifications 2486
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2492
Remove 2492
Disassemble 2502
Clean 2505
Inspect 2505
Assemble 2505
Install 2506
63 0 cc/rev – Variable Displacement Pump Repair 2509
Remove 2509
Disassemble 2512
Clean 2512
Inspect 2512
Assemble 2514
Install 2514
Variable Displacement Pump Checks and Adjustments (Single Pump) 2516
Margin Pressure Check 2516
Flow Compensator Adjustment 2517
Pressure Compensator Adjustment 2517
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2518
Variable Displacement Pump Specifications 2521
Torque Specifications 2522
Hydraulic Gear Pump 2523
Variable Displacement Pump 2524
Special Tools 2524
524223767 2000YRM1137 (01 2017) UK EN 2529
General 2535
Electro-Hydraulic Main Control Valve 2536
Description 2536
Remove 2544
Electro-Hydraulic Control Valve Sections 2549
General 2549
Outlet Control Valve Section 2549
Remove 2549
Disassemble 2550
Clean 2552
Inspect 2552
Assemble 2552
Install 2553
Auxiliary Control Valve Sections 2553
Remove 2553
Disassemble 2560
Clean 2561
Inspect 2562
Assemble 2562
Install 2564
Tilt Control Valve Section 2565
Remove 2565
Disassemble 2565
Clean 2571
Inspect 2571
Assemble 2571
Install 2572
Lift/Lower Control Valve Section 2573
Remove 2573
Disassemble 2573
Clean 2582
Inspect 2582
Assemble 2582
Install 2583
Mid-Inlet Section 2583
Remove 2583
Clean 2584
Inspect 2584
Install 2584
Install 2584
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2589
Lift Pilot Pin 2589
Lower Pilot Pin 2593
Abnormal/Erroneous EHPV Adjustment 2595
Manual Main Control Valve 2596
Description 2596
Remove 2600
OPS Solenoid Assembly 2608
General 2608
Remove 2609
Clean and Inspect 2612
Install 2612
Manual Control Valve Sections 2613
General 2613
Outlet Control Valve Section 2613
Remove 2613
Disassemble 2613
Clean 2616
Inspect 2616
Assemble 2616
Install 2617
Auxiliary Control Valve Sections 2617
Remove 2617
Disassemble 2617
Clean 2620
Inspect 2620
Assemble 2620
Install 2621
Lift/Tilt Control Valve Section 2621
Remove 2621
Disassemble 2621
Clean 2628
Inspect 2628
Assemble 2629
Install 2630
Mid-Inlet Section 2631
Remove 2631
Clean 2631
Inspect 2631
Install 2631
Install 2632
Pressure Relief Valve Check and Adjustment 2638
Primary Relief Valve 2639
Secondary Relief Valve 2643
Steering Control Unit Repair 2650
Steering Control Unit, Remove 2650
Steering Control Unit, Disassemble 2654
Steering Control Unit, Clean 2656
Steering Control Unit, Inspect 2656
Steering Control Unit, Assemble 2656
Relief Valve, Disassemble 2657
Relief Valve, Clean 2657
Relief Valve, Inspect 2658
Relief Valve, Assemble 2658
Steering Control Unit, Install 2658
524223768 2100YRM1139 (02 2014) UK EN 2663
524223769 2200YRM1128 (07 2020) UK EN 2711
Series Code / Model Designation Reference Table 2717
General 2720
Deutsch Crimping Tool 2720
How to Strip a Wire for Use With Deutsch Crimping Tool 2720
How to Crimp With the Deutsch Crimping Tool 2721
Calibration Test for the Deutsch Crimping Tool 2723
Deutsch Connectors 2725
DT, DTM, and DTP Series Connectors 2725
HD Series Connectors 2767
Metri-Pack Connectors 2790
Remove and Install 2790
Micro-Pack Connectors 2792
Weather-Pack Connectors 2793
AMPSEAL Crimping Tools 2795
AMP Hand Crimping Tool With Certi-Crimp 2795
Description 2795
Stripping Wire for Use with AMP Hand Crimping Tool 2795
Insulation Crimp Adjustment 2796
Maintenance and Inspection for AMP Hand Crimping Tool 2796
AMP Hand Crimping Tool 2796
Crimp Height Inspection 2796
How to use AMP Hand Crimping Tool 2797
AMP Pro-Crimper II Tool 2797
Description 2797
Remove and Install Die Set and Locator Assembly 2798
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2799
Contact Support Adjustment 2799
Crimp Height Adjustment 2800
Maintenance and Inspection Procedures 2800
PRO-CRIMPER II Tool 2800
Crimp Height Inspection 2800
How to Use AMP PRO-CRIMPER II Tool 2801
AMPSEAL Connector Assemblies 2802
Description for Plug Connector Assembly 2802
Seal Plug 2803
Contact Crimping 2803
Description for Plug Connector and Header Assembly 2808
Voltage Reading 2810
Seal Plug 2810
Contact Crimping 2810
AMP Superseal 1 5 Crimping Tools 2817
Mini Mic Receptacle and Tab Contacts 2817
Description 2817
Crimping Conditions and Measurements 2817
Insertion of Rubber Seal on Cable 2819
AMP Hand Application Tool 2824
Description 2824
Maintenance and Inspection 2824
Crimp Height Inspection 2824
Crimp Height Adjustment 2825
How to Use AMP Hand Application Tool 2825
AMP Pro-Crimper II Tool 2826
Description 2826
Remove and Install Die Set and Locator Assembly 2827
Adjustments 2827
Contact Support 2827
Crimp Height 2828
Inspections and Maintenance 2829
Crimp Height Inspection 2829
Visual Inspection 2829
Maintenance 2830
How to Use Pro-Crimper II Tool 2830
AMP Superseal 1 5 Connector Assemblies 2831
Description 2831
Repair and Maintenance 2838
Panel Mount Option 2838
AMP Fastin-Faston Hand Tools 2839
Description – AMP Double Action Hand Tool 2839
Maintenance and Inspection Procedures 2839
Daily Maintenance 2839
Periodic Tool Inspection 2840
Lubrication 2840
Visual Inspection 2840
Crimp Height Inspection 2840
Certi-Crimp Ratchet Inspection 2841
How to Use AMP Double Action Hand Tool 2842
Description – AMP Extraction Tool 2843
Maintenance and Inspection 2843
How to Use AMP Extraction Tool 2844
AMP Fastin-Faston Receptacles and Housings 2845
Description 2845
Wire Repair 2852
Wire Splicing Requirements 2852
Deutsch Jiffy Splice 2853
Twisted/Shielded Cable and Leads Repair 2858
Special Tools 2861
524223770 2200YRM1130 (03 2020) UK EN 2869
General 2873
Description 2873
Dash Display Menu Access 2873
Menu Navigation 2874
Standard Display 2874
Main Menu 2874
Passwords Menu 2875
Password Administration 2875
Add Password 2875
Delete Password 2876
Edit Password 2876
Other Password Functions 2877
Operator Passwords – Enable/Disable 2877
Password Time-Out Delay 2877
Passwords – Number Wrong to Disable 2878
Lockout Reset Password 2878
View Password Log 2879
View Versions 2880
VSM Versions 2880
Dash Display Versions 2881
Engine Controller Version 2882
Transmission (Xmsn) Controller Version 2883
Truck Serial Number 2884
Diagnostics 2885
View Fault Log 2885
Set Travel and Braking 2886
Speed Limit 2886
Acceleration Rate 2887
Auto-Deceleration Rate 2887
Set Power Reversal Rate 2888
Set Inching/Brake Overlap 2889
Setup Display Menu 2890
Set Operator Language 2890
Set Units 2891
Set Time Format (12/24 Hour) 2891
Set Daylight Saving Time 2891
Set Time 2894
Set Date Format 2895
Set Date 2895
Setup Hydraulics 2896
Return to Set Tilt Delay/On/Off 2896
Setup General Items 2897
Light Shutdown Time-Out 2897
Impact Sensor – Enable/Disable 2898
Impact Sensor – Soft Impact Settings 2899
Impact Sensor – Hard Impact Settings 2900
Adjust Impact Sensor Settings 2900
Initial Adjustment of Soft and Hard Impact Settings 2902
Readjustment of Soft and Hard Impact Settings 2902
Impact Sensor – Impact Alarm/Shutdown Reset 2903
Impact Sensor – Alarm Time Duration and Deactivation 2904
Impact Sensor – View Impact Event Log 2905
Engine Mode Indicator 2906
Generation 1 (ECO-eLo ONLY) 2906
Generation 2 2907
Operator Checklist 2908
Operator Checklist Off-On Mode 2908
Edit Operator Checklist 2908
Set Operator Checklist Expiration 2909
View Checklist Log 2909
Clear Operator Checklist Log 2910
Clear Operator Checklist Fault 2910
Calibrations 2911
Set Tilt Stop Point 2911
Calibrate Loaded Weight 2911
524223771 2200YRM1131 (03 2020) UK EN 2913
Series Code / Model Designation Reference Table 2919
General 2921
Description 2921
Dash Display Menu Access 2921
Menu Navigation 2922
Main Menu 2922
Passwords 2923
Adding Passwords 2923
Hourmeters 2925
View Versions 2926
VSM Versions 2926
Dash Display Versions 2927
Engine Controller Version 2928
Transmission (Xmsn) Controller Version 2929
Truck Serial Number 2930
Truck Configuration 2931
Diagnostics 2932
Clear Fault Log 2932
View Fault Log 2933
No-Run Data Display 2934
Engine Accelerator and Throttle Data Display 2934
Engine Speeds and Governor Data Display 2935
Engine Fuel and Emissions Data Display 2936
Engine General Data Display 2938
XMSN/Brake Data Display 2939
Hydraulic Data Display 2942
General Truck Data Display 2944
Set Travel and Braking 2945
Speed Limit 2945
Acceleration Rate 2946
Auto-Deceleration Rate 2947
Set Power Reversal Rate 2947
Set Inching/Brake Overlap 2948
Setup Hydraulics 2948
Lift Maximum Speed 2949
Lower Maximum Speed 2949
Tilt Maximum Speed 2950
Auxiliary Function One, Direction A, Maximum Speed 2952
Auxiliary Function One, Direction B, Maximum Speed 2954
Auxiliary Function Two, Direction A, Maximum Speed 2954
Auxiliary Function Two, Direction B, Maximum Speed 2955
Auxiliary Function Three, Direction A, Maximum Speed 2956
Auxiliary Function Three, Direction B, Maximum Speed 2956
Lift/Lower Ramp Rate 2957
Hydraulic Auxiliary Ramp Rate 2957
Return to Set Tilt Delay/On/Off 2958
Hydraulic Input Device 2959
Auxiliary Solenoid 2959
Dual Function 2960
Setup Display 2961
Set Service Language 2961
Setup General Items 2961
Motion Alarm Activation Type 2962
Light Shutdown Time-Out 2963
Restore Default Settings 2963
Restore Engine Controller Default Calibration 2964
Impact Sensor – Enable/Disable 2964
Impact Sensor – Soft Impact Settings 2965
Impact Sensor – Hard Impact Settings 2966
Adjust Impact Sensor Settings 2967
Initial Adjustment of Soft and Hard Impact Settings 2969
Readjustment of Soft and Hard Impact Settings 2969
Impact Sensor – Impact Alarm/Shutdown Reset 2970
Impact Sensor – Alarm Time Duration and Deactivation 2971
Impact Sensor – View Impact Event Log 2972
Engine Mode Indicator 2972
Generation 1 (ECO-eLo ONLY) 2972
Generation 2 2973
Diesel Particulate Filter (DPF) Display 2974
General Description 2974
Passive Regeneration Only 2974
Regeneration Level 0 2974
Auto/Active Regeneration Inhibited 2975
Auto/Active Regeneration 2975
Regeneration Level 1 2975
Parked Regeneration Request 2976
Regeneration Level 2 2976
Warning Level 2976
Regeneration Level 3 2976
Service Level 2977
Regeneration Level 4 2977
Display, Diesel Particulate Filter (DPF), Revised 2977
Operator Interface 2977
Refer to Operator Manual 2977
CAN Communication Lost 2978
Passive Regeneration Only 2978
Regeneration Level 0 2978
Auto/Active Regeneration Inhibited 2978
Auto/Active Regeneration 2979
Regeneration Level 1 2979
Idle-up Auto/Active Regeneration 2979
Parked Regeneration Request 2979
Regeneration Level 2 2979
Warning Level 2981
Regeneration Level 3 2981
Service Level 2981
Regeneration Level 4 2981
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2981
Display, Diesel Particulate Filter (DPF), Stage V Engine 2981
Operator Interface 2982
Refer to Operator Manual 2982
CAN Communication Lost 2982
Passive Regeneration Only 2982
Regeneration Level 0 2982
Auto/Active Regeneration Inhibited 2983
Auto/Active Regeneration 2983
Regeneration Level 1 2983
Idle-up Auto/Active Regeneration 2984
Parked Regeneration Request 2984
Regeneration Level 2 2984
Warning Level 2985
Regeneration Level 3 2985
Service Level 2986
Regeneration Level 4 2986
Stage V Content 2986
Emissions System Malfunction 2986
Ash Load 2986
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2987
Operator Interface 2987
Refer to Operator Manual 2987
CAN Communication Lost 2988
Passive Regeneration Only 2988
Regeneration Level 0 2988
Auto/Active Regeneration Inhibited 2988
Auto/Active Regeneration 2989
Regeneration Level 1 2989
Idle-up Auto/Active Regeneration 2989
Parked Regeneration Request 2989
Regeneration Level 2 2989
Warning Level 2991
Regeneration Level 3 2991
Service Level 2991
Regeneration Level 4 2991
Calibrations 2992
Calibrate Transmission Valve 2994
Set Tilt Stop Point 2994
Calibrate Loaded Weight 2994
Calibrate Travel Speed Sensor 2995
Calibrate Mazda LP and Gas Accelerator Pedal 2995
524223772 2200YRM1142 (01 2020) UK EN 2997
General 3007
Display Switch Cluster 3010
Remove 3010
Install 3013
Direction Control and Turn Signal Levers 3013
Remove 3013
Install 3015
Key Switch 3015
Remove 3015
Install 3016
Display Switch Cluster Panel Bezel and Overlay 3016
Remove 3016
Install 3016
Steering Column Repair 3016
Remove 3016
Disassemble 3019
Assemble 3019
Install 3019
Sensors and Switches 3020
General 3020
Dash and Kick Panel, Remove and Install 3020
Remove 3020
Install 3021
Accelerator Pedal Position Sensor 3022
Remove 3022
Install 3025
Brake Fluid Level Switch 3026
Remove 3026
Install 3028
Service Brake Pedal Position Sensor 3029
Remove 3029
Install 3032
Parking Brake Sensor 3033
Remove 3033
Install 3034
Service Brake Pressure Sensor 3035
Remove 3035
Install 3037
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3038
Remove 3038
Install 3038
Sensor Microswitch (Foot Directional Control Pedal) 3039
Remove 3039
Install 3042
Low Coolant Level Sensor 3043
Remove 3043
Install 3046
Fuel Level Sensor, Gas and Diesel Engines Only 3047
Remove 3047
Install 3048
Armrest Switch 3048
Remove 3048
Install 3050
Seat Sensor (Operator Presence System) 3050
Non-Suspension and Semi-Suspension Seats; For Lift truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-8VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (C879, D879, E879, F879) 3050
Remove 3050
Install 3051
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3051
Remove 3051
Install 3052
Full Suspension Seats; All Lift Truck Models 3052
Remove 3052
Install 3052
Hood Shut Off Switch 3052
Remove 3052
Install 3055
Remote Key Switch 3056
Remove 3056
Install 3056
Hydraulic Filter Pressure Switch 3057
Remove 3057
Install 3059
Transmission Speed Sensor 3059
Remove 3059
Install 3062
Transmission Pressure Sensors 3063
Remove 3063
Install 3065
Transmission Temperature Sensor 3066
Remove 3066
Install 3068
Engine Speed Sensor 3070
Remove 3070
Install 3070
Intermediate Speed Sensor 3071
Remove 3071
Install 3071
Return to Set Tilt (Tilt Angle) Sensor 3071
Lift Truck Models GLC20-35VX (GC/GCL040-070VX, GC/GLC055SVX) (A910); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP30VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) 3071
Remove 3071
Install 3072
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3073
Remove 3073
Install 3074
Rear Horn Button Switch 3074
Remove 3074
Install 3075
Impact Sensor 3076
Lift Truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX,) (C879, D879, E879, F879) 3076
Remove 3076
Install 3079
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3079
Remove 3079
Install 3080
Load Weight Sensor 3081
Remove 3081
Install 3082
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3083
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3083
Crankshaft Position (CKP) Sensor 3083
Camshaft Position (CMP) Sensor 3083
Oil Pressure Sensor 3083
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3083
Engine Coolant Temperature (ECT) Sensor 3084
Air Flow Restriction Switch 3084
Remove for GM 2 4L Gas and LPG Trucks 3084
Install for GM 2 4L Gas and LPG Trucks 3084
Oxygen Sensor 3085
Remove 3085
Install 3088
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3089
Crankshaft Position (CKP) Sensor 3089
Camshaft Position (CMP) Sensor 3089
Oil Pressure Sensor 3089
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3089
Engine Coolant Temperature (ECT) Sensor 3089
Air Flow Restriction Switch 3089
Oxygen Sensor 3089
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3089
Low LPG Pressure Switch 3089
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3090
Air Filter Restriction Switch 3090
Remove 3090
Install 3090
Oil Pressure Sensor 3090
Remove 3090
Install 3090
Engine Speed Sensor 3090
Remove 3090
Install 3090
Engine Coolant Temperature (ECT) Sensor 3090
Remove 3090
Install 3090
Throttle Position Sensor (TPS) 3093
Remove 3093
Install 3094
Fuel/Water Separator Sensor 3094
Remove 3094
Install 3094
Glow Plug Relay 3095
Remove 3095
Install 3097
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3097
Air Filter Restriction Switch 3097
Remove 3097
Install 3097
Engine Oil Pressure Sensor 3102
Remove 3102
Install 3102
Engine Speed Sensor 3102
Remove 3102
Install 3103
Engine Coolant Temperature (ECT) Sensor 3103
Remove 3103
Install 3104
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3105
Remove 3105
Install 3105
Fuel/Water Separator Sensor 3106
Remove 3106
Install 3106
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3107
Intake Air Temperature Sensor 3107
Remove 3107
Install 3108
Intake Air Pressure Sensor 3108
Remove 3108
Install 3108
Air Inlet Heater 3108
Remove 3108
Install 3109
Engine Oil Pressure Sensor 3109
Remove 3109
Install 3109
Engine Coolant Temperature (ECT) Sensor 3109
Remove 3109
Install 3109
Crankshaft Position Sensor 3110
Remove 3110
Install 3110
Adjust Shim Procedure 3111
Camshaft Position Sensor 3112
Remove 3112
Install 3112
Air Flow Restriction Sensor 3113
Remove 3113
Install 3113
Fuel/Water Separator 3113
Remove 3113
Install 3114
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3114
Intake Air Temperature Sensor 3118
Remove 3118
Install 3119
Boost Sensor 3119
Remove 3119
Install 3120
Throttle Valve Assembly and Air Intake Heater 3120
Remove 3120
Install 3120
Engine Coolant Temperature (ECT) Sensor 3121
Remove 3121
Install 3121
Engine Oil Pressure Sensor 3121
Remove 3121
Install 3122
Crankshaft Position Sensor 3122
Remove 3122
Install 3122
Adjust Shim Procedure 3123
Camshaft Position Sensor 3124
Remove 3124
Install 3125
Differential Pressure Sensor 3125
Remove 3125
Install 3125
Mass Air Flow Sensor 3126
Remove 3126
Install 3127
Fuel/Water Separator 3127
Remove 3127
Install 3128
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3128
Engine Coolant Temperature (ECT) Sensor 3129
Remove 3129
Install 3129
Throttle Position Sensor 3130
Engine Oil Pressure Sensor 3130
Remove 3130
Install 3130
Engine Speed Sensor 3130
Remove 3130
Install 3130
Fuel Shut Off Solenoid 3130
Remove 3130
Install 3130
Vehicle System Manager (VSM) 3131
General 3131
VSM Replacement 3131
Remove 3131
Install 3133
Programming a New VSM and/or Display Switch Cluster 3133
General 3133
PC Service Tool Software 3134
Data Transferring 3134
New VSM 3134
New (Blank) Display Switch Cluster 3134
Used (Non-Blank) Display Switch Cluster 3134
Power Distribution Module (PDM) and Component Parts 3136
Remove 3136
PDM as a Unit 3136
Install 3140
PDM as a Unit 3140
Remove and Install 3141
PDM Component Parts 3141
Transmission Control Unit 3141
Remove 3141
Install 3145
Battery 3147
Remove 3147
Install 3147
Lights 3148
Work Lights (Front and Rear) 3148
Remove 3148
Install 3148
Strobe Light 3149
Remove 3149
Install 3149
LED Tail, Backup, and Brake Lights 3150
Remove 3150
Install 3151
Front Marker/Turn Signal Lights 3152
Replacing Whole Front Marker/Turn Signal Light Assembly 3152
Remove 3152
Install 3152
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3153
Remove 3153
Install 3153
Diesel Particulate Filter (DPF) Display 3153
Remove 3153
Clean and Inspect 3154
Install 3154
Electronic-Hydraulic Controls – Generation 1 3155
E-Hydraulic Controls – Test 3155
Mini-Levers 3155
Full Stroke Test 3155
Function Returns to Neutral Test 3155
Push Button Switch 3155
General 3156
Mini-Lever Replacement 3156
Remove 3156
Clean and Inspect 3157
Install 3157
Push Button Switch Replacement 3158
Remove 3158
Install 3160
Mini-Lever Module (MLM) 3160
Remove 3160
Install 3160
Joystick 3161
Remove and Disassemble 3161
Inspect 3161
Assemble and Install 3161
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3162
General 3162
Mini-levers, Remove and Install 3162
Armrest Assembly 3163
Remove 3163
Install 3166
Horn Button 3166
Remove 3166
Install 3166
Direction Control Switch 3167
Remove 3167
Install 3167
push (override) buttons and Toggle Switch 3167
Remove 3168
Install 3169
Joystick 3170
Remove and Disassemble 3170
Inspect 3170
Assemble and Install 3170
Joystick Armrest Slider Assembly 3171
Remove 3171
Install 3172
Electronic-Hydraulic Controls, After January, 2020 3172
E-Hydraulic Controls – TEST 3172
Mini-Levers 3172
Full Stroke Test 3172
Function Returns to Neutral Test 3172
Push (Override) Button 3173
General 3173
Mini-levers, Remove and Install 3173
Armrest Assembly 3174
Remove 3174
Install 3177
Horn Button 3177
Remove 3177
Install 3177
Direction Control Switch 3177
Remove 3177
Install 3178
Push (Override) buttons and Toggle Switch 3178
Remove 3179
Install 3181
Special Tools 3182
524223773 2200YRM1143 (10 2005) UK EN 3185
toc 3185
Electrical System 3185
Safety Precautions Maintenance and Repair 3186
Ignition System 3189
General 3189
Ignition Timing Adjustment, Gasoline and LPG 3189
Spark Plugs Check 3189
Spark Plug Wires Check 3189
Distributor Repair 3192
Remove 3192
Disassemble 3193
Inspect 3193
Assemble 3194
Install 3194
Igniter 3195
Remove 3195
Test 3195
Install 3195
Camshaft Position (CMP) Sensor 3196
Voltage Check 3196
Ignition Coil Check 3197
Primary Coil Winding 3197
Secondary Coil Winding 3197
Starter Repair 3198
General 3198
Remove 3198
No-Load Test 3199
Magnetic Switch Test 3199
Pull-Out Test 3199
Holding Coil Test 3200
Return Test 3200
Pinion Movement Inspection 3200
Install 3200
Alternator Repair 3201
General 3201
Charging System Inspection 3201
Output Current Check 3202
No-Load Adjusted Voltage Check 3202
Remove 3203
Inspect 3203
Rectifier Check 3203
Install 3204
tables 3185
Table 1 Spark Plug Wire 3189
Table 2 Starter Specifications 3198
Table 3 Problem Diagnosis Chart 3199
Table 4 Specifications 3202
Table 5 Rectifier Check Table 3203
524223776 4000YRM1148 (09 2015) UK EN 3207
General 3211
Safety Procedures When Working Near Mast 3212
Fork Replacement 3214
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3214
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3216
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3217
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3217
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3218
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3219
Carriages Repair 3220
Standard Carriage 3220
Remove 3220
Repair 3221
Install 3221
Standard Carriage, Remove 3222
Hang-On Sideshift Carriage, Remove 3223
Standard Carriage and Hang-On Sideshift Carriage, Repair 3224
Standard Carriage, Install 3225
Hang-On Sideshift Carriage, Install 3225
Integral Sideshift Carriage 3226
Remove 3226
Clean and Inspect 3229
Repair 3230
Install 3230
Fork Positioner 3231
Remove 3231
Clean and Inspect 3236
Disassemble and Assemble 3236
Install 3236
Fork Positioner Hydraulic Hose Adjustment 3237
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3239
Connecting Attachment Hydraulic Quick Disconnect Hoses 3239
Mast Repair 3240
Mast, Remove 3240
Two-Stage LFL and Two-Stage FFL Masts 3243
Disassemble 3243
Clean and Inspect 3253
Three-Stage FFL Mast 3254
Disassemble 3254
Clean and Inspect 3262
Two-Stage LFL and Two-Stage FFL Mast 3264
Assemble 3264
Three-Stage FFL Mast 3267
Assemble 3267
Four-Stage FFL Mast – Manufactured Before July, 2009 3269
Disassemble 3269
Clean and Inspect 3274
Assemble 3276
Four-Stage FFL Mast – Manufactured After July, 2009 3277
Disassemble 3277
Clean and Inspect 3284
Assemble 3287
Mast, Install 3288
Header Hose Arrangement 3291
Two-Stage LFL 3291
Two-Stage FFL 3299
Three-Stage FFL 3314
Standard 3314
Optional Equipment Lift Truck GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 3331
Four-Stage FFL Mast – Manufactured Before July, 2009 3339
Four-Stage FFL Mast – Manufactured After July, 2009 3348
Adjustment 3355
Lift Chains Adjustment 3355
Carriage Adjustments 3358
Mast Adjustments 3358
Load Roller Adjustment 3358
Mast Side Kicking Adjustment 3361
524223779 8000YRM1152 (03 2020) UK EN 3365
General Information About Diagrams and Schematics 3369
Symbol Definitions 3369
Diagrams Manual Applications 3370
Diagrams and Schematics 3372
524223780 8000YRM1134 (03 2020) UK EN 3435
Series Code / Model Designation Reference Table 3441
Description 3443
Proc_Cal_001: Service Password Entry 3445
When to Perform 3445
Why Perform 3445
How to Perform 3445
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3446
When to Perform 3446
Calibration Order 3446
Why Perform 3446
How to Perform 3447
Proc_Cal_003: Save and Exit 3448
When to Perform 3448
Why Perform 3448
How to Perform 3448
Proc_Cal_004: Lift Valve Output Threshold 3449
When to Perform 3449
Calibration Order 3449
Why Perform 3449
How to Perform 3450
Proc_Cal_005: Lower Valve Output Threshold 3452
When to Perform 3452
Calibration Order 3452
Why Perform 3452
How to Perform 3452
Proc_Cal_006: Tilt Back Valve Output Threshold 3455
When to Perform 3455
Calibration Order 3455
Why Perform 3455
How to Perform 3455
Proc_Cal_007: Tilt Forward Valve Output Threshold 3458
When to Perform 3458
Calibration Order 3458
Why Perform 3458
How to Perform 3458
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3461
When to Perform 3461
Calibration Order 3461
Why Perform 3461
How to Perform 3461
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3464
When to Perform 3464
Calibration Order 3464
Why Perform 3464
How to Perform 3464
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3467
When to Perform 3467
Calibration Order 3467
Why Perform 3467
How to Perform 3467
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3470
When to Perform 3470
Calibration Order 3470
Why Perform 3470
How to Perform 3470
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3473
When to Perform 3473
Calibration Order 3473
Why Perform 3473
How to Perform 3473
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3476
When to Perform 3476
Calibration Order 3476
Why Perform 3476
How to Perform 3476
Proc_Cal_014: Load Weight Zero Point 3480
When to Perform 3480
Calibration Order 3480
Why Perform 3480
How to Perform 3480
Proc_Cal_015: Loaded Weight Calibration 3482
When to Perform 3482
Calibration Order 3482
Why Perform 3482
How to Perform 3482
Proc_Cal_016: Transmission Valve Calibration 3485
Applicable System/Option 3485
When to Perform 3485
Calibration Order 3485
Why Perform 3485
How to Perform 3485
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3487
Applicable System/Option 3487
When to Perform 3487
Calibration Order 3487
Why Perform 3487
How to Perform 3487
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3489
Applicable System/Option 3489
When to Perform 3489
Calibration Order 3489
Why Perform 3489
How to Perform 3490
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3491
Required Tools 3491
When to Perform 3491
Calibration Order 3491
Why Perform 3492
How to Perform 3492
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3493
When to Perform 3493
Why Perform 3493
How to Perform 3493
Proc_Cal_026: Travel Speed Calibration 3495
When to Perform 3495
Calibration Order 3495
Why Perform 3495
How to Perform 3495
524240453 0600YRM1205 (01 2017) UK EN 3499
General 3505
Engine Identification 3505
Major Engine Component Identification 3505
Location of Labels 3506
Engine Removal and Installation 3507
Cylinder Head Assembly Repair 3507
Glow Plugs 3510
Remove 3510
Install 3510
Valve Cover 3510
Remove 3510
Clean and Inspect 3511
Install 3511
Rocker Arm Assembly 3511
Remove 3511
Disassemble 3512
Clean and Inspect 3513
Push Rods 3513
Rocker Arm Assembly 3513
Assemble 3513
Install 3514
Valve Clearance Adjustments 3514
Cylinder Head Assembly 3515
Remove 3515
Disassemble 3520
Valves and Valve Springs, Remove 3520
Valve Guides, Remove 3520
Clean and Inspect 3521
Cylinder Head 3521
Valve Guides 3522
Valves 3522
Valve Sink 3522
Valve Seat 3523
Valve Springs 3523
Assemble 3524
Valve Guides, Install 3524
Valves and Valve Springs, Install 3524
Install 3525
Timing Gear Case and Timing Gears Repair 3526
Timing Gear Case Cover 3527
Remove 3527
Clean and Inspect 3527
Install 3528
Timing Gears 3528
Crankshaft Gear 3529
Remove 3529
Install 3529
Idler Gear 3529
Remove 3529
Inspect 3530
Install 3530
Camshaft Gear 3530
Remove 3530
Install 3531
Timing Gear Case 3531
Remove 3531
Clean and Inspect 3532
Install 3532
Drive Train, Camshaft, and Cylinder Block Repair 3533
Remove 3533
Disassemble 3534
Pistons and Connecting Rods 3534
Crankshaft 3534
Camshaft 3537
Clean and Inspect 3538
Cylinder Block 3538
Honing and Boring 3541
Pistons 3542
Piston Pin 3542
Connecting Rod 3543
Tappets 3543
Crankshaft 3544
Camshaft 3545
Camshaft Bushing 3546
Assemble 3546
Camshaft 3546
Crankshaft 3546
Pistons and Connecting Rods 3547
Install 3548
Lubrication System Repair 3549
Engine Oil and Oil Filter Change 3549
Oil Pan 3549
Remove 3549
Install 3550
Oil Suction Tube 3550
Remove 3550
Clean 3551
Install 3551
Oil Pump 3551
Remove 3551
Clean and Inspect 3552
Outer Rotor Outside Clearance 3552
Outer Rotor to Inner Rotor Tip Clearance 3553
Outer Rotor Side Clearance 3553
Rotor Shaft Clearance 3553
Install 3554
Fuel System Repair 3554
Fuel Injectors 3555
Remove 3555
Inspect 3556
Clean 3556
Test 3556
Install 3559
Electronic Throttle System 3559
Remove 3559
Install 3562
Inspect 3563
Adjust 3564
Manual Throttle System 3565
Fuel Injection Pump 3565
Remove 3565
Clean and Inspect 3569
Install 3569
Check/Adjust Fuel Injection Timing 3570
Cooling System Repair 3572
V-Belt 3572
Remove 3572
Inspect 3572
Install 3572
Adjust 3572
Water Pump 3574
4TNE92-NMHA, 4TNE92-NMHA/580090035, 4TNE92-SNMU, and 4TNE98-SNMU Engines 3574
Remove 3574
Install 3575
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/580090036, and 4TNE98-BNMH Engines 3576
Remove 3576
Install 3577
Thermostat 3579
Remove 3579
Inspect 3580
Install 3580
Flywheel and Flywheel Housing 3580
Flywheel 3581
Remove 3581
Install 3582
Flywheel Housing 3582
Remove 3582
Install 3582
Electrical Equipment Repair 3584
Alternator 3584
Remove 3584
Bench Test 3586
Regulate Voltage Check 3586
No Load Test 3588
Output Test 3588
Install 3588
Starter 3589
Remove 3590
No Load Test 3590
Install 3591
Engine Specifications 3592
Engine Data 3592
Engine Tuning 3600
Cylinder Head 3600
Intake/Exhaust Valve and Guide 3601
Valve Spring 3601
Rocker Arm and Shaft 3601
Push Rod 3602
Gear Train and Camshaft 3602
Camshaft 3602
Idle Gear Shaft and Bushing 3602
Backlash of Each Gear 3603
Cylinder Block 3603
Crankshaft 3603
Thrust Bearing 3604
Piston 3604
Piston Ring 3604
Connecting Rod 3605
Rod Small End 3605
Tappet 3605
Oil Pump 3606
Engine Oil Pressure 3606
Outer Rotor Outside Clearance 3606
Outer Rotor Side Clearance 3606
Outer Rotor to Inner Rotor Tip Clearance 3606
Rotor Shaft Clearance 3606
Standard Torque Specifications 3607
Standard Torque Chart 3607
Special Torque Specifications 3608
Special Tools 3609
524240454 1400YRM1206 (11 2008) UK EN 3617
toc 3617
Drive Axle and Differential Assembly Repair 3617
Safety Precautions Maintenance and Repair 3618
General 3621
Drive Axle Repair 3621
Remove and Disassemble 3621
Clean and Inspect 3623
Assemble and Install 3623
Differential Repair 3626
Remove 3626
Differential Assembly From Center Section Assembly 3626
Drive Pinion, Pinion Gear, and Bearings From Center Section 3630
Disassemble 3635
Differential Assembly 3635
Drop Box Housing 3639
Center Section 3640
Clean and Inspect 3642
Assemble 3642
Center Section 3642
Drop Box Housing 3645
Differential Assembly 3646
Install 3650
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 3650
Drive Pinion, Pinion Gear, and Bearings Into Center Section 3652
Differential Assembly Into Center Section 3655
Ring Gear Backlash, Adjust 3660
Ring Gear, Runout Check 3662
Gear Set, Tooth Contact Pattern Check 3662
Torque Specifications 3665
tables 3617
Table 1 Pinion Variation Numbers Examples 3651
Table 2 Ring and Pinion Tooth Contact Adjustment 3662
Table 3 Correct Tooth Contact 3663
Table 4 Incorrect Tooth Contact 3664
524240456 8000YRM1208 (08 2019) UK EN 3669
Lift Truck Lifting Capacity 3673
Counterweight Weights 3673
Tire Sizes 3673
Capacities 3674
Electrical System 3678
Transmission Oil Pressures 3679
Hydraulic System Relief Pressures 3680
Steering System 3681
Stall Speeds (in RPM ±100 rpm) 3682
Mazda (Except 2007 Emission Compliant Engines) 3682
Mazda (2007 Emission Compliant Engines Only) 3682
Yanmar 2 6L 3682
Mast Speeds 3682
Tilt Angles 3683
Front End Equipment – Mast Creep 3684
Mast Creep 3684
Engine Specifications 3685
Torque Specifications 3686
Frame 3686
Mast 3686
Steering System, Cushion Tire Trucks 3686
Steering System, Pneumatic Tire Trucks 3686
Drive Axle 3686
Transmission – Iron Housing 3687
Transmission – Aluminum Housing 3687
Engine – Mazda FE 3688
Engine – Yanmar 2 6L Diesel 3689
524242681 8000YRM1207 (08 2019) UK EN 3691
General 3697
Serial Number Data 3697
How to Move Disabled Lift Truck 3697
How to Tow Lift Truck 3697
How to Put Lift Truck on Blocks 3698
How to Raise Drive Tires 3698
How to Raise Steering Tires 3699
How to Clean a Lift Truck 3699
Maintenance Schedule 3700
Maintenance Procedures Every 8 Hours or Daily 3712
How to Make Checks With Engine Stopped 3712
Tires and Wheels 3712
Safety Labels 3713
Mast, Carriage, Lift Chains, Header Hoses, Attachment 3713
Operator Restraint System 3714
Emergency Locking Retractor (ELR) 3714
Adjust Seat – Full Suspension 3715
Adjust Seat – Internal Suspension 3717
Hood and Seat Latches 3717
Engine Compartment 3718
Paper Application 3718
Fuel, Oil, and Coolant Leaks, Check 3718
Hydraulic Hoses 3719
Coolant Hoses 3719
Steering Column Gas Cylinder 3719
Transmission 3719
Hydraulic System Oil 3719
Engine Oil 3720
Air Filter 3722
Forks 3722
Remove 3722
Inspect 3723
Install 3723
Adjust 3724
Forks 3724
Remove 3724
Inspect 3724
How to Make Checks With Engine Running 3725
Indicator Lights, Horn, Fuses, and Relays 3725
Service Brakes 3727
Brake Fluid Level 3727
Operation, Check 3728
Parking Brake 3728
Engine Oil Pressure 3728
Cooling System 3729
Steering System 3729
Control Levers and Pedals 3730
Lift System, Operate 3730
First Service After First 100 Hours of Operation 3730
Mazda and GM Engine Oil and Oil Filter 3730
Yanmar Engine Oil and Oil Filter 3731
Maintenance Procedures Every 500 Hours or 1 Year 3732
Hydraulic System Oil 3732
Hydraulic Tank Breather 3732
Inspect 3732
Battery 3733
Engine Oil And Oil Filter, Mazda And Yanmar Engines 3733
Drive Belt 3734
Mazda EnginesFE 3734
Fan and Alternator Drive Belt 3734
Yanmar Diesel Engine 3734
Fan and Alternator Drive Belt 3734
PCV Valve 3735
Clean Debris From Radiator Core 3735
Transmission Oil Level 3736
Forks 3737
Mast Lubrication 3737
Header Hose Checks 3741
Lift Chain Lubrication 3741
Tilt Cylinder Lubrication 3741
Master Brake Cylinder Rod End Pin Lubrication 3742
Manual Hydraulic Levers Lubrication 3743
Brake Fluid 3743
Drain Tar From LPG Regulator 3743
Tie Rod Lubrication 3744
Differential and Drive Axle Oil (Dry Brake) 3744
Maintenance Procedures Every 1000 Hours or 1 Year 3745
Valve Clearance, Check and Adjust 3745
Ignition System 3745
Mazda EnginesFE 3745
LPG Vapor Fuel Filter Replace, Mazda Engines 3745
Fuel Filter Replacement, Yanmar Engine 3745
Priming the Fuel System (Yanmar) 3747
Lift Chains Wear Check 3747
Lift Chain Lubrication 3748
Integral Sideshift Carriage, Check Bearings 3748
Integral Sideshift Carriage, Check Lower Mounting Hooks 3749
Steering Axle 3749
Control Levers and Pedals 3750
Maintenance Procedures Every 2000 Hours or Annually 3750
Hydraulic System 3750
Hydraulic Filter, Replace 3750
Hydraulic Tank Breather, Replace 3752
Air Filter 3752
PCV Valve 3754
Oxygen Sensor 3754
LPG Regulator Fuel Filter, Mazda Engines 3754
Remove and Replace 3754
Timing Belt 3755
Mazda Engines 3755
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 3755
Fuel Injector, Yanmar Engines 3755
Forks 3755
Integral Sideshift Carriage 3755
Bearings, Replace 3755
Transmission Oil and Filter (Dry Brake), Replace 3755
Iron Transmission Housing 3755
Aluminum Transmission Housing 3756
Remove 3756
Clean and Inspect 3760
Install 3760
Brake Fluid (Master Cylinder), Change 3761
Brake Fluid (Dry Brake), Remove 3762
Steer Axle, Wheel Bearings Lubrication 3762
Service Brakes (Dry Brake) 3762
Differential (Dry Brake) 3762
Maintenance Procedures Every 4000 Hours or 2 Years 3764
Hydraulic Oil, Replace 3764
Cooling System 3765
Safety Procedures When Working Near Mast 3766
Hood Latch Check 3768
Lift Chain Adjustments 3769
Jump-Starting the Lift Truck 3771
Jump-Starting Using a Battery Charger 3771
Jump-Starting a Lift Truck Using Another Lift Truck 3771
Welding Repairs 3771
Overhead Guard Changes 3772
Wheel Repair 3772
General 3772
Pneumatic Tire With Tube, Repair 3772
Remove Wheels From Lift Truck 3772
Remove Tire From Wheel 3773
Install Wheel in Tire 3776
Add Air to Pneumatic Tires With Tube 3778
Wheels, Install 3779
Pneumatic Tubeless Tire, Repair 3779
Remove Wheels From Lift Truck 3779
Add Air to Pneumatic Tubeless Tire 3784
Wheels, Install 3784
Solid Rubber Tires on Pneumatic Wheels, Change 3785
Snap-On-Tire, Change 3788
Easy Mounting Style Solid Rubber Tires on Pneumatic Wheels, Change 3790
Adhesives and Sealants 3796
524289374 0900YRM1326 (04 2018) UK EN 3799
General 3805
LPG Tank and Bracket Replacement 3805
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) 3805
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) 3807
Remove LPG Tank for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 3808
LPG Tank Install for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 3810
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) 3811
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) 3813
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) 3814
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) 3816
Remove LPG Bracket for Lift Truck Models and GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 3817
Install LPG Bracket for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 3817
Fuel Filter Unit Repair 3817
Fuel Filter Element 3817
Remove 3817
Clean/Inspect 3818
Install 3818
Fuel Filter Housing 3818
Remove 3818
Disassemble 3821
Assemble 3823
Install 3824
Electronic Throttle Body Repair 3824
Remove 3824
Install 3826
Electronic Pressure Regulator (EPR) Repair 3826
Remove 3827
Disassemble 3831
Assemble 3833
Install 3834
LPG Shutoff Valve Assembly 3834
Remove 3834
Install 3838
Fuel Mixer Repair 3840
Remove 3840
Install 3843
Control System 3843
Engine Control Unit (ECU) 3843
Remove 3843
Install 3845
Low LPG Pressure Switch 3845
Remove 3845
Install 3846
LPG Low Level Sensor 3846
Remove 3847
Install 3850
Exhaust System 3851
Counterweight Exhaust System 3851
Remove and Disassemble 3851
Inspect 3853
Assemble and Install 3853
Overhead Exhaust System 3853
Remove and Disassemble 3854
Inspect 3856
Assemble and Install 3856
Exhaust Manifold 3857
Remove 3857
Install 3858
Positive Crankcase Ventilation (PCV) Valve 3859
Remove 3859
Inspect 3859
Install 3859
Oxygen Sensor 3859
Remove 3859
Install 3861
LPG Fuel Testing 3862
General 3862
Available Fuel Tests 3862
Composition Test (ASTM D-2163) 3862
Ammonia Test (ASTM D-4490) 3862
Basic Nitrogen Test (ASTM UOP269-90) 3862
Residues Test (ASTM D-2158) 3862
Vapor Pressure Test (ASTM D-2598) 3862
Sulfur Compounds Test (ASTM D-5623) 3863
Methanol Test (ASTM D-4864) 3863
Copper Corrosion (ASTM D-1838) 3863
Where To Send LPG Fuel Samples For Testing 3863
524289375 2200YRM1327 (09 2012) UK EN 3867
General 3871
Ignition System 3871
General 3871
Ignition Timing Adjustment, Gasoline and LPG 3871
Spark Plugs Check 3876
Spark Plug Wires Check 3876
Coil Replacement 3877
Remove 3877
Inspect 3878
Install 3878
Starter Repair 3879
General 3879
Remove 3879
No-Load Test 3880
Magnetic Switch Test 3881
Pull-Out Test 3881
Holding Coil Test 3881
Return Test 3881
Pinion Movement Inspection 3882
Install 3882
Alternator Repair 3882
General 3882
Charging System Inspection 3884
Output Current Check 3884
No-Load Adjusted Voltage Check 3885
Remove 3886
Inspect 3886
Rectifier Check 3886
Install 3887
Engine Sensors and Switches 3888
Oil Pressure Sensor, Gas and LPG Engines 3888
Remove 3888
Install 3888
Air Filter Restriction Switch, Gas and LPG Engines 3888
Remove 3888
Install 3888
Cam Angle Sensor, Gas and LPG Engines 3889
Remove 3889
Install 3890
Voltage Check 3890
Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Engines 3891
Remove 3891
Install 3892
Intake Air Temperature (IAT) Sensor, LPG Engines 3893
Remove 3893
Install 3893
Intake Air Temperature (IAT) Sensor, Gas Engines 3893
Remove 3893
Install 3893
Fuel Temperature Sensor, LPG Engines 3896
Remove 3896
Install 3896
Engine Coolant Temperature (ECT) Sensor 3897
2007 Emissions Compliant Gas Engines 3897
Remove 3897
Install 3897
2007 and 2010 Emissions Compliant LPG Engines 3898
Remove 3898
Install 3898
2010 Emissions Compliant Gas and LPG Engines 3900
Remove 3900
Install 3900
524306203 0100YRM1290 (04 2014) UK EN 3905
524329117 8000YRM1387 (03 2020) UK EN 4009
General Information About Diagrams and Schematics 4013
Symbol Definitions 4013
Diagrams Manual Applications 4014
Diagrams and Schematics 4016
550001092 8000YRM1409 (03 2020) UK EN 4081
General Information About Diagrams and Schematics 4085
Symbol Definitions 4085
Diagrams Manual Applications 4086
Diagrams and Schematics 4088
550010194 1300YRM1421 (08 2013) UK EN 4169
toc 4169
Single Speed PowerShift 4169
Safety Precautions Maintenance and Repair 4170
General 4173
Serial Number 4173
Hydraulic Gear Pump 4174
Remove 4174
Install 4174
Charge Pump Repair 4175
Original Charge Pump 4175
Remove 4175
Disassemble 4176
Clean 4176
Inspect 4176
Assemble 4176
Install 4176
New Charge Pump, Manufactured After July, 2013 4177
Remove 4177
Clean 4178
Inspect 4178
Install 4179
Torque Converter Replacement 4181
Remove 4181
Clean and Inspect 4181
Install 4181
Stator Support Assembly Repair 4182
Remove 4182
Disassemble 4187
Clean 4188
Inspect 4188
Assemble 4189
Install 4189
Clutch Packs Repair 4191
Remove 4191
Engine, Torque Converter, and Transmission Assembly 4191
Transmission Components 4192
Disassemble 4194
Transmission 4194
Housings 4194
Forward Clutch Pack 4197
Reverse Clutch Pack 4202
Clean 4208
Inspect 4208
Assemble 4209
Transmission 4209
Reverse Clutch Pack 4209
Forward Clutch Pack 4216
Housings 4222
Install 4224
Transmission Components 4224
Engine, Torque Converter, and Transmission Assembly 4227
Inching Overlap Adjustment 4227
Proportional and Enable Solenoid Valves 4228
Proportional Valves 4228
Remove 4228
Disassemble 4230
Clean and Inspect 4230
Assemble 4230
Install 4230
Enable Solenoid Valve 4230
Remove 4230
Disassemble 4230
Clean and Inspect 4230
Assemble 4231
Install 4231
Foot Directional Control Pedal Repair 4231
Remove and Disassembly 4231
Clean and Inspect 4235
Assemble and Install 4235
550030170 1300YRM1447 (08 2013) UK EN 4239
toc 4239
Single Speed Powershift 4239
Safety Precautions Maintenance and Repair 4240
General 4243
Serial Number 4243
Hydraulic Gear Pump 4244
Remove 4244
Install 4244
Housing Fittings Replacement 4244
Remove 4244
Disassemble 4245
Assemble 4245
Install 4245
Charge Pump Repair 4245
Lift Trucks Manufactured Before July, 2013 4245
Remove 4245
Disassemble 4247
Clean 4247
Inspect 4247
Assemble 4247
Install 4247
Lift Trucks Manufactured After July, 2013 4249
Remove 4249
Clean 4249
Inspect 4249
Install 4250
Torque Converter Replacement 4253
Remove 4253
Clean and Inspect 4253
Install 4253
Stator Support Assembly Repair 4255
Remove 4255
Disassemble 4260
Clean 4264
Inspect 4264
Assemble 4265
Install 4265
Clutch Packs Repair 4268
Remove 4268
Disassemble 4269
Housings 4269
Clutch Packs 4274
Forward Clutch Pack 4274
Reverse Clutch Pack 4279
Clean 4285
Inspect 4285
Assemble 4286
Clutch Packs 4286
Reverse Clutch Pack 4286
Forward Clutch Pack 4293
Housings 4300
Install 4300
Drive Chains and Sprockets 4306
Remove 4306
Clean 4308
Inspect 4308
Install 4308
Proportional and Enable Solenoid Valves 4309
Proportional Valves 4309
Remove 4309
Disassemble 4309
Clean and Inspect 4309
Assemble 4312
Install 4312
Enable Solenoid Valve 4312
Remove 4312
Disassemble 4313
Clean and Inspect 4313
Assemble 4313
Install 4313
Foot Directional Control Pedal Repair 4315
Remove and Disassemble 4315
Clean and Inspect 4319
Assemble and Install 4319
550043436 1300YRM1529 (11 2018) UK EN 4325
General 4329
Serial Number 4329
Charge Pump Repair 4329
Lift Trucks Manufactured Before July, 2013 4329
Remove 4329
Inspect 4329
Install 4329
Lift Trucks Manufactured After July, 2013 4330
Remove 4330
Inspect 4330
Install 4330
Torque Converter Replace 4331
Remove 4331
Install 4340
Housings and Chain Drive Repair 4346
Remove 4346
Clean 4357
Inspect 4357
Install 4357
Clutch Packs Repair 4364
Remove and Disassemble 4364
Transmission, Remove and Disassemble 4364
Clean 4383
Inspect 4383
Assemble and Install 4384
Transmission, Assemble and Install 4392
Control Valve Repair 4396
Remove and Disassemble 4396
Clean 4400
Inspect 4400
Assemble and Install 4400
Foot Directional Control Pedal Repair 4401
Remove and Disassemble 4401
Assemble and Install 4405
Direction Control Lever 4406
Remove 4406
Install 4406
550055283 8000YRM1585 (07 2020) UK EN 4411
General Information About Diagrams and Schematics 4415
Symbol Definitions 4415
Diagrams Manual Applications 4416
Diagrams and Schematics 4418
550073240 1900YRM1620 (01 2023) US EN 4507
Proper Flushing after Major Hydraulic Repairs 4513
Introduction 4513
The Phases of Wear 4513
Causes of Hydraulic System Failure 4513
Progression of Contaminant Caused Hydraulic System Failure 4514
Hydraulic System Flushing Techniques 4514
Double Oil and Filter Change 4514
Mechanical Cleaning 4515
Cleaning of Components 4515
How to Clean Tubes and Hoses 4515
Filter Caddy 4515
Start-Up Procedure for Cleaned System 4516
Contaminated Oil Coolers 4516
Additional Filter Caddy Functions 4517
How to Handle Different Fluids 4517
Water Removal Filters 4517
Fluid Conditioning and System Flushing Procedures 4518
Operation of the Filter Caddy 4518
Filter Caddy operation 4518
Fluid Conditioning Procedure 4518
Filter Caddy Start-Up 4519
System Flushing Procedure 4519
Component Cleaning Procedure 4520
Reservoir Cleaning Procedure 4520
Cylinder Cleaning Procedure 4520
Hose and Tube Cleaning Procedure 4520
Valve Cleaning Procedure 4521
Front-End Attachment Cleaning Procedure 4522
System Flushing Procedure 4522
Filter Caddy Start-Up 4523
System Start-Up and Flushing 4523
Reservoir Fluid Cleaning Times 4524
Dealing With Different Fluid Types 4525
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4525
Filter Caddy Maintenance 4525
Servicing the Strainer 4525
DC Motor 4525
Hydraulic Oil Sampling Method and Procedure 4526
Hydraulic Oil Sampling Method 4526
Objective 4526
General Guidelines 4526
Synopsis 4527
Hydraulic Oil Analysis Report Guidelines 4528
Sampling Conditions 4528
Equipment 4528
Sampling Procedure 4529
Hydraulic Oil Sampling 4529
Sample Labeling 4529
Results Documentation 4529
550073240 1900YRM1620 (03 2020) UK EN 4531
Proper Flushing after Major Hydraulic Repairs 4535
Introduction 4535
The Phases of Wear 4535
Causes of Hydraulic System Failure 4535
Progression of Contaminant Caused Hydraulic System Failure 4536
Hydraulic System Flushing Techniques 4536
Double Oil and Filter Change 4536
Mechanical Cleaning 4537
Cleaning of Components 4537
How to Clean Tubes and Hoses 4537
Filter Caddy 4537
Start-Up Procedure for Cleaned System 4538
Contaminated Oil Coolers 4538
Additional Filter Caddy Functions 4538
How to Handle Different Fluids 4538
Water Removal Filters 4539
Fluid Conditioning and System Flushing Procedures 4539
Operation of the Filter Caddy 4539
Filter Caddy operation 4539
Fluid Conditioning Procedure 4540
Filter Caddy Start-Up 4540
System Flushing Procedure 4541
Component Cleaning Procedure 4541
Reservoir Cleaning Procedure 4541
Cylinder Cleaning Procedure 4541
Hose and Tube Cleaning Procedure 4542
Valve Cleaning Procedure 4542
Front-End Attachment Cleaning Procedure 4543
System Flushing Procedure 4543
Filter Caddy Start-Up 4544
System Start-Up and Flushing 4544
Reservoir Fluid Cleaning Times 4545
Dealing With Different Fluid Types 4545
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4545
Filter Caddy Maintenance 4546
Servicing the Strainer 4546
DC Motor 4546
Hydraulic Oil Sampling Method and Procedure 4546
Hydraulic Oil Sampling Method 4546
Objective 4546
General Guidelines 4546
Synopsis 4547
Hydraulic Oil Analysis Report Guidelines 4548
Sampling Conditions 4549
Equipment 4549
Sampling Procedure 4549
Hydraulic Oil Sampling 4549
Sample Labeling 4550
Results Documentation 4550
550096331 8000YRM1689 (03 2020) UK EN 4553
General Information About Diagrams and Schematics 4557
Symbol Definitions 4557
Diagrams Manual Applications 4558
Diagrams and Schematics 4560