Yale Forklift C875 (GLP20-35VX. GDP20-35VX Europe) Service Manual PDF

Yale Forklift C875 (GLP20-35VX. GDP20-35VX Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift C875 (GLP20-35VX. GDP20-35VX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2812
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift C875 (GLP20-35VX. GDP20-35VX Europe) 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) UK EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524223769 2200YRM1128 (01 2023) US EN 43
Series Code / Model Designation Reference Table 51
General 53
Deutsch Crimping Tool 54
How to Strip a Wire for Use With Deutsch Crimping Tool 54
How to Crimp With the Deutsch Crimping Tool 55
Calibration Test for the Deutsch Crimping Tool 57
Deutsch Connectors 59
DT, DTM, and DTP Series Connectors 59
HD Series Connectors 102
Metri-Pack Connectors 124
Remove and Install 124
Micro-Pack Connectors 127
Weather-Pack Connectors 128
AMPSEAL Crimping Tools 130
AMP Hand Crimping Tool With Certi-Crimp 130
Description 130
Stripping Wire for Use with AMP Hand Crimping Tool 131
Insulation Crimp Adjustment 132
Maintenance and Inspection for AMP Hand Crimping Tool 132
AMP Hand Crimping Tool 132
Crimp Height Inspection 132
How to use AMP Hand Crimping Tool 133
AMP Pro-Crimper II Tool 133
Description 133
Remove and Install Die Set and Locator Assembly 134
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 134
Contact Support Adjustment 135
Crimp Height Adjustment 136
Maintenance and Inspection Procedures 136
PRO-CRIMPER II Tool 136
Crimp Height Inspection 136
How to Use AMP PRO-CRIMPER II Tool 137
AMPSEAL Connector Assemblies 138
Description for Plug Connector Assembly 138
Seal Plug 139
Contact Crimping 139
Description for Plug Connector and Header Assembly 144
Voltage Reading 147
Seal Plug 147
Contact Crimping 147
AMP Superseal 1 5 Crimping Tools 154
Mini Mic Receptacle and Tab Contacts 154
Description 154
Crimping Conditions and Measurements 154
Insertion of Rubber Seal on Cable 156
AMP Hand Application Tool 161
Description 161
Maintenance and Inspection 161
Crimp Height Inspection 161
Crimp Height Adjustment 162
How to Use AMP Hand Application Tool 162
AMP Pro-Crimper II Tool 163
Description 163
Remove and Install Die Set and Locator Assembly 163
Adjustments 164
Contact Support 164
Crimp Height 165
Inspections and Maintenance 166
Crimp Height Inspection 166
Visual Inspection 166
Maintenance 167
How to Use Pro-Crimper II Tool 167
AMP Superseal 1 5 Connector Assemblies 168
Description 168
Repair and Maintenance 175
Panel Mount Option 175
AMP Fastin-Faston Hand Tools 176
Description – AMP Double Action Hand Tool 176
Maintenance and Inspection Procedures 176
Daily Maintenance 176
Periodic Tool Inspection 177
Lubrication 177
Visual Inspection 177
Crimp Height Inspection 177
Certi-Crimp Ratchet Inspection 178
How to Use AMP Double Action Hand Tool 179
Description – AMP Extraction Tool 180
Maintenance and Inspection 181
How to Use AMP Extraction Tool 181
AMP Fastin-Faston Receptacles and Housings 183
Description 183
Wire Repair 191
Wire Splicing Requirements 191
Deutsch Jiffy Splice 192
Twisted/Shielded Cable and Leads Repair 198
Special Tools 200
524223769 2200YRM1128 (07 2020) UK EN 209
Series Code / Model Designation Reference Table 215
General 218
Deutsch Crimping Tool 218
How to Strip a Wire for Use With Deutsch Crimping Tool 218
How to Crimp With the Deutsch Crimping Tool 219
Calibration Test for the Deutsch Crimping Tool 221
Deutsch Connectors 223
DT, DTM, and DTP Series Connectors 223
HD Series Connectors 265
Metri-Pack Connectors 288
Remove and Install 288
Micro-Pack Connectors 290
Weather-Pack Connectors 291
AMPSEAL Crimping Tools 293
AMP Hand Crimping Tool With Certi-Crimp 293
Description 293
Stripping Wire for Use with AMP Hand Crimping Tool 293
Insulation Crimp Adjustment 294
Maintenance and Inspection for AMP Hand Crimping Tool 294
AMP Hand Crimping Tool 294
Crimp Height Inspection 294
How to use AMP Hand Crimping Tool 295
AMP Pro-Crimper II Tool 295
Description 295
Remove and Install Die Set and Locator Assembly 296
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 297
Contact Support Adjustment 297
Crimp Height Adjustment 298
Maintenance and Inspection Procedures 298
PRO-CRIMPER II Tool 298
Crimp Height Inspection 298
How to Use AMP PRO-CRIMPER II Tool 299
AMPSEAL Connector Assemblies 300
Description for Plug Connector Assembly 300
Seal Plug 301
Contact Crimping 301
Description for Plug Connector and Header Assembly 306
Voltage Reading 308
Seal Plug 308
Contact Crimping 308
AMP Superseal 1 5 Crimping Tools 315
Mini Mic Receptacle and Tab Contacts 315
Description 315
Crimping Conditions and Measurements 315
Insertion of Rubber Seal on Cable 317
AMP Hand Application Tool 322
Description 322
Maintenance and Inspection 322
Crimp Height Inspection 322
Crimp Height Adjustment 323
How to Use AMP Hand Application Tool 323
AMP Pro-Crimper II Tool 324
Description 324
Remove and Install Die Set and Locator Assembly 325
Adjustments 325
Contact Support 325
Crimp Height 326
Inspections and Maintenance 327
Crimp Height Inspection 327
Visual Inspection 327
Maintenance 328
How to Use Pro-Crimper II Tool 328
AMP Superseal 1 5 Connector Assemblies 329
Description 329
Repair and Maintenance 336
Panel Mount Option 336
AMP Fastin-Faston Hand Tools 337
Description – AMP Double Action Hand Tool 337
Maintenance and Inspection Procedures 337
Daily Maintenance 337
Periodic Tool Inspection 338
Lubrication 338
Visual Inspection 338
Crimp Height Inspection 338
Certi-Crimp Ratchet Inspection 339
How to Use AMP Double Action Hand Tool 340
Description – AMP Extraction Tool 341
Maintenance and Inspection 341
How to Use AMP Extraction Tool 342
AMP Fastin-Faston Receptacles and Housings 343
Description 343
Wire Repair 350
Wire Splicing Requirements 350
Deutsch Jiffy Splice 351
Twisted/Shielded Cable and Leads Repair 356
Special Tools 359
524223770 2200YRM1130 (03 2020) UK EN 367
General 371
Description 371
Dash Display Menu Access 371
Menu Navigation 372
Standard Display 372
Main Menu 372
Passwords Menu 373
Password Administration 373
Add Password 373
Delete Password 374
Edit Password 374
Other Password Functions 375
Operator Passwords – Enable/Disable 375
Password Time-Out Delay 375
Passwords – Number Wrong to Disable 376
Lockout Reset Password 376
View Password Log 377
View Versions 378
VSM Versions 378
Dash Display Versions 379
Engine Controller Version 380
Transmission (Xmsn) Controller Version 381
Truck Serial Number 382
Diagnostics 383
View Fault Log 383
Set Travel and Braking 384
Speed Limit 384
Acceleration Rate 385
Auto-Deceleration Rate 385
Set Power Reversal Rate 386
Set Inching/Brake Overlap 387
Setup Display Menu 388
Set Operator Language 388
Set Units 389
Set Time Format (12/24 Hour) 389
Set Daylight Saving Time 389
Set Time 392
Set Date Format 393
Set Date 393
Setup Hydraulics 394
Return to Set Tilt Delay/On/Off 394
Setup General Items 395
Light Shutdown Time-Out 395
Impact Sensor – Enable/Disable 396
Impact Sensor – Soft Impact Settings 397
Impact Sensor – Hard Impact Settings 398
Adjust Impact Sensor Settings 398
Initial Adjustment of Soft and Hard Impact Settings 400
Readjustment of Soft and Hard Impact Settings 400
Impact Sensor – Impact Alarm/Shutdown Reset 401
Impact Sensor – Alarm Time Duration and Deactivation 402
Impact Sensor – View Impact Event Log 403
Engine Mode Indicator 404
Generation 1 (ECO-eLo ONLY) 404
Generation 2 405
Operator Checklist 406
Operator Checklist Off-On Mode 406
Edit Operator Checklist 406
Set Operator Checklist Expiration 407
View Checklist Log 407
Clear Operator Checklist Log 408
Clear Operator Checklist Fault 408
Calibrations 409
Set Tilt Stop Point 409
Calibrate Loaded Weight 409
524223771 2200YRM1131 (03 2020) UK EN 411
Series Code / Model Designation Reference Table 417
General 419
Description 419
Dash Display Menu Access 419
Menu Navigation 420
Main Menu 420
Passwords 421
Adding Passwords 421
Hourmeters 423
View Versions 424
VSM Versions 424
Dash Display Versions 425
Engine Controller Version 426
Transmission (Xmsn) Controller Version 427
Truck Serial Number 428
Truck Configuration 429
Diagnostics 430
Clear Fault Log 430
View Fault Log 431
No-Run Data Display 432
Engine Accelerator and Throttle Data Display 432
Engine Speeds and Governor Data Display 433
Engine Fuel and Emissions Data Display 434
Engine General Data Display 436
XMSN/Brake Data Display 437
Hydraulic Data Display 440
General Truck Data Display 442
Set Travel and Braking 443
Speed Limit 443
Acceleration Rate 444
Auto-Deceleration Rate 445
Set Power Reversal Rate 445
Set Inching/Brake Overlap 446
Setup Hydraulics 446
Lift Maximum Speed 447
Lower Maximum Speed 447
Tilt Maximum Speed 448
Auxiliary Function One, Direction A, Maximum Speed 450
Auxiliary Function One, Direction B, Maximum Speed 452
Auxiliary Function Two, Direction A, Maximum Speed 452
Auxiliary Function Two, Direction B, Maximum Speed 453
Auxiliary Function Three, Direction A, Maximum Speed 454
Auxiliary Function Three, Direction B, Maximum Speed 454
Lift/Lower Ramp Rate 455
Hydraulic Auxiliary Ramp Rate 455
Return to Set Tilt Delay/On/Off 456
Hydraulic Input Device 457
Auxiliary Solenoid 457
Dual Function 458
Setup Display 459
Set Service Language 459
Setup General Items 459
Motion Alarm Activation Type 460
Light Shutdown Time-Out 461
Restore Default Settings 461
Restore Engine Controller Default Calibration 462
Impact Sensor – Enable/Disable 462
Impact Sensor – Soft Impact Settings 463
Impact Sensor – Hard Impact Settings 464
Adjust Impact Sensor Settings 465
Initial Adjustment of Soft and Hard Impact Settings 467
Readjustment of Soft and Hard Impact Settings 467
Impact Sensor – Impact Alarm/Shutdown Reset 468
Impact Sensor – Alarm Time Duration and Deactivation 469
Impact Sensor – View Impact Event Log 470
Engine Mode Indicator 470
Generation 1 (ECO-eLo ONLY) 470
Generation 2 471
Diesel Particulate Filter (DPF) Display 472
General Description 472
Passive Regeneration Only 472
Regeneration Level 0 472
Auto/Active Regeneration Inhibited 473
Auto/Active Regeneration 473
Regeneration Level 1 473
Parked Regeneration Request 474
Regeneration Level 2 474
Warning Level 474
Regeneration Level 3 474
Service Level 475
Regeneration Level 4 475
Display, Diesel Particulate Filter (DPF), Revised 475
Operator Interface 475
Refer to Operator Manual 475
CAN Communication Lost 476
Passive Regeneration Only 476
Regeneration Level 0 476
Auto/Active Regeneration Inhibited 476
Auto/Active Regeneration 477
Regeneration Level 1 477
Idle-up Auto/Active Regeneration 477
Parked Regeneration Request 477
Regeneration Level 2 477
Warning Level 479
Regeneration Level 3 479
Service Level 479
Regeneration Level 4 479
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 479
Display, Diesel Particulate Filter (DPF), Stage V Engine 479
Operator Interface 480
Refer to Operator Manual 480
CAN Communication Lost 480
Passive Regeneration Only 480
Regeneration Level 0 480
Auto/Active Regeneration Inhibited 481
Auto/Active Regeneration 481
Regeneration Level 1 481
Idle-up Auto/Active Regeneration 482
Parked Regeneration Request 482
Regeneration Level 2 482
Warning Level 483
Regeneration Level 3 483
Service Level 484
Regeneration Level 4 484
Stage V Content 484
Emissions System Malfunction 484
Ash Load 484
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 485
Operator Interface 485
Refer to Operator Manual 485
CAN Communication Lost 486
Passive Regeneration Only 486
Regeneration Level 0 486
Auto/Active Regeneration Inhibited 486
Auto/Active Regeneration 487
Regeneration Level 1 487
Idle-up Auto/Active Regeneration 487
Parked Regeneration Request 487
Regeneration Level 2 487
Warning Level 489
Regeneration Level 3 489
Service Level 489
Regeneration Level 4 489
Calibrations 490
Calibrate Transmission Valve 492
Set Tilt Stop Point 492
Calibrate Loaded Weight 492
Calibrate Travel Speed Sensor 493
Calibrate Mazda LP and Gas Accelerator Pedal 493
524223780 8000YRM1134 (03 2020) UK EN 495
Series Code / Model Designation Reference Table 501
Description 503
Proc_Cal_001: Service Password Entry 505
When to Perform 505
Why Perform 505
How to Perform 505
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 506
When to Perform 506
Calibration Order 506
Why Perform 506
How to Perform 507
Proc_Cal_003: Save and Exit 508
When to Perform 508
Why Perform 508
How to Perform 508
Proc_Cal_004: Lift Valve Output Threshold 509
When to Perform 509
Calibration Order 509
Why Perform 509
How to Perform 510
Proc_Cal_005: Lower Valve Output Threshold 512
When to Perform 512
Calibration Order 512
Why Perform 512
How to Perform 512
Proc_Cal_006: Tilt Back Valve Output Threshold 515
When to Perform 515
Calibration Order 515
Why Perform 515
How to Perform 515
Proc_Cal_007: Tilt Forward Valve Output Threshold 518
When to Perform 518
Calibration Order 518
Why Perform 518
How to Perform 518
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 521
When to Perform 521
Calibration Order 521
Why Perform 521
How to Perform 521
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 524
When to Perform 524
Calibration Order 524
Why Perform 524
How to Perform 524
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 527
When to Perform 527
Calibration Order 527
Why Perform 527
How to Perform 527
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 530
When to Perform 530
Calibration Order 530
Why Perform 530
How to Perform 530
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 533
When to Perform 533
Calibration Order 533
Why Perform 533
How to Perform 533
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 536
When to Perform 536
Calibration Order 536
Why Perform 536
How to Perform 536
Proc_Cal_014: Load Weight Zero Point 540
When to Perform 540
Calibration Order 540
Why Perform 540
How to Perform 540
Proc_Cal_015: Loaded Weight Calibration 542
When to Perform 542
Calibration Order 542
Why Perform 542
How to Perform 542
Proc_Cal_016: Transmission Valve Calibration 545
Applicable System/Option 545
When to Perform 545
Calibration Order 545
Why Perform 545
How to Perform 545
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 547
Applicable System/Option 547
When to Perform 547
Calibration Order 547
Why Perform 547
How to Perform 547
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 549
Applicable System/Option 549
When to Perform 549
Calibration Order 549
Why Perform 549
How to Perform 550
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 551
Required Tools 551
When to Perform 551
Calibration Order 551
Why Perform 552
How to Perform 552
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 553
When to Perform 553
Why Perform 553
How to Perform 553
Proc_Cal_026: Travel Speed Calibration 555
When to Perform 555
Calibration Order 555
Why Perform 555
How to Perform 555
524223780 8000YRM1134 (05 2022) US EN 559
Series Code / Model Designation Reference Table 565
Description 568
Proc_Cal_001: Service Password Entry 570
When to Perform 570
Why Perform 570
How to Perform 570
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 571
When to Perform 571
Calibration Order 571
Why Perform 571
How to Perform 571
Proc_Cal_003: Save and Exit 573
When to Perform 573
Why Perform 573
How to Perform 573
Proc_Cal_004: Lift Valve Output Threshold 574
When to Perform 574
Calibration Order 574
Why Perform 574
How to Perform 574
Proc_Cal_005: Lower Valve Output Threshold 577
When to Perform 577
Calibration Order 577
Why Perform 577
How to Perform 577
Proc_Cal_006: Tilt Back Valve Output Threshold 580
When to Perform 580
Calibration Order 580
Why Perform 580
How to Perform 580
Proc_Cal_007: Tilt Forward Valve Output Threshold 583
When to Perform 583
Calibration Order 583
Why Perform 583
How to Perform 583
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 586
When to Perform 586
Calibration Order 586
Why Perform 586
How to Perform 586
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 589
When to Perform 589
Calibration Order 589
Why Perform 589
How to Perform 589
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 592
When to Perform 592
Calibration Order 592
Why Perform 592
How to Perform 592
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 595
When to Perform 595
Calibration Order 595
Why Perform 595
How to Perform 595
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 598
When to Perform 598
Calibration Order 598
Why Perform 598
How to Perform 598
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 601
When to Perform 601
Calibration Order 601
Why Perform 601
How to Perform 601
Proc_Cal_014: Load Weight Zero Point 604
When to Perform 604
Calibration Order 604
Why Perform 604
How to Perform 604
Proc_Cal_015: Loaded Weight Calibration 606
When to Perform 606
Calibration Order 606
Why Perform 606
How to Perform 606
Proc_Cal_016: Transmission Valve Calibration 609
Applicable System/Option 609
When to Perform 609
Calibration Order 609
Why Perform 609
How to Perform 609
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 611
Applicable System/Option 611
When to Perform 611
Calibration Order 611
Why Perform 611
How to Perform 611
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 614
Applicable System/Option 614
When to Perform 614
Calibration Order 614
Why Perform 614
How to Perform 614
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 617
Required Tools 617
When to Perform 617
Calibration Order 617
Why Perform 617
How to Perform 617
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 619
When to Perform 619
Why Perform 619
How to Perform 619
Proc_Cal_026: Travel Speed Calibration 621
When to Perform 621
Calibration Order 621
Why Perform 621
How to Perform 621
524240453 0600YRM1205 (01 2017) UK EN 625
General 631
Engine Identification 631
Major Engine Component Identification 631
Location of Labels 632
Engine Removal and Installation 633
Cylinder Head Assembly Repair 633
Glow Plugs 636
Remove 636
Install 636
Valve Cover 636
Remove 636
Clean and Inspect 637
Install 637
Rocker Arm Assembly 637
Remove 637
Disassemble 638
Clean and Inspect 639
Push Rods 639
Rocker Arm Assembly 639
Assemble 639
Install 640
Valve Clearance Adjustments 640
Cylinder Head Assembly 641
Remove 641
Disassemble 646
Valves and Valve Springs, Remove 646
Valve Guides, Remove 646
Clean and Inspect 647
Cylinder Head 647
Valve Guides 648
Valves 648
Valve Sink 648
Valve Seat 649
Valve Springs 649
Assemble 650
Valve Guides, Install 650
Valves and Valve Springs, Install 650
Install 651
Timing Gear Case and Timing Gears Repair 652
Timing Gear Case Cover 653
Remove 653
Clean and Inspect 653
Install 654
Timing Gears 654
Crankshaft Gear 655
Remove 655
Install 655
Idler Gear 655
Remove 655
Inspect 656
Install 656
Camshaft Gear 656
Remove 656
Install 657
Timing Gear Case 657
Remove 657
Clean and Inspect 658
Install 658
Drive Train, Camshaft, and Cylinder Block Repair 659
Remove 659
Disassemble 660
Pistons and Connecting Rods 660
Crankshaft 660
Camshaft 663
Clean and Inspect 664
Cylinder Block 664
Honing and Boring 667
Pistons 668
Piston Pin 668
Connecting Rod 669
Tappets 669
Crankshaft 670
Camshaft 671
Camshaft Bushing 672
Assemble 672
Camshaft 672
Crankshaft 672
Pistons and Connecting Rods 673
Install 674
Lubrication System Repair 675
Engine Oil and Oil Filter Change 675
Oil Pan 675
Remove 675
Install 676
Oil Suction Tube 676
Remove 676
Clean 677
Install 677
Oil Pump 677
Remove 677
Clean and Inspect 678
Outer Rotor Outside Clearance 678
Outer Rotor to Inner Rotor Tip Clearance 679
Outer Rotor Side Clearance 679
Rotor Shaft Clearance 679
Install 680
Fuel System Repair 680
Fuel Injectors 681
Remove 681
Inspect 682
Clean 682
Test 682
Install 685
Electronic Throttle System 685
Remove 685
Install 688
Inspect 689
Adjust 690
Manual Throttle System 691
Fuel Injection Pump 691
Remove 691
Clean and Inspect 695
Install 695
Check/Adjust Fuel Injection Timing 696
Cooling System Repair 698
V-Belt 698
Remove 698
Inspect 698
Install 698
Adjust 698
Water Pump 700
4TNE92-NMHA, 4TNE92-NMHA/580090035, 4TNE92-SNMU, and 4TNE98-SNMU Engines 700
Remove 700
Install 701
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/580090036, and 4TNE98-BNMH Engines 702
Remove 702
Install 703
Thermostat 705
Remove 705
Inspect 706
Install 706
Flywheel and Flywheel Housing 706
Flywheel 707
Remove 707
Install 708
Flywheel Housing 708
Remove 708
Install 708
Electrical Equipment Repair 710
Alternator 710
Remove 710
Bench Test 712
Regulate Voltage Check 712
No Load Test 714
Output Test 714
Install 714
Starter 715
Remove 716
No Load Test 716
Install 717
Engine Specifications 718
Engine Data 718
Engine Tuning 726
Cylinder Head 726
Intake/Exhaust Valve and Guide 727
Valve Spring 727
Rocker Arm and Shaft 727
Push Rod 728
Gear Train and Camshaft 728
Camshaft 728
Idle Gear Shaft and Bushing 728
Backlash of Each Gear 729
Cylinder Block 729
Crankshaft 729
Thrust Bearing 730
Piston 730
Piston Ring 730
Connecting Rod 731
Rod Small End 731
Tappet 731
Oil Pump 732
Engine Oil Pressure 732
Outer Rotor Outside Clearance 732
Outer Rotor Side Clearance 732
Outer Rotor to Inner Rotor Tip Clearance 732
Rotor Shaft Clearance 732
Standard Torque Specifications 733
Standard Torque Chart 733
Special Torque Specifications 734
Special Tools 735
524306203 0100YRM1290 (04 2014) UK EN 743
550073240 1900YRM1620 (01 2023) US EN 847
Proper Flushing after Major Hydraulic Repairs 853
Introduction 853
The Phases of Wear 853
Causes of Hydraulic System Failure 853
Progression of Contaminant Caused Hydraulic System Failure 854
Hydraulic System Flushing Techniques 854
Double Oil and Filter Change 854
Mechanical Cleaning 855
Cleaning of Components 855
How to Clean Tubes and Hoses 855
Filter Caddy 855
Start-Up Procedure for Cleaned System 856
Contaminated Oil Coolers 856
Additional Filter Caddy Functions 857
How to Handle Different Fluids 857
Water Removal Filters 857
Fluid Conditioning and System Flushing Procedures 858
Operation of the Filter Caddy 858
Filter Caddy operation 858
Fluid Conditioning Procedure 858
Filter Caddy Start-Up 859
System Flushing Procedure 859
Component Cleaning Procedure 860
Reservoir Cleaning Procedure 860
Cylinder Cleaning Procedure 860
Hose and Tube Cleaning Procedure 860
Valve Cleaning Procedure 861
Front-End Attachment Cleaning Procedure 862
System Flushing Procedure 862
Filter Caddy Start-Up 863
System Start-Up and Flushing 863
Reservoir Fluid Cleaning Times 864
Dealing With Different Fluid Types 865
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 865
Filter Caddy Maintenance 865
Servicing the Strainer 865
DC Motor 865
Hydraulic Oil Sampling Method and Procedure 866
Hydraulic Oil Sampling Method 866
Objective 866
General Guidelines 866
Synopsis 867
Hydraulic Oil Analysis Report Guidelines 868
Sampling Conditions 868
Equipment 868
Sampling Procedure 869
Hydraulic Oil Sampling 869
Sample Labeling 869
Results Documentation 869
550073240 1900YRM1620 (03 2020) UK EN 871
Proper Flushing after Major Hydraulic Repairs 875
Introduction 875
The Phases of Wear 875
Causes of Hydraulic System Failure 875
Progression of Contaminant Caused Hydraulic System Failure 876
Hydraulic System Flushing Techniques 876
Double Oil and Filter Change 876
Mechanical Cleaning 877
Cleaning of Components 877
How to Clean Tubes and Hoses 877
Filter Caddy 877
Start-Up Procedure for Cleaned System 878
Contaminated Oil Coolers 878
Additional Filter Caddy Functions 878
How to Handle Different Fluids 878
Water Removal Filters 879
Fluid Conditioning and System Flushing Procedures 879
Operation of the Filter Caddy 879
Filter Caddy operation 879
Fluid Conditioning Procedure 880
Filter Caddy Start-Up 880
System Flushing Procedure 881
Component Cleaning Procedure 881
Reservoir Cleaning Procedure 881
Cylinder Cleaning Procedure 881
Hose and Tube Cleaning Procedure 882
Valve Cleaning Procedure 882
Front-End Attachment Cleaning Procedure 883
System Flushing Procedure 883
Filter Caddy Start-Up 884
System Start-Up and Flushing 884
Reservoir Fluid Cleaning Times 885
Dealing With Different Fluid Types 885
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 885
Filter Caddy Maintenance 886
Servicing the Strainer 886
DC Motor 886
Hydraulic Oil Sampling Method and Procedure 886
Hydraulic Oil Sampling Method 886
Objective 886
General Guidelines 886
Synopsis 887
Hydraulic Oil Analysis Report Guidelines 888
Sampling Conditions 889
Equipment 889
Sampling Procedure 889
Hydraulic Oil Sampling 889
Sample Labeling 890
Results Documentation 890
550093750 2100YRM1668 (02 2018) UK EN 893
General 897
Safety Procedures When Working Near Mast 898
Main Lift Cylinder Repair 900
Remove 900
Disassemble 902
Clean 904
Inspect 904
Assemble 904
Install 905
Main Lift Cylinder Leak Check 905
Free-Lift Cylinder 906
Remove 906
Disassemble 907
Clean 909
Inspect 909
Assemble 909
Install 909
Tilt Cylinder Repair 910
Remove 910
Disassemble 912
Clean 914
Inspect 914
Assemble 914
Install 915
Tilt Cylinder Adjustment 916
Tilt Cylinder Leak Check 917
Integral Sideshift Cylinder Repair Prior to December 2016 919
Remove 919
Disassemble 920
Clean 921
Inspect 921
Assemble 921
Install 921
Integral Sideshift Cylinder Repair After December 2016 922
General 922
Remove 922
Disassemble 924
Clean 924
Inspect 924
Assemble 924
Install 925
Integral Side-Shift Cylinder Gland Leak Checks 926
Fork Positioner Cylinder Repair Prior to December 2016 927
Remove 927
Disassemble 927
Clean 929
Inspect 930
Assemble 930
Install 930
Fork Positioner Cylinder Adjustment 930
Fork Positioner Cylinder Repair After December 2016 931
General 931
Remove 931
Disassemble 931
Clean 934
Inspect 935
Assemble 935
Install 935
Fork Positioner Cylinder Adjustment 935
Seal Kit Installation 936
External Installation (Seal and Backup Ring) 936
Internal Installation (Piston Rod Assembly) 936
Torque Specifications 937
Main Lift Cylinders 937
Free-Lift Cylinder 937
Tilt Cylinders 937
Integral Sideshift Cylinder 937
Fork Positioner Cylinder 937
550093750 2100YRM1668 (04 2023) US EN 941
General 947
Safety Procedures When Working Near Mast 950
Main Lift Cylinder Repair 952
Remove 952
Disassemble 954
Clean 956
Inspect 956
Assemble 956
Install 957
Main Lift Cylinder Leak Check 957
Free-Lift Cylinder 958
Remove 958
Disassemble 959
Clean 961
Inspect 961
Assemble 961
Install 961
Tilt Cylinder Repair 963
Remove 963
Disassemble 965
Clean 966
Inspect 967
Assemble 967
Install 968
Tilt Cylinder Adjustment 968
Tilt Cylinder Leak Check 970
Integral Sideshift Cylinder Repair Prior to December 2016 972
Remove 972
Disassemble 972
Clean 973
Inspect 973
Assemble 973
Install 974
Integral Sideshift Cylinder Repair After December 2016 975
General 975
Remove 975
Disassemble 976
Clean 977
Inspect 977
Assemble 977
Install 977
Integral Side-Shift Cylinder Gland Leak Checks 978
Fork Positioner Cylinder Repair Prior to December 2016 979
Remove 979
Disassemble 979
Clean 982
Inspect 982
Assemble 983
Install 983
Fork Positioner Cylinder Adjustment 983
Fork Positioner Cylinder Repair After December 2016 985
General 985
Remove 985
Disassemble 985
Clean 988
Inspect 988
Assemble 989
Install 989
Fork Positioner Cylinder Adjustment 989
Seal Kit Installation 991
External Installation (Seal and Backup Ring) 991
Internal Installation (Piston Rod Assembly) 991
Torque Specifications 992
Main Lift Cylinders 992
Free-Lift Cylinder 992
Tilt Cylinders 992
Integral Sideshift Cylinder 992
Fork Positioner Cylinder 992
550093755 4000YRM1669 (04 2023) US EN 995
General 1003
Safety Procedures When Working Near Mast 1005
Fork Replacement 1007
Standard Carriage and Integral Sideshift Carriage 1007
Remove 1007
Install 1008
Checks 1008
Fork Positioner Carriage 1010
Remove 1011
Install 1011
Checks 1013
Carriages Repair, Two-Stage LFL Mast 1016
Standard Carriage 1016
Remove 1016
Clean and Inspect 1017
Install 1017
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 1017
Remove 1017
Disassemble 1019
Clean and Inspect 1020
Assemble 1021
Install 1021
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 1022
Remove 1022
Disassemble 1025
Clean and Inspect 1025
Assemble 1026
Install 1027
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 1027
Remove 1027
Disassemble 1030
Clean and Inspect 1030
Assemble 1031
Install 1032
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 1032
Remove 1032
Install 1034
Fork Positioner Hydraulic Hose Adjustment 1036
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 1037
Remove 1037
Disassemble and Assemble 1041
Clean and Inspect 1041
Install 1041
Fork Positioner Hydraulic Hose Adjustment 1042
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 1043
Remove 1043
Disassemble and Assemble 1047
Clean and Inspect 1047
Install 1047
Fork Positioner Hydraulic Hose Adjustment 1048
Two-Stage LFL Mast Repair 1050
Mast With Serial Number F507 1050
Remove 1050
Disassemble 1054
Clean and Inspect 1061
Assemble 1063
Install 1064
Header Hoses 1066
Remove 1066
Installation 1066
Adjustment 1070
Mast With Serial Number F562 1071
Remove 1071
Disassemble 1075
Clean and Inspect 1082
Assemble 1084
Install 1085
Header Hose Installation and Adjustment 1086
Remove 1086
Installation 1087
Adjustment 1091
Carriages Repair, Three-Stage FFL Mast 1093
Standard Carriage 1093
Remove 1093
Clean and Inspect 1094
Install 1095
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 1095
Remove 1095
Disassemble 1096
Clean and Inspect 1097
Assemble 1098
Install 1098
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 1099
Remove 1099
Disassemble 1101
Clean and Inspect 1102
Assemble 1103
Install 1103
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 1104
Remove 1104
Disassemble 1106
Clean and Inspect 1107
Assemble 1108
Install 1108
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 1109
Remove 1109
Install 1111
Fork Positioner Hydraulic Hose Adjustment 1113
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 1114
Remove 1114
Disassemble and Assemble 1116
Clean and Inspect 1116
Install 1116
Fork Positioner Hydraulic Hose Adjustment 1117
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 1118
Remove 1118
Disassemble and Assemble 1121
Clean and Inspect 1121
Install 1121
Fork Positioner Hydraulic Hose Adjustment 1122
Three-Stage FFL Mast Repair 1124
Mast With Serial Number F508 1124
Remove 1124
Disassemble 1127
Clean and Inspect 1137
Assemble 1140
Install 1141
Header Hose Installation and Adjustment 1143
Remove 1143
Installation 1143
Adjustment 1152
Mast With Serial Number F563 1152
Remove 1152
Disassemble 1156
Clean and Inspect 1166
Assemble 1169
Install 1170
Header Hose Installation and Adjustment 1172
Remove 1172
Installation 1172
Adjustment 1180
Mast Adjustments 1182
Load Roller, Adjust 1182
Mast Side Kicking, Adjust 1184
Carriage Adjustments 1185
Lift Chains Adjustment 1187
Hydraulic Quick Disconnect Hoses 1189
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 1189
Lift Trucks Equipped With E-Hydraulic Controls 1189
Lift Trucks Equipped With Manual Hydraulic Controls 1189
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 1190
Lift Trucks Equipped With E-Hydraulic Controls 1190
Lift Trucks Equipped With Manual Hydraulic Controls 1190
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1190
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1190
550093755 4000YRM1669 (06 2019) UK EN 1193
General 1199
Safety Procedures When Working Near Mast 1200
Fork Replacement 1202
Standard Carriage and Integral Sideshift Carriage 1202
Remove 1202
Install 1204
Checks 1204
Fork Positioner Carriage 1206
Remove 1207
Install 1207
Checks 1209
Carriages Repair, Two-Stage LFL Mast 1211
Standard Carriage 1211
Remove 1211
Clean and Inspect 1212
Install 1213
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 1213
Remove 1213
Disassemble 1214
Clean and Inspect 1215
Assemble 1216
Install 1216
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 1217
Remove 1217
Disassemble 1220
Clean and Inspect 1220
Assemble 1221
Install 1221
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 1222
Remove 1222
Disassemble 1225
Clean and Inspect 1225
Assemble 1226
Install 1226
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 1227
Remove 1227
Install 1229
Fork Positioner Hydraulic Hose Adjustment 1231
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 1232
Remove 1232
Disassemble and Assemble 1236
Clean and Inspect 1236
Install 1236
Fork Positioner Hydraulic Hose Adjustment 1237
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 1238
Remove 1238
Disassemble and Assemble 1242
Clean and Inspect 1242
Install 1242
Fork Positioner Hydraulic Hose Adjustment 1243
Two-Stage LFL Mast Repair 1244
Mast With Serial Number F507 1244
Remove 1244
Disassemble 1248
Clean and Inspect 1255
Assemble 1257
Install 1258
Header Hoses 1260
Remove 1260
Installation 1260
Adjustment 1264
Mast With Serial Number F562 1265
Remove 1265
Disassemble 1269
Clean and Inspect 1276
Assemble 1278
Install 1279
Header Hose Installation and Adjustment 1280
Remove 1280
Installation 1281
Adjustment 1285
Carriages Repair, Three-Stage FFL Mast 1286
Standard Carriage 1286
Remove 1286
Clean and Inspect 1288
Install 1288
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 1288
Remove 1288
Disassemble 1290
Clean and Inspect 1291
Assemble 1292
Install 1292
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 1293
Remove 1293
Disassemble 1295
Clean and Inspect 1296
Assemble 1297
Install 1297
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 1298
Remove 1298
Disassemble 1300
Clean and Inspect 1301
Assemble 1302
Install 1302
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 1303
Remove 1303
Install 1305
Fork Positioner Hydraulic Hose Adjustment 1307
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 1308
Remove 1308
Disassemble and Assemble 1310
Clean and Inspect 1310
Install 1310
Fork Positioner Hydraulic Hose Adjustment 1311
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 1312
Remove 1312
Disassemble and Assemble 1315
Clean and Inspect 1315
Install 1315
Fork Positioner Hydraulic Hose Adjustment 1316
Three-Stage FFL Mast Repair 1317
Mast With Serial Number F508 1317
Remove 1317
Disassemble 1321
Clean and Inspect 1331
Assemble 1334
Install 1335
Header Hose Installation and Adjustment 1337
Remove 1337
Installation 1337
Adjustment 1345
Mast With Serial Number F563 1346
Remove 1346
Disassemble 1349
Clean and Inspect 1359
Assemble 1362
Install 1363
Header Hose Installation and Adjustment 1365
Remove 1365
Installation 1365
Adjustment 1373
Mast Adjustments 1374
Load Roller, Adjust 1374
Mast Side Kicking, Adjust 1376
Carriage Adjustments 1376
Lift Chains Adjustment 1378
Hydraulic Quick Disconnect Hoses 1380
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 1380
Lift Trucks Equipped With E-Hydraulic Controls 1380
Lift Trucks Equipped With Manual Hydraulic Controls 1381
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 1381
Lift Trucks Equipped With E-Hydraulic Controls 1381
Lift Trucks Equipped With Manual Hydraulic Controls 1382
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1382
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1382
550096309 8000YRM1687 (11 2017) UK EN 1385
General 1391
Serial Number Data 1391
How to Move Disabled Lift Truck 1391
How to Tow Lift Truck 1391
How to Put Lift Truck on Blocks 1392
How to Raise Drive Tires 1392
How to Raise Steering Tires 1392
How to Clean a Lift Truck 1393
Maintenance Schedule 1394
Maintenance Procedures Every 8 Hours or Daily 1406
How to Make Checks With Engine Stopped 1407
Tires and Wheels 1407
Safety Labels 1408
Mast, Carriage, Lift Chains, Header Hoses, Attachment 1408
Operator Restraint System 1409
Emergency Locking Retractor (ELR) 1409
Adjust Seat – Full Suspension 1409
Adjust Seat – Internal Suspension 1410
Hood and Seat Latches 1412
Engine Compartment 1412
Paper Application 1412
Fuel, Oil, and Coolant Leaks, Check 1413
Hydraulic Hoses 1413
Coolant Hoses 1413
Steering Column Gas Cylinder 1414
Transmission 1414
Hydraulic System Oil 1414
Engine Oil 1414
Air Filter 1417
Forks 1417
Remove 1417
Inspect 1417
Install 1419
Adjust 1419
How to Make Checks With Engine Running 1419
Indicator Lights, Horn, Fuses, and Relays 1419
Service Brakes 1422
Brake Fluid Level 1422
Operation, Check 1422
Parking Brake 1422
Engine Oil Pressure 1422
Cooling System 1423
Steering System 1424
Control Levers and Pedals 1424
Lift System, Operate 1424
First Service After First 100 Hours of Operation 1424
Mazda and Kubota Engine Oil and Oil Filter 1425
Yanmar Engine Oil and Oil Filter 1426
Maintenance Procedures Every 500 Hours or 1 Year 1426
Hydraulic System Oil 1426
Hydraulic Tank Breather 1426
Inspect 1426
Battery 1427
Engine Oil and Oil Filter, Mazda and Yanmar Engines 1427
Engine Oil and Oil Filter, Kubota 2 5L Engine 1428
Drive Belt 1429
Mazda 2 2L Engines 1429
Fan and Alternator Drive Belt 1429
Yanmar Diesel Engine 1429
Fan and Alternator Drive Belt 1429
Kubota 2 5L Engine 1430
Fan and Alternator Drive Belt 1430
PCV Valve 1430
Clean Debris From Radiator Core 1431
Transmission Oil Level 1431
Wet Brake Planetary Housing Oil Level Check 1432
Forks 1435
Mast Lubrication 1435
Header Hose Checks 1439
Lift Chain Lubrication 1439
Tilt Cylinder Lubrication 1440
Master Brake Cylinder Rod End Pin Lubrication 1441
Manual Hydraulic Levers Lubrication 1442
Brake Fluid 1442
Tie Rod Lubrication 1443
Lift Truck Models 1443
Differential and Drive Axle Oil (Dry Brake) 1444
Maintenance Procedures Every 1000 Hours or 1 Year 1444
Valve Clearance, Check and Adjust 1445
PCV Valve, Kubota Engine 1445
Ignition System 1445
Mazda 2 2L Engines 1445
LPG Fuel Filter Element Replace, Kubota 2 5L Engine 1445
Remove 1445
Install 1446
LPG Vapor Fuel Filter Replace, Mazda Engines 1446
Fuel Filter Replacement, Yanmar Engine 1446
Priming the Fuel System (Yanmar) 1448
Lift Chains Wear Check 1449
Lift Chain Lubrication 1449
Integral Sideshift Carriage, Check Bearings 1450
Integral Sideshift Carriage, Check Lower Mounting Hooks 1450
Steering Axle 1451
Control Levers and Pedals 1451
Maintenance Procedures Every 2000 Hours or Annually 1451
Hydraulic System 1452
Hydraulic Filter, Replace 1452
Hydraulic Tank Breather, Replace 1453
Air Filter 1454
Ignition System 1455
Kubota 2 5L Engine 1455
PCV Valve 1455
Oxygen Sensor 1456
Timing Belt 1456
Mazda Engines 1456
Fuel Injector, Yanmar Engines 1456
Forks 1456
Integral Sideshift Carriage 1456
Bearings, Replace 1456
Transmission Oil and Filter (Dry Brake), Replace 1456
Iron Transmission Housing 1456
Aluminum Transmission Housing 1458
Remove 1458
Clean and Inspect 1459
Install 1459
Transmission Oil Change, Wet Brake Drive Axle 1459
Iron Transmission Housing 1459
Aluminum Transmission Housing 1461
Wet Brake Axle Center Section and Planetary Housing, Oil Change 1464
Brake Fluid (Master Cylinder), Change 1467
Brake Fluid (Dry Brake), Remove 1468
Service Brakes (Dry Brake) 1468
Differential (Dry Brake) 1469
Steering Axle Wheel Bearing Lubrication 1469
Maintenance Procedures Every 4000 Hours or 2 Years 1469
Hydraulic Oil, Replace 1470
Cooling System 1470
Safety Procedures When Working Near Mast 1471
Hood Latch Check 1474
Lift Chain Adjustments 1475
Jump-Starting the Lift Truck 1477
Jump-Starting Using a Battery Charger 1477
Jump-Starting a Lift Truck Using Another Lift Truck 1477
Welding Repairs 1477
Wheel and Tire Replacement 1478
General 1478
Solid Rubber Tire, Change ( Series)GC/GLC 1478
Remove and Install Tire on Wheel 1478
Pneumatic Tire With Tube, Repair 1480
Remove Wheels From Lift Truck 1480
Remove Tire From Wheel 1480
Install Wheel in Tire 1483
Install Tire on Two-Piece Wheel 1485
Add Air to Pneumatic Tires With Tube 1486
Install the Wheels 1487
Dual Drive Wheels, Install 1487
Pneumatic Tubeless Tire, Repair 1488
Remove Wheels From Lift Truck 1488
Add Air to Pneumatic Tubeless Tire 1494
Wheels, Install 1494
Solid Rubber Tires on Pneumatic Wheels, Change 1494
Snap-On-Tire, Change 1498
Easy Mounting Style Solid Rubber Tires on Pneumatic Wheels, Change 1501
Overhead Guard Changes 1506
Adhesives and Sealants 1506
550096314 0100YRM1672 (04 2014) UK EN 1509
550096315 0600YRM1673 (04 2014) UK EN 1581
550096316 0600YRM1670 (07 2019) UK EN 1621
General 1625
Fan Belt Installation 1625
Remove 1625
Inspect 1625
Installation 1626
Thermostat Repair 1626
Remove 1626
Thermostat Operation Check 1627
Install 1627
Water Pump Repair 1627
Remove 1627
Clean and Inspect 1627
Install 1628
Lubrication System Repair 1628
Oil Pan and Oil Pickup, Remove 1628
Oil Pan and Oil Pickup, Inspection 1628
Oil Pump, Remove 1629
Oil Pump, Inspection 1629
Rotor Lobe Clearance 1629
Rotor Cover Clearance 1630
Oil Pump, Assemble and Install 1630
Oil Pan and Oil Pickup, Assemble and Install 1630
Cylinder Head Repair 1631
Remove and Disassemble 1631
Clean and Inspect 1634
Valve Guides and Seats 1636
Valve Lapping 1636
Valve Guide, Replacement 1636
Valve Seats, Inspection and Repair 1637
Valve and Valve Seat Correction 1637
Valve Springs 1638
Assemble and Install 1639
Valve Clearance Adjustments 1642
Gear Case, Timing Gears, and Camshaft 1644
Gear Case 1644
Fan Drive Pulley, Remove 1644
Fan Drive Pulley, Install 1645
Gear Case, Remove 1645
Gear Case, Install 1645
Timing Gears 1645
Oil Pump, Remove 1645
Oil Pump, Install 1645
Crankshaft Oil Slinger, Remove 1645
Crankshaft Oil Slinger, Install 1646
Idler Gear, Remove 1646
Idler Gear, Install 1646
Camshaft 1646
Camshaft, Remove 1646
Camshaft, Install 1647
Piston and Connecting Rod Assemblies Repair 1647
Disassemble 1647
Piston, Clean and Inspect 1648
Piston Ring Gap 1648
Piston Ring Groove 1649
Connecting Rod and Piston Pin, Clean and Inspect 1649
Cylinder Bores, Clean and Inspect 1650
Cylinder Correction (Oversize) 1652
Assemble 1652
Piston Bore Preparation 1654
Cylinder Wear 1654
Cylinder Correction (Oversize) 1654
Flywheel and Bearing Case Cover 1655
Flywheel, Remove 1655
Bearing Case Cover, Remove 1655
Bearing Case Cover, Install 1656
Flywheel, Install 1656
Crankshaft Repair 1657
Crankshaft, Remove 1657
Inspect and Repair 1658
Crankshaft Journal Oil Clearance Bearing 1 1658
Crankshaft Journal Oil Clearance Bearing 2 1659
Crankshaft Bend 1660
Crankshaft, Install 1660
Crankshaft Side Clearance 1662
Engine Block Cleaning and Inspection 1663
Clean and Inspect 1663
Engine Removal and Installation 1664
Engine Specifications 1664
Engine Data 1664
Torque Specifications 1665
550096317 0700YRM1674 (03 2014) UK EN 1667
550096318 0900YRM1675 (04 2018) UK EN 1693
General 1697
LPG Tank and Bracket Replacement 1697
Remove LPG Tank 1697
Install LPG Tank 1700
Remove LPG Bracket 1700
Install LPG Bracket 1703
Remove LPG Tank Bracket Alignment Pin 1703
Install LPG Tank Bracket Alignment Pin 1705
Fuel Filter Unit Repair 1706
Fuel Filter Element 1706
Remove 1706
Clean/Inspect 1707
Install 1707
Fuel Filter Housing 1707
Remove 1707
Disassemble 1709
Assemble 1710
Install 1710
Electronic Throttle Body Repair 1711
Remove 1711
Install 1712
Electronic Pressure Regulator (EPR) Repair 1713
Remove 1713
Disassemble 1715
Assemble 1718
Install 1719
LPG Shutoff Valve Assembly 1719
Remove 1719
Install 1721
Fuel Mixer Repair 1722
Remove 1722
Install 1724
Control System 1726
Engine Control Unit (ECU) 1726
Remove 1726
Install 1727
Low LPG Pressure Switch 1728
Remove 1728
Install 1729
LPG Low Level Sensor 1729
Remove 1729
Install 1731
Exhaust System 1732
Counterweight Exhaust System 1732
Remove and Disassemble 1732
Inspect 1734
Assemble and Install 1734
Overhead Exhaust System 1734
Remove and Disassemble 1734
Inspect 1737
Assemble and Install 1737
Exhaust Manifold 1737
Remove 1737
Install 1739
Positive Crankcase Ventilation (PCV) Valve 1739
Remove 1739
Inspect 1739
Install 1739
Oxygen Sensor 1739
Remove 1739
Install 1740
LPG Fuel Testing 1741
General 1741
Available Fuel Tests 1741
Composition Test (ASTM D-2163) 1741
Ammonia Test (ASTM D-4490) 1741
Basic Nitrogen Test (ASTM UOP269-90) 1741
Residues Test (ASTM D-2158) 1741
Vapor Pressure Test (ASTM D-2598) 1741
Sulfur Compounds Test (ASTM D-5623) 1741
Methanol Test (ASTM D-4864) 1742
Copper Corrosion (ASTM D-1838) 1742
Where To Send LPG Fuel Samples For Testing 1742
550096320 0900YRM1677 (04 2018) UK EN 1745
General 1749
LPG Tank and Bracket Replacement 1749
Remove LPG Tank 1749
Install LPG Tank 1752
Remove LPG Bracket 1752
Install LPG Bracket 1755
Remove LPG Tank Bracket Alignment Pin 1755
Install LPG Tank Bracket Alignment Pin 1757
LPG Fuel Filter Unit Repair 1758
LPG Fuel Filter Element 1758
Remove/Disassemble 1758
Clean/Inspect 1759
Assemble/Install 1759
Fuel Filter Housing 1760
Remove 1760
Disassemble 1763
Clean and Inspect 1764
Assemble 1764
Install 1765
Electronic Throttle Body Repair 1765
Remove 1766
Install 1767
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 1768
Remove 1768
Install 1769
Control System 1770
Engine Control Unit (ECU) 1770
Remove 1770
Install 1771
Low LPG Pressure Switch 1771
Remove 1771
Install 1772
LPG Low Level Sensor 1772
Remove 1773
Install 1774
LPG Converter 1775
Remove 1775
Install 1778
LPG Lock-Off Valve 1779
Remove 1779
Install 1781
Exhaust System 1782
Counterweight Exhaust System 1782
Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (B910, C910) 1782
Remove and Disassemble 1782
Inspect 1783
Assemble and Install 1783
Lift Truck Models GLP20-35VX (GLP040-070VX) (C875, D875) 1784
Remove and Disassemble 1784
Inspect 1785
Assemble and Install 1786
Overhead Exhaust System 1786
Remove and Disassemble 1786
Inspect 1787
Assemble and Install 1788
Exhaust Manifold 1788
Remove 1788
Install 1789
Oxygen (HEGO) Sensor 1789
Remove 1789
Install 1790
PCV Valve 1790
LPG Fuel Testing 1791
General 1791
Available Fuel Tests 1791
Composition Test (ASTM D-2163) 1791
Ammonia Test (ASTM D-4490) 1791
Basic Nitrogen Test (ASTM UOP269-90) 1791
Residues Test (ASTM D-2158) 1791
Vapor Pressure Test (ASTM D-2598) 1791
Sulfur Compounds Test (ASTM D-5623) 1791
Methanol Test (ASTM D-4864) 1792
Copper Corrosion (ASTM D-1838) 1792
Where To Send LPG Fuel Samples For Testing 1792
550096321 1300YRM1678 (04 2014) UK EN 1795
550096322 1400YRM1679 (02 2018) UK EN 1863
General 1867
Identification Plate 1867
Drive Axle Removal 1867
Reduction Gear Assembly 1873
Reduction Gear Assembly Repair 1873
Clean and Inspect 1883
Brake Repair 1896
Wet Disc Brake 1896
Clean and Inspect 1912
Wet Brake Noise Reduction 1925
General 1925
Adding Additive To Transmission 1926
Parking Brake Control Lever 1926
General 1926
Clean and Inspect 1929
Differential Repair 1933
Remove 1933
Disassemble 1947
Clean and Inspect 1949
Assemble 1950
Install 1955
Gear Set, Tooth Contact Pattern Check 1969
Drive Axle Installation 1973
Special Tools 1979
Torque Specifications 1982
550096323 1400YRM1680 (01 2023) US EN 1987
General 1993
Drive Axle Repair 1993
Remove and Disassemble 1993
Clean and Inspect 1996
Assemble and Install 1996
Differential Repair 2000
Remove 2000
Disassemble 2012
Clean and Inspect 2019
Install 2030
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 2030
Ring Gear Backlash, Adjust 2047
Ring Gear, Runout Check 2049
Gear Set, Tooth Contact Pattern Check 2049
Torque Specifications 2052
550096323 1400YRM1680 (04 2014) UK EN 2055
550096324 1600YRM1681 (04 2014) UK EN 2117
550096325 1800YRM1682 (04 2014) UK EN 2141
550096326 1900YRM1683 (04 2014) UK EN 2175
550096327 2000YRM1684 (01 2016) UK EN 2209
General 2213
Electro-Hydraulic Main Control Valve 2214
Description 2214
Remove 2217
Electro-Hydraulic Control Valve Sections 2219
General 2219
Outlet Control Valve Section 2220
Remove 2220
Disassemble 2220
Clean 2222
Inspect 2222
Assemble 2222
Install 2223
Auxiliary Control Valve Sections 2223
Remove 2223
Disassemble 2224
Clean 2224
Inspect 2225
Assemble 2225
Install 2225
Tilt Control Valve Section 2225
Remove 2225
Disassemble 2226
Clean 2227
Inspect 2227
Assemble 2227
Install 2227
Lift/Lower Control Valve Section 2227
Remove 2227
Disassemble 2227
Clean 2229
Inspect 2229
Assemble 2230
Install 2231
Install 2231
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2233
Lift Pilot Pin 2233
Lower Pilot Pin 2235
Abnormal/Erroneous EHPV Adjustment 2237
Manual Main Control Valve 2237
Description 2237
Remove 2240
OPS Solenoid Assembly 2246
General 2246
Remove 2247
Clean and Inspect 2250
Install 2250
Manual Control Valve Sections 2251
General 2251
Outlet Control Valve Section 2251
Remove 2251
Disassemble 2251
Clean 2254
Inspect 2254
Assemble 2254
Install 2255
Auxiliary Control Valve Sections 2255
Remove 2255
Disassemble 2255
Clean 2258
Inspect 2258
Assemble 2258
Install 2259
Lift/Tilt Control Valve Section 2259
Remove 2259
Disassemble 2259
Clean 2262
Inspect 2262
Assemble 2263
Install 2263
Install 2263
Pressure Relief Valve Check and Adjustment 2268
Primary Relief Valve 2269
Secondary Relief Valve 2269
Steering Control Unit Repair 2270
Steering Control Unit, Remove 2270
Steering Control Unit, Disassemble 2270
Steering Control Unit, Clean 2273
Steering Control Unit, Inspect 2273
Steering Control Unit, Assemble 2273
Relief Valve, Disassemble 2274
Relief Valve, Clean 2274
Relief Valve, Inspect 2275
Relief Valve, Assemble 2275
Steering Control Unit, Install 2275
550096328 2200YRM1685 (04 2014) UK EN 2279
550096329 2200YRM1686 (04 2014) UK EN 2351
550096330 8000YRM1688 (10 2016) UK EN 2381
Lift Truck Lifting Capacity 2385
Counterweight Weights 2385
Tire Sizes 2386
Capacities 2386
Electrical System 2391
Transmission Oil Pressures 2391
Hydraulic System Relief Pressures 2395
Steering System 2396
Stall Speeds (in RPM ±100 rpm) 2397
Mazda 2 2L 2397
Kubota 2 5L 2397
Yanmar 2 6L 2397
Yanmar 3 0L 2397
Yanmar 3 3L 2397
Mast Speeds 2398
Tilt Angles 2402
Front End Equipment – Mast Creep 2403
Mast Creep 2403
Engine Specifications 2404
Torque Specifications 2406
Frame 2406
Mast 2406
Steering System, Cushioned Tire Trucks 2406
Steering System, Pneumatic Tire Trucks 2406
Drive Axle (Dry Brake) 2406
Drive Axle (Wet Brake) 2407
Transmission – Iron Housing 2407
Transmission – Aluminum Housing 2408
Engine – Mazda 2 2L 2408
Engine – Kubota 2 5L 2409
Engine – Yanmar 2 6L, 3 0L and 3 3L Diesel 2410
550096331 8000YRM1689 (03 2020) UK EN 2415
General Information About Diagrams and Schematics 2419
Symbol Definitions 2419
Diagrams Manual Applications 2420
Diagrams and Schematics 2422
550096632 1300YRM1690 (04 2014) UK EN 2525
550096637 2000YRM1691 (04 2014) UK EN 2593
550100651 2100YRM1692 (11 2016) UK EN 2633
General 2639
Description 2641
Safety Procedures When Working Near Mast 2642
Tilt Cylinder Repair 2644
Remove 2644
Disassemble 2645
Clean 2646
Inspect 2646
Assemble 2647
Install 2647
Tilt Cylinders, Adjust 2648
Tilt Cylinders With Tilt Limit Spacers 2648
Tilt Cylinders Without Tilt Limit Spacers 2648
Tilt Cylinder Leak Check 2649
Main Lift And Free-Lift Cylinders Repair 2649
Main Lift Cylinders 2650
Remove 2650
Two-Stage FFL 2650
Four-Stage FFL 2650
Disassemble 2653
Two-Stage FFL 2653
Four-Stage FFL 2655
Clean 2657
Inspect 2657
Assemble 2657
Two-Stage FFL 2657
Four-Stage FFL 2657
Install 2658
Two-Stage FFL 2658
System Air Bleed Procedures 2658
Four-Stage FFL 2659
Free-Lift Cylinder 2659
Remove 2659
Two-Stage FFL 2659
Four-Stage FFL 2661
Disassemble 2663
Two-Stage FFL 2663
Four-Stage FFL 2664
Clean 2665
Inspect 2665
Assemble 2665
Two-Stage FFL 2665
Four-Stage FFL 2665
Install 2666
Two-Stage FFL 2666
Four-Stage FFL 2666
Lift Cylinder Leak Check 2667
Integral Sideshift Cylinder Repair
Prior to December 2016 2668
Remove 2668
Disassemble 2668
Clean and Inspect 2668
Assemble and Install 2669
Integral Sideshift Cylinder Repair
After December 2016 2671
Remove 2671
Disassemble 2671
Clean and Inspect 2671
Assemble and Install 2672
Fork Positioner Cylinder Repair Prior to December 2016 2674
Remove 2674
Disassemble 2674
Clean 2674
Inspect 2677
Assemble 2677
Install 2678
Fork Positioner Cylinder Adjustment 2678
Fork Positioner Cylinder Repair After December 2016 2679
Remove 2679
Disassemble 2679
Clean 2682
Inspect 2682
Assemble 2683
Install 2683
Fork Positioner Cylinder Adjustment 2683
Seal Kit Installation 2683
External Installation (Seal and Back-Up Ring) 2684
Internal Installation (Piston Rod Assembly) 2684
Torque Specifications 2684
Tilt Cylinders 2684
Piston Rod Nut 2684
Gland 2685
Tilt Cylinder Mounting Capscrew 2685
Tilt Cylinder Rod End Nut 2685
Main Lift and Free-Lift Cylinders 2685
Gland, Main Lift Cylinders 2685
Gland, Free-Lift Cylinder 2685
Piston, Main Lift Cylinders 2685
Main Lift Cylinder Mounting Nut To Outer
Mast 2685
Main Lift Cylinder Mounting Nut To Intermediate
Mast (Four-Stage FFL, Right Cylinder Only) 2685
Retainer Nuts 2685
Chain Guard Capscrew (Free-Lift Cylinder) 2685
Crosshead Mounting Capscrew (Free-Lift Cylinder) 2685
Free-Lift Cylinder Mounting Capscrews 2685
Cylinder Shell Capscrew, Main Lift Cylinders 2685
Fork Positioner 2685
Cylinder Rod Retainer 2685
Fork Positioner Cylinder Mounting Capscrews 2685
Cylinder Rod Anchor Plug 2686
Fork Carrier Capscrews 2686
Hose Guide Capscrews 2686
Integral Sideshift Cylinder 2686
Cylinder Rod Retainer 2686
Gland 2686
550100656 4000YRM1693 (10 2017) UK EN 2689
General 2695
Safety Procedures When Working Near Mast 2697
Fork Replacement 2699
Standard Carriage and Integral Sideshift Carriage 2699
Remove 2699
Install 2700
Checks 2700
Fork Positioner Carriage 2702
Remove 2702
Install 2702
Checks 2704
Carriages Repair, Two-Stage FFL Mast 2705
Standard Carriage 2706
Remove 2706
Clean and Inspect 2707
Install 2707
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 2708
Remove 2708
Disassemble 2708
Clean and Inspect 2711
Assemble 2712
Install 2712
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 2713
Remove 2713
Disassemble 2716
Clean and Inspect 2716
Assemble 2716
Install 2717
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 2717
Remove 2717
Install 2718
Fork Positioner Hydraulic Hose Adjustment 2722
Fork Positioner Carriage, Lift Trucks Manufactured After December, 2016 2723
Remove 2723
Disassemble and Assemble 2726
Clean and Inspect 2726
Install 2726
Fork Positioner Hydraulic Hose Adjustment 2727
Two-Stage Mast With Full Free-Lift Repair 2728
Mast With Serial Number E509 2728
Remove 2728
Disassemble 2731
Clean and Inspect 2735
Assemble 2737
Install 2738
Header Hose Procedures 2739
Remove 2739
Installation 2740
Adjustment 2746
Mast With Serial Number E564 2746
Remove 2746
Disassemble 2750
Clean and Inspect 2755
Assemble 2757
Install 2758
Header Hose Procedures 2759
Remove 2759
Installation 2759
Adjustment 2766
Carriages Repair, Four-Stage FFL Mast 2766
Standard Carriage 2766
Remove 2766
Clean and Inspect 2767
Install 2768
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 2769
Remove 2769
Disassemble 2771
Clean and Inspect 2771
Assemble 2772
Install 2772
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 2773
Remove 2773
Disassemble 2773
Clean and Inspect 2776
Assemble 2776
Install 2776
Fork Positioner Carriage 2777
Four-Stage Mast With Full Free-Lift Repair 2778
Mast With Serial Number D515 2778
Remove 2778
Disassemble 2782
Clean and Inspect 2788
Assemble 2790
Install 2793
Header Hose Procedures 2794
Remove 2794
Installation 2794
Adjustment 2802
Carriage Adjustments 2802
Lift Chains Adjustment 2805
Mast Adjustments 2806
Load Roller, Adjust 2807
Mast Side Kicking, Adjust 2809
Hydraulic Quick Disconnect Hoses 2809
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 2809
Lift Trucks Equipped With E-Hydraulic Controls 2809
Lift Trucks Equipped With Manual Hydraulic Controls 2810
Connecting Attachment Hydraulic Quick Disconnect Hoses 2810
Lift Trucks Equipped With E-Hydraulic Controls 2810
Lift Trucks Equipped With Manual Hydraulic Controls 2810