Yale Forklift C875 (GP40-70VX, GLP40-70VX, GDP40-70VX) Service Manual PDF

Yale Forklift C875 (GP40-70VX, GLP40-70VX, GDP40-70VX) Service Manual – PDF DOWNLOAD

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Yale Forklift C875 (GP40-70VX, GLP40-70VX, GDP40-70VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 6814
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift C875 (GP40-70VX, GLP40-70VX, GDP40-70VX) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (03 2020) US 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
524221866 9000YRM1112 (10 2020) US EN 2075
SECTION 9010 Operational Diagnostic Procedures 2091
Group 05 – Operational Checkout 2093
SECTION 9020 Engine 2111
Group 10 – Principles of Operation 2121
Group 30 – Observed Symptoms 2319
Group 40 – Tests and Adjustments 2421
SECTION 9030 Electrical System 2453
Group 03 – General Maintenance and Diagnostic Data 2477
Group 10 – Principles of Operation 2571
Group 20 – Diagnostic Trouble Codes 2595
Group 30 – Observed Symptoms 3567
SECTION 9040 Drive Train 3623
Group 10 – Principles of Operation 3627
Group 30 – Observed Symptoms 3683
Group 40 – Tests and Adjustments 3733
SECTION 9050 Hydraulic Systems 3743
Group 10 – Principles of Operation 3747
Group 30 – Observed Symptoms 3805
Group 33 – Observed Symptoms-Gear Pump 3807
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 3895
Group 40 – Tests and Adjustments 3939
Group 43 – Tests and Adjustments-Gear Pump 3941
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 3965
SECTION 9060 Operators Station 3983
Group 10 – Principles of Operation 3985
SECTION 9070 Front End (Mast) and Chassis 4021
Group 10 – Principles of Operation 4023
Group 30 – Observed Symptoms 4045
SECTION 9080 Supplementary Data 4103
Group 50 – Abbreviations and Acronyms 4105
Group 60 – Special Tools List 4113
Group 70 – Fault Mode Indicator Reference 4123
Group 80 – Supplier Specification Data 4125
524223769 2200YRM1128 (01 2023) US EN 4129
Series Code / Model Designation Reference Table 4137
General 4139
Deutsch Crimping Tool 4140
How to Strip a Wire for Use With Deutsch Crimping Tool 4140
How to Crimp With the Deutsch Crimping Tool 4141
Calibration Test for the Deutsch Crimping Tool 4143
Deutsch Connectors 4145
DT, DTM, and DTP Series Connectors 4145
HD Series Connectors 4188
Metri-Pack Connectors 4210
Remove and Install 4210
Micro-Pack Connectors 4213
Weather-Pack Connectors 4214
AMPSEAL Crimping Tools 4216
AMP Hand Crimping Tool With Certi-Crimp 4216
Description 4216
Stripping Wire for Use with AMP Hand Crimping Tool 4217
Insulation Crimp Adjustment 4218
Maintenance and Inspection for AMP Hand Crimping Tool 4218
AMP Hand Crimping Tool 4218
Crimp Height Inspection 4218
How to use AMP Hand Crimping Tool 4219
AMP Pro-Crimper II Tool 4219
Description 4219
Remove and Install Die Set and Locator Assembly 4220
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 4220
Contact Support Adjustment 4221
Crimp Height Adjustment 4222
Maintenance and Inspection Procedures 4222
PRO-CRIMPER II Tool 4222
Crimp Height Inspection 4222
How to Use AMP PRO-CRIMPER II Tool 4223
AMPSEAL Connector Assemblies 4224
Description for Plug Connector Assembly 4224
Seal Plug 4225
Contact Crimping 4225
Description for Plug Connector and Header Assembly 4230
Voltage Reading 4233
Seal Plug 4233
Contact Crimping 4233
AMP Superseal 1 5 Crimping Tools 4240
Mini Mic Receptacle and Tab Contacts 4240
Description 4240
Crimping Conditions and Measurements 4240
Insertion of Rubber Seal on Cable 4242
AMP Hand Application Tool 4247
Description 4247
Maintenance and Inspection 4247
Crimp Height Inspection 4247
Crimp Height Adjustment 4248
How to Use AMP Hand Application Tool 4248
AMP Pro-Crimper II Tool 4249
Description 4249
Remove and Install Die Set and Locator Assembly 4249
Adjustments 4250
Contact Support 4250
Crimp Height 4251
Inspections and Maintenance 4252
Crimp Height Inspection 4252
Visual Inspection 4252
Maintenance 4253
How to Use Pro-Crimper II Tool 4253
AMP Superseal 1 5 Connector Assemblies 4254
Description 4254
Repair and Maintenance 4261
Panel Mount Option 4261
AMP Fastin-Faston Hand Tools 4262
Description – AMP Double Action Hand Tool 4262
Maintenance and Inspection Procedures 4262
Daily Maintenance 4262
Periodic Tool Inspection 4263
Lubrication 4263
Visual Inspection 4263
Crimp Height Inspection 4263
Certi-Crimp Ratchet Inspection 4264
How to Use AMP Double Action Hand Tool 4265
Description – AMP Extraction Tool 4266
Maintenance and Inspection 4267
How to Use AMP Extraction Tool 4267
AMP Fastin-Faston Receptacles and Housings 4269
Description 4269
Wire Repair 4277
Wire Splicing Requirements 4277
Deutsch Jiffy Splice 4278
Twisted/Shielded Cable and Leads Repair 4284
Special Tools 4286
524223769 2200YRM1128 (07 2020) US EN 4295
Series Code / Model Designation Reference Table 4301
General 4304
Deutsch Crimping Tool 4304
How to Strip a Wire for Use With Deutsch Crimping Tool 4304
How to Crimp With the Deutsch Crimping Tool 4305
Calibration Test for the Deutsch Crimping Tool 4307
Deutsch Connectors 4309
DT, DTM, and DTP Series Connectors 4309
HD Series Connectors 4351
Metri-Pack Connectors 4374
Remove and Install 4374
Micro-Pack Connectors 4376
Weather-Pack Connectors 4377
AMPSEAL Crimping Tools 4379
AMP Hand Crimping Tool With Certi-Crimp 4379
Description 4379
Stripping Wire for Use with AMP Hand Crimping Tool 4379
Insulation Crimp Adjustment 4380
Maintenance and Inspection for AMP Hand Crimping Tool 4380
AMP Hand Crimping Tool 4380
Crimp Height Inspection 4380
How to use AMP Hand Crimping Tool 4381
AMP Pro-Crimper II Tool 4381
Description 4381
Remove and Install Die Set and Locator Assembly 4382
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 4383
Contact Support Adjustment 4383
Crimp Height Adjustment 4384
Maintenance and Inspection Procedures 4384
PRO-CRIMPER II Tool 4384
Crimp Height Inspection 4384
How to Use AMP PRO-CRIMPER II Tool 4385
AMPSEAL Connector Assemblies 4386
Description for Plug Connector Assembly 4386
Seal Plug 4387
Contact Crimping 4387
Description for Plug Connector and Header Assembly 4392
Voltage Reading 4394
Seal Plug 4394
Contact Crimping 4394
AMP Superseal 1 5 Crimping Tools 4401
Mini Mic Receptacle and Tab Contacts 4401
Description 4401
Crimping Conditions and Measurements 4401
Insertion of Rubber Seal on Cable 4403
AMP Hand Application Tool 4408
Description 4408
Maintenance and Inspection 4408
Crimp Height Inspection 4408
Crimp Height Adjustment 4409
How to Use AMP Hand Application Tool 4409
AMP Pro-Crimper II Tool 4410
Description 4410
Remove and Install Die Set and Locator Assembly 4411
Adjustments 4411
Contact Support 4411
Crimp Height 4412
Inspections and Maintenance 4413
Crimp Height Inspection 4413
Visual Inspection 4413
Maintenance 4414
How to Use Pro-Crimper II Tool 4414
AMP Superseal 1 5 Connector Assemblies 4415
Description 4415
Repair and Maintenance 4422
Panel Mount Option 4422
AMP Fastin-Faston Hand Tools 4423
Description – AMP Double Action Hand Tool 4423
Maintenance and Inspection Procedures 4423
Daily Maintenance 4423
Periodic Tool Inspection 4424
Lubrication 4424
Visual Inspection 4424
Crimp Height Inspection 4424
Certi-Crimp Ratchet Inspection 4425
How to Use AMP Double Action Hand Tool 4426
Description – AMP Extraction Tool 4427
Maintenance and Inspection 4427
How to Use AMP Extraction Tool 4428
AMP Fastin-Faston Receptacles and Housings 4429
Description 4429
Wire Repair 4436
Wire Splicing Requirements 4436
Deutsch Jiffy Splice 4437
Twisted/Shielded Cable and Leads Repair 4442
Special Tools 4445
524223770 2200YRM1130 (03 2020) US EN 4453
General 4457
Description 4457
Dash Display Menu Access 4457
Menu Navigation 4458
Standard Display 4458
Main Menu 4458
Passwords Menu 4459
Password Administration 4459
Add Password 4459
Delete Password 4460
Edit Password 4460
Other Password Functions 4461
Operator Passwords – Enable/Disable 4461
Password Time-Out Delay 4461
Passwords – Number Wrong to Disable 4462
Lockout Reset Password 4462
View Password Log 4463
View Versions 4464
VSM Versions 4464
Dash Display Versions 4465
Engine Controller Version 4466
Transmission (Xmsn) Controller Version 4467
Truck Serial Number 4468
Diagnostics 4469
View Fault Log 4469
Set Travel and Braking 4470
Speed Limit 4470
Acceleration Rate 4471
Auto-Deceleration Rate 4471
Set Power Reversal Rate 4472
Set Inching/Brake Overlap 4473
Setup Display Menu 4474
Set Operator Language 4474
Set Units 4475
Set Time Format (12/24 Hour) 4475
Set Daylight Saving Time 4475
Set Time 4478
Set Date Format 4479
Set Date 4479
Setup Hydraulics 4480
Return to Set Tilt Delay/On/Off 4480
Setup General Items 4481
Light Shutdown Time-Out 4481
Impact Sensor – Enable/Disable 4482
Impact Sensor – Soft Impact Settings 4483
Impact Sensor – Hard Impact Settings 4484
Adjust Impact Sensor Settings 4484
Initial Adjustment of Soft and Hard Impact Settings 4486
Readjustment of Soft and Hard Impact Settings 4486
Impact Sensor – Impact Alarm/Shutdown Reset 4487
Impact Sensor – Alarm Time Duration and Deactivation 4488
Impact Sensor – View Impact Event Log 4489
Engine Mode Indicator 4490
Generation 1 (ECO-eLo ONLY) 4490
Generation 2 4491
Operator Checklist 4492
Operator Checklist Off-On Mode 4492
Edit Operator Checklist 4492
Set Operator Checklist Expiration 4493
View Checklist Log 4493
Clear Operator Checklist Log 4494
Clear Operator Checklist Fault 4494
Calibrations 4495
Set Tilt Stop Point 4495
Calibrate Loaded Weight 4495
524223771 2200YRM1131 (03 2020) US EN 4497
Series Code / Model Designation Reference Table 4503
General 4505
Description 4505
Dash Display Menu Access 4505
Menu Navigation 4506
Main Menu 4506
Passwords 4507
Adding Passwords 4507
Hourmeters 4509
View Versions 4510
VSM Versions 4510
Dash Display Versions 4511
Engine Controller Version 4512
Transmission (Xmsn) Controller Version 4513
Truck Serial Number 4514
Truck Configuration 4515
Diagnostics 4516
Clear Fault Log 4516
View Fault Log 4517
No-Run Data Display 4518
Engine Accelerator and Throttle Data Display 4518
Engine Speeds and Governor Data Display 4519
Engine Fuel and Emissions Data Display 4520
Engine General Data Display 4522
XMSN/Brake Data Display 4523
Hydraulic Data Display 4526
General Truck Data Display 4528
Set Travel and Braking 4529
Speed Limit 4529
Acceleration Rate 4530
Auto-Deceleration Rate 4531
Set Power Reversal Rate 4531
Set Inching/Brake Overlap 4532
Setup Hydraulics 4532
Lift Maximum Speed 4533
Lower Maximum Speed 4533
Tilt Maximum Speed 4534
Auxiliary Function One, Direction A, Maximum Speed 4536
Auxiliary Function One, Direction B, Maximum Speed 4538
Auxiliary Function Two, Direction A, Maximum Speed 4538
Auxiliary Function Two, Direction B, Maximum Speed 4539
Auxiliary Function Three, Direction A, Maximum Speed 4540
Auxiliary Function Three, Direction B, Maximum Speed 4540
Lift/Lower Ramp Rate 4541
Hydraulic Auxiliary Ramp Rate 4541
Return to Set Tilt Delay/On/Off 4542
Hydraulic Input Device 4543
Auxiliary Solenoid 4543
Dual Function 4544
Setup Display 4545
Set Service Language 4545
Setup General Items 4545
Motion Alarm Activation Type 4546
Light Shutdown Time-Out 4547
Restore Default Settings 4547
Restore Engine Controller Default Calibration 4548
Impact Sensor – Enable/Disable 4548
Impact Sensor – Soft Impact Settings 4549
Impact Sensor – Hard Impact Settings 4550
Adjust Impact Sensor Settings 4551
Initial Adjustment of Soft and Hard Impact Settings 4553
Readjustment of Soft and Hard Impact Settings 4553
Impact Sensor – Impact Alarm/Shutdown Reset 4554
Impact Sensor – Alarm Time Duration and Deactivation 4555
Impact Sensor – View Impact Event Log 4556
Engine Mode Indicator 4556
Generation 1 (ECO-eLo ONLY) 4556
Generation 2 4557
Diesel Particulate Filter (DPF) Display 4558
General Description 4558
Passive Regeneration Only 4558
Regeneration Level 0 4558
Auto/Active Regeneration Inhibited 4559
Auto/Active Regeneration 4559
Regeneration Level 1 4559
Parked Regeneration Request 4560
Regeneration Level 2 4560
Warning Level 4560
Regeneration Level 3 4560
Service Level 4561
Regeneration Level 4 4561
Display, Diesel Particulate Filter (DPF), Revised 4561
Operator Interface 4561
Refer to Operator Manual 4561
CAN Communication Lost 4562
Passive Regeneration Only 4562
Regeneration Level 0 4562
Auto/Active Regeneration Inhibited 4562
Auto/Active Regeneration 4563
Regeneration Level 1 4563
Idle-up Auto/Active Regeneration 4563
Parked Regeneration Request 4563
Regeneration Level 2 4563
Warning Level 4565
Regeneration Level 3 4565
Service Level 4565
Regeneration Level 4 4565
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 4565
Display, Diesel Particulate Filter (DPF), Stage V Engine 4565
Operator Interface 4566
Refer to Operator Manual 4566
CAN Communication Lost 4566
Passive Regeneration Only 4566
Regeneration Level 0 4566
Auto/Active Regeneration Inhibited 4567
Auto/Active Regeneration 4567
Regeneration Level 1 4567
Idle-up Auto/Active Regeneration 4568
Parked Regeneration Request 4568
Regeneration Level 2 4568
Warning Level 4569
Regeneration Level 3 4569
Service Level 4570
Regeneration Level 4 4570
Stage V Content 4570
Emissions System Malfunction 4570
Ash Load 4570
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 4571
Operator Interface 4571
Refer to Operator Manual 4571
CAN Communication Lost 4572
Passive Regeneration Only 4572
Regeneration Level 0 4572
Auto/Active Regeneration Inhibited 4572
Auto/Active Regeneration 4573
Regeneration Level 1 4573
Idle-up Auto/Active Regeneration 4573
Parked Regeneration Request 4573
Regeneration Level 2 4573
Warning Level 4575
Regeneration Level 3 4575
Service Level 4575
Regeneration Level 4 4575
Calibrations 4576
Calibrate Transmission Valve 4578
Set Tilt Stop Point 4578
Calibrate Loaded Weight 4578
Calibrate Travel Speed Sensor 4579
Calibrate Mazda LP and Gas Accelerator Pedal 4579
524223780 8000YRM1134 (03 2020) US EN 4581
Series Code / Model Designation Reference Table 4587
Description 4589
Proc_Cal_001: Service Password Entry 4591
When to Perform 4591
Why Perform 4591
How to Perform 4591
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 4592
When to Perform 4592
Calibration Order 4592
Why Perform 4592
How to Perform 4593
Proc_Cal_003: Save and Exit 4594
When to Perform 4594
Why Perform 4594
How to Perform 4594
Proc_Cal_004: Lift Valve Output Threshold 4595
When to Perform 4595
Calibration Order 4595
Why Perform 4595
How to Perform 4596
Proc_Cal_005: Lower Valve Output Threshold 4598
When to Perform 4598
Calibration Order 4598
Why Perform 4598
How to Perform 4598
Proc_Cal_006: Tilt Back Valve Output Threshold 4601
When to Perform 4601
Calibration Order 4601
Why Perform 4601
How to Perform 4601
Proc_Cal_007: Tilt Forward Valve Output Threshold 4604
When to Perform 4604
Calibration Order 4604
Why Perform 4604
How to Perform 4604
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 4607
When to Perform 4607
Calibration Order 4607
Why Perform 4607
How to Perform 4607
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 4610
When to Perform 4610
Calibration Order 4610
Why Perform 4610
How to Perform 4610
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 4613
When to Perform 4613
Calibration Order 4613
Why Perform 4613
How to Perform 4613
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 4616
When to Perform 4616
Calibration Order 4616
Why Perform 4616
How to Perform 4616
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 4619
When to Perform 4619
Calibration Order 4619
Why Perform 4619
How to Perform 4619
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 4622
When to Perform 4622
Calibration Order 4622
Why Perform 4622
How to Perform 4622
Proc_Cal_014: Load Weight Zero Point 4626
When to Perform 4626
Calibration Order 4626
Why Perform 4626
How to Perform 4626
Proc_Cal_015: Loaded Weight Calibration 4628
When to Perform 4628
Calibration Order 4628
Why Perform 4628
How to Perform 4628
Proc_Cal_016: Transmission Valve Calibration 4631
Applicable System/Option 4631
When to Perform 4631
Calibration Order 4631
Why Perform 4631
How to Perform 4631
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 4633
Applicable System/Option 4633
When to Perform 4633
Calibration Order 4633
Why Perform 4633
How to Perform 4633
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 4635
Applicable System/Option 4635
When to Perform 4635
Calibration Order 4635
Why Perform 4635
How to Perform 4636
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 4637
Required Tools 4637
When to Perform 4637
Calibration Order 4637
Why Perform 4638
How to Perform 4638
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 4639
When to Perform 4639
Why Perform 4639
How to Perform 4639
Proc_Cal_026: Travel Speed Calibration 4641
When to Perform 4641
Calibration Order 4641
Why Perform 4641
How to Perform 4641
524240453 0600YRM1205 (01 2017) US EN 4645
General 4651
Engine Identification 4651
Major Engine Component Identification 4651
Location of Labels 4652
Engine Removal and Installation 4653
Cylinder Head Assembly Repair 4653
Glow Plugs 4656
Remove 4656
Install 4656
Valve Cover 4656
Remove 4656
Clean and Inspect 4657
Install 4657
Rocker Arm Assembly 4657
Remove 4657
Disassemble 4658
Clean and Inspect 4659
Push Rods 4659
Rocker Arm Assembly 4659
Assemble 4659
Install 4660
Valve Clearance Adjustments 4660
Cylinder Head Assembly 4661
Remove 4661
Disassemble 4666
Valves and Valve Springs, Remove 4666
Valve Guides, Remove 4666
Clean and Inspect 4667
Cylinder Head 4667
Valve Guides 4668
Valves 4668
Valve Sink 4668
Valve Seat 4669
Valve Springs 4669
Assemble 4670
Valve Guides, Install 4670
Valves and Valve Springs, Install 4670
Install 4671
Timing Gear Case and Timing Gears Repair 4672
Timing Gear Case Cover 4673
Remove 4673
Clean and Inspect 4673
Install 4674
Timing Gears 4674
Crankshaft Gear 4675
Remove 4675
Install 4675
Idler Gear 4675
Remove 4675
Inspect 4676
Install 4676
Camshaft Gear 4676
Remove 4676
Install 4677
Timing Gear Case 4677
Remove 4677
Clean and Inspect 4678
Install 4678
Drive Train, Camshaft, and Cylinder Block Repair 4679
Remove 4679
Disassemble 4680
Pistons and Connecting Rods 4680
Crankshaft 4680
Camshaft 4683
Clean and Inspect 4684
Cylinder Block 4684
Honing and Boring 4687
Pistons 4688
Piston Pin 4688
Connecting Rod 4689
Tappets 4689
Crankshaft 4690
Camshaft 4691
Camshaft Bushing 4692
Assemble 4692
Camshaft 4692
Crankshaft 4692
Pistons and Connecting Rods 4693
Install 4694
Lubrication System Repair 4695
Engine Oil and Oil Filter Change 4695
Oil Pan 4695
Remove 4695
Install 4696
Oil Suction Tube 4696
Remove 4696
Clean 4697
Install 4697
Oil Pump 4697
Remove 4697
Clean and Inspect 4698
Outer Rotor Outside Clearance 4698
Outer Rotor to Inner Rotor Tip Clearance 4699
Outer Rotor Side Clearance 4699
Rotor Shaft Clearance 4699
Install 4700
Fuel System Repair 4700
Fuel Injectors 4701
Remove 4701
Inspect 4702
Clean 4702
Test 4702
Install 4705
Electronic Throttle System 4705
Remove 4705
Install 4708
Inspect 4709
Adjust 4710
Manual Throttle System 4711
Fuel Injection Pump 4711
Remove 4711
Clean and Inspect 4715
Install 4715
Check/Adjust Fuel Injection Timing 4716
Cooling System Repair 4718
V-Belt 4718
Remove 4718
Inspect 4718
Install 4718
Adjust 4718
Water Pump 4720
4TNE92-NMHA, 4TNE92-NMHA/580090035, 4TNE92-SNMU, and 4TNE98-SNMU Engines 4720
Remove 4720
Install 4721
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/580090036, and 4TNE98-BNMH Engines 4722
Remove 4722
Install 4723
Thermostat 4725
Remove 4725
Inspect 4726
Install 4726
Flywheel and Flywheel Housing 4726
Flywheel 4727
Remove 4727
Install 4728
Flywheel Housing 4728
Remove 4728
Install 4728
Electrical Equipment Repair 4730
Alternator 4730
Remove 4730
Bench Test 4732
Regulate Voltage Check 4732
No Load Test 4734
Output Test 4734
Install 4734
Starter 4735
Remove 4736
No Load Test 4736
Install 4737
Engine Specifications 4738
Engine Data 4738
Engine Tuning 4746
Cylinder Head 4746
Intake/Exhaust Valve and Guide 4747
Valve Spring 4747
Rocker Arm and Shaft 4747
Push Rod 4748
Gear Train and Camshaft 4748
Camshaft 4748
Idle Gear Shaft and Bushing 4748
Backlash of Each Gear 4749
Cylinder Block 4749
Crankshaft 4749
Thrust Bearing 4750
Piston 4750
Piston Ring 4750
Connecting Rod 4751
Rod Small End 4751
Tappet 4751
Oil Pump 4752
Engine Oil Pressure 4752
Outer Rotor Outside Clearance 4752
Outer Rotor Side Clearance 4752
Outer Rotor to Inner Rotor Tip Clearance 4752
Rotor Shaft Clearance 4752
Standard Torque Specifications 4753
Standard Torque Chart 4753
Special Torque Specifications 4754
Special Tools 4755
524306203 0100YRM1290 (04 2014) US EN 4763
550073240 1900YRM1620 (01 2023) US EN 4867
Proper Flushing after Major Hydraulic Repairs 4873
Introduction 4873
The Phases of Wear 4873
Causes of Hydraulic System Failure 4873
Progression of Contaminant Caused Hydraulic System Failure 4874
Hydraulic System Flushing Techniques 4874
Double Oil and Filter Change 4874
Mechanical Cleaning 4875
Cleaning of Components 4875
How to Clean Tubes and Hoses 4875
Filter Caddy 4875
Start-Up Procedure for Cleaned System 4876
Contaminated Oil Coolers 4876
Additional Filter Caddy Functions 4877
How to Handle Different Fluids 4877
Water Removal Filters 4877
Fluid Conditioning and System Flushing Procedures 4878
Operation of the Filter Caddy 4878
Filter Caddy operation 4878
Fluid Conditioning Procedure 4878
Filter Caddy Start-Up 4879
System Flushing Procedure 4879
Component Cleaning Procedure 4880
Reservoir Cleaning Procedure 4880
Cylinder Cleaning Procedure 4880
Hose and Tube Cleaning Procedure 4880
Valve Cleaning Procedure 4881
Front-End Attachment Cleaning Procedure 4882
System Flushing Procedure 4882
Filter Caddy Start-Up 4883
System Start-Up and Flushing 4883
Reservoir Fluid Cleaning Times 4884
Dealing With Different Fluid Types 4885
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4885
Filter Caddy Maintenance 4885
Servicing the Strainer 4885
DC Motor 4885
Hydraulic Oil Sampling Method and Procedure 4886
Hydraulic Oil Sampling Method 4886
Objective 4886
General Guidelines 4886
Synopsis 4887
Hydraulic Oil Analysis Report Guidelines 4888
Sampling Conditions 4888
Equipment 4888
Sampling Procedure 4889
Hydraulic Oil Sampling 4889
Sample Labeling 4889
Results Documentation 4889
550073240 1900YRM1620 (03 2020) US EN 4891
Proper Flushing after Major Hydraulic Repairs 4895
Introduction 4895
The Phases of Wear 4895
Causes of Hydraulic System Failure 4895
Progression of Contaminant Caused Hydraulic System Failure 4896
Hydraulic System Flushing Techniques 4896
Double Oil and Filter Change 4896
Mechanical Cleaning 4897
Cleaning of Components 4897
How to Clean Tubes and Hoses 4897
Filter Caddy 4897
Start-Up Procedure for Cleaned System 4898
Contaminated Oil Coolers 4898
Additional Filter Caddy Functions 4898
How to Handle Different Fluids 4898
Water Removal Filters 4899
Fluid Conditioning and System Flushing Procedures 4899
Operation of the Filter Caddy 4899
Filter Caddy operation 4899
Fluid Conditioning Procedure 4900
Filter Caddy Start-Up 4900
System Flushing Procedure 4901
Component Cleaning Procedure 4901
Reservoir Cleaning Procedure 4901
Cylinder Cleaning Procedure 4901
Hose and Tube Cleaning Procedure 4902
Valve Cleaning Procedure 4902
Front-End Attachment Cleaning Procedure 4903
System Flushing Procedure 4903
Filter Caddy Start-Up 4904
System Start-Up and Flushing 4904
Reservoir Fluid Cleaning Times 4905
Dealing With Different Fluid Types 4905
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4905
Filter Caddy Maintenance 4906
Servicing the Strainer 4906
DC Motor 4906
Hydraulic Oil Sampling Method and Procedure 4906
Hydraulic Oil Sampling Method 4906
Objective 4906
General Guidelines 4906
Synopsis 4907
Hydraulic Oil Analysis Report Guidelines 4908
Sampling Conditions 4909
Equipment 4909
Sampling Procedure 4909
Hydraulic Oil Sampling 4909
Sample Labeling 4910
Results Documentation 4910
550093750 2100YRM1668 (02 2018) US EN 4913
General 4917
Safety Procedures When Working Near Mast 4918
Main Lift Cylinder Repair 4920
Remove 4920
Disassemble 4922
Clean 4924
Inspect 4924
Assemble 4924
Install 4925
Main Lift Cylinder Leak Check 4925
Free-Lift Cylinder 4926
Remove 4926
Disassemble 4927
Clean 4929
Inspect 4929
Assemble 4929
Install 4929
Tilt Cylinder Repair 4930
Remove 4930
Disassemble 4932
Clean 4934
Inspect 4934
Assemble 4934
Install 4935
Tilt Cylinder Adjustment 4936
Tilt Cylinder Leak Check 4937
Integral Sideshift Cylinder Repair Prior to December 2016 4939
Remove 4939
Disassemble 4940
Clean 4941
Inspect 4941
Assemble 4941
Install 4941
Integral Sideshift Cylinder Repair After December 2016 4942
General 4942
Remove 4942
Disassemble 4944
Clean 4944
Inspect 4944
Assemble 4944
Install 4945
Integral Side-Shift Cylinder Gland Leak Checks 4946
Fork Positioner Cylinder Repair Prior to December 2016 4947
Remove 4947
Disassemble 4947
Clean 4949
Inspect 4950
Assemble 4950
Install 4950
Fork Positioner Cylinder Adjustment 4950
Fork Positioner Cylinder Repair After December 2016 4951
General 4951
Remove 4951
Disassemble 4951
Clean 4954
Inspect 4955
Assemble 4955
Install 4955
Fork Positioner Cylinder Adjustment 4955
Seal Kit Installation 4956
External Installation (Seal and Backup Ring) 4956
Internal Installation (Piston Rod Assembly) 4956
Torque Specifications 4957
Main Lift Cylinders 4957
Free-Lift Cylinder 4957
Tilt Cylinders 4957
Integral Sideshift Cylinder 4957
Fork Positioner Cylinder 4957
550093750 2100YRM1668 (04 2023) US EN 4961
General 4967
Safety Procedures When Working Near Mast 4970
Main Lift Cylinder Repair 4972
Remove 4972
Disassemble 4974
Clean 4976
Inspect 4976
Assemble 4976
Install 4977
Main Lift Cylinder Leak Check 4977
Free-Lift Cylinder 4978
Remove 4978
Disassemble 4979
Clean 4981
Inspect 4981
Assemble 4981
Install 4981
Tilt Cylinder Repair 4983
Remove 4983
Disassemble 4985
Clean 4986
Inspect 4987
Assemble 4987
Install 4988
Tilt Cylinder Adjustment 4988
Tilt Cylinder Leak Check 4990
Integral Sideshift Cylinder Repair Prior to December 2016 4992
Remove 4992
Disassemble 4992
Clean 4993
Inspect 4993
Assemble 4993
Install 4994
Integral Sideshift Cylinder Repair After December 2016 4995
General 4995
Remove 4995
Disassemble 4996
Clean 4997
Inspect 4997
Assemble 4997
Install 4997
Integral Side-Shift Cylinder Gland Leak Checks 4998
Fork Positioner Cylinder Repair Prior to December 2016 4999
Remove 4999
Disassemble 4999
Clean 5002
Inspect 5002
Assemble 5003
Install 5003
Fork Positioner Cylinder Adjustment 5003
Fork Positioner Cylinder Repair After December 2016 5005
General 5005
Remove 5005
Disassemble 5005
Clean 5008
Inspect 5008
Assemble 5009
Install 5009
Fork Positioner Cylinder Adjustment 5009
Seal Kit Installation 5011
External Installation (Seal and Backup Ring) 5011
Internal Installation (Piston Rod Assembly) 5011
Torque Specifications 5012
Main Lift Cylinders 5012
Free-Lift Cylinder 5012
Tilt Cylinders 5012
Integral Sideshift Cylinder 5012
Fork Positioner Cylinder 5012
550093755 4000YRM1669 (04 2023) US EN 5015
General 5023
Safety Procedures When Working Near Mast 5025
Fork Replacement 5027
Standard Carriage and Integral Sideshift Carriage 5027
Remove 5027
Install 5028
Checks 5028
Fork Positioner Carriage 5030
Remove 5031
Install 5031
Checks 5033
Carriages Repair, Two-Stage LFL Mast 5036
Standard Carriage 5036
Remove 5036
Clean and Inspect 5037
Install 5037
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5037
Remove 5037
Disassemble 5039
Clean and Inspect 5040
Assemble 5041
Install 5041
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 5042
Remove 5042
Disassemble 5045
Clean and Inspect 5045
Assemble 5046
Install 5047
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5047
Remove 5047
Disassemble 5050
Clean and Inspect 5050
Assemble 5051
Install 5052
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5052
Remove 5052
Install 5054
Fork Positioner Hydraulic Hose Adjustment 5056
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5057
Remove 5057
Disassemble and Assemble 5061
Clean and Inspect 5061
Install 5061
Fork Positioner Hydraulic Hose Adjustment 5062
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 5063
Remove 5063
Disassemble and Assemble 5067
Clean and Inspect 5067
Install 5067
Fork Positioner Hydraulic Hose Adjustment 5068
Two-Stage LFL Mast Repair 5070
Mast With Serial Number F507 5070
Remove 5070
Disassemble 5074
Clean and Inspect 5081
Assemble 5083
Install 5084
Header Hoses 5086
Remove 5086
Installation 5086
Adjustment 5090
Mast With Serial Number F562 5091
Remove 5091
Disassemble 5095
Clean and Inspect 5102
Assemble 5104
Install 5105
Header Hose Installation and Adjustment 5106
Remove 5106
Installation 5107
Adjustment 5111
Carriages Repair, Three-Stage FFL Mast 5113
Standard Carriage 5113
Remove 5113
Clean and Inspect 5114
Install 5115
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5115
Remove 5115
Disassemble 5116
Clean and Inspect 5117
Assemble 5118
Install 5118
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5119
Remove 5119
Disassemble 5121
Clean and Inspect 5122
Assemble 5123
Install 5123
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5124
Remove 5124
Disassemble 5126
Clean and Inspect 5127
Assemble 5128
Install 5128
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5129
Remove 5129
Install 5131
Fork Positioner Hydraulic Hose Adjustment 5133
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5134
Remove 5134
Disassemble and Assemble 5136
Clean and Inspect 5136
Install 5136
Fork Positioner Hydraulic Hose Adjustment 5137
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 5138
Remove 5138
Disassemble and Assemble 5141
Clean and Inspect 5141
Install 5141
Fork Positioner Hydraulic Hose Adjustment 5142
Three-Stage FFL Mast Repair 5144
Mast With Serial Number F508 5144
Remove 5144
Disassemble 5147
Clean and Inspect 5157
Assemble 5160
Install 5161
Header Hose Installation and Adjustment 5163
Remove 5163
Installation 5163
Adjustment 5172
Mast With Serial Number F563 5172
Remove 5172
Disassemble 5176
Clean and Inspect 5186
Assemble 5189
Install 5190
Header Hose Installation and Adjustment 5192
Remove 5192
Installation 5192
Adjustment 5200
Mast Adjustments 5202
Load Roller, Adjust 5202
Mast Side Kicking, Adjust 5204
Carriage Adjustments 5205
Lift Chains Adjustment 5207
Hydraulic Quick Disconnect Hoses 5209
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) 5209
Lift Trucks Equipped With E-Hydraulic Controls 5209
Lift Trucks Equipped With Manual Hydraulic Controls 5209
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) 5210
Lift Trucks Equipped With E-Hydraulic Controls 5210
Lift Trucks Equipped With Manual Hydraulic Controls 5210
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5210
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5210
550093755 4000YRM1669 (06 2019) US EN 5213
General 5219
Safety Procedures When Working Near Mast 5220
Fork Replacement 5222
Standard Carriage and Integral Sideshift Carriage 5222
Remove 5222
Install 5224
Checks 5224
Fork Positioner Carriage 5226
Remove 5227
Install 5227
Checks 5229
Carriages Repair, Two-Stage LFL Mast 5231
Standard Carriage 5231
Remove 5231
Clean and Inspect 5232
Install 5233
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5233
Remove 5233
Disassemble 5234
Clean and Inspect 5235
Assemble 5236
Install 5236
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 5237
Remove 5237
Disassemble 5240
Clean and Inspect 5240
Assemble 5241
Install 5241
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5242
Remove 5242
Disassemble 5245
Clean and Inspect 5245
Assemble 5246
Install 5246
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5247
Remove 5247
Install 5249
Fork Positioner Hydraulic Hose Adjustment 5251
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5252
Remove 5252
Disassemble and Assemble 5256
Clean and Inspect 5256
Install 5256
Fork Positioner Hydraulic Hose Adjustment 5257
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 5258
Remove 5258
Disassemble and Assemble 5262
Clean and Inspect 5262
Install 5262
Fork Positioner Hydraulic Hose Adjustment 5263
Two-Stage LFL Mast Repair 5264
Mast With Serial Number F507 5264
Remove 5264
Disassemble 5268
Clean and Inspect 5275
Assemble 5277
Install 5278
Header Hoses 5280
Remove 5280
Installation 5280
Adjustment 5284
Mast With Serial Number F562 5285
Remove 5285
Disassemble 5289
Clean and Inspect 5296
Assemble 5298
Install 5299
Header Hose Installation and Adjustment 5300
Remove 5300
Installation 5301
Adjustment 5305
Carriages Repair, Three-Stage FFL Mast 5306
Standard Carriage 5306
Remove 5306
Clean and Inspect 5308
Install 5308
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5308
Remove 5308
Disassemble 5310
Clean and Inspect 5311
Assemble 5312
Install 5312
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5313
Remove 5313
Disassemble 5315
Clean and Inspect 5316
Assemble 5317
Install 5317
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5318
Remove 5318
Disassemble 5320
Clean and Inspect 5321
Assemble 5322
Install 5322
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5323
Remove 5323
Install 5325
Fork Positioner Hydraulic Hose Adjustment 5327
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5328
Remove 5328
Disassemble and Assemble 5330
Clean and Inspect 5330
Install 5330
Fork Positioner Hydraulic Hose Adjustment 5331
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 5332
Remove 5332
Disassemble and Assemble 5335
Clean and Inspect 5335
Install 5335
Fork Positioner Hydraulic Hose Adjustment 5336
Three-Stage FFL Mast Repair 5337
Mast With Serial Number F508 5337
Remove 5337
Disassemble 5341
Clean and Inspect 5351
Assemble 5354
Install 5355
Header Hose Installation and Adjustment 5357
Remove 5357
Installation 5357
Adjustment 5365
Mast With Serial Number F563 5366
Remove 5366
Disassemble 5369
Clean and Inspect 5379
Assemble 5382
Install 5383
Header Hose Installation and Adjustment 5385
Remove 5385
Installation 5385
Adjustment 5393
Mast Adjustments 5394
Load Roller, Adjust 5394
Mast Side Kicking, Adjust 5396
Carriage Adjustments 5396
Lift Chains Adjustment 5398
Hydraulic Quick Disconnect Hoses 5400
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) 5400
Lift Trucks Equipped With E-Hydraulic Controls 5400
Lift Trucks Equipped With Manual Hydraulic Controls 5401
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) 5401
Lift Trucks Equipped With E-Hydraulic Controls 5401
Lift Trucks Equipped With Manual Hydraulic Controls 5402
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5402
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5402
550096306 8000YRM1687 (11 2017) US EN 5405
General 5411
Serial Number Data 5411
How to Move Disabled Lift Truck 5412
How to Tow Lift Truck 5412
How to Put Lift Truck on Blocks 5412
How to Raise Drive Tires 5412
How to Raise Steering Tires 5413
How to Clean a Lift Truck 5414
Maintenance Schedule 5414
Maintenance Procedures Every 8 Hours or Daily 5426
How to Make Checks With Engine Stopped 5427
Tires and Wheels 5427
Safety Labels 5428
Mast, Carriage, Lift Chains, Header Hoses, Attachment 5428
Operator Restraint System 5429
Emergency Locking Retractor (ELR) 5430
Adjust Seat – Full Suspension 5430
Adjust Seat – Internal Suspension 5431
Hood and Seat Latches 5432
Engine Compartment 5432
Paper Application 5432
Fuel, Oil, and Coolant Leaks, Check 5433
Hydraulic Hoses 5433
Coolant Hoses 5433
Steering Column Gas Cylinder 5433
Transmission 5433
Hydraulic System Oil 5433
Engine Oil 5434
Air Filter 5437
Forks 5437
Remove 5437
Inspect 5439
Install 5440
Adjust 5440
Forks 5440
Remove 5440
Inspect 5441
How to Make Checks With Engine Running 5442
Indicator Lights, Horn, Fuses, and Relays 5442
Service Brakes 5444
Brake Fluid Level 5444
Operation, Check 5445
Parking Brake 5445
Engine Oil Pressure 5445
Cooling System 5446
Steering System 5447
Control Levers and Pedals 5447
Lift System, Operate 5447
First Service After First 100 Hours of Operation 5447
Mazda and Kubota Engine Oil and Oil Filter 5448
Yanmar Engine Oil and Oil Filter 5449
Maintenance Procedures Every 250 Hours or 6 Months 5449
Mazda Engine Oil and Oil Filter 5449
Drive Belt 5450
Mazda 2 2L Engines 5450
Fan and Alternator Drive Belt 5450
Kubota 2 5L Engine 5450
Fan and Alternator Drive Belt 5450
Maintenance Procedures Every 500 Hours or 6 Months 5450
Kubota Engine Oil and Oil Filter 5451
Hydraulic System Oil 5451
Hydraulic Tank Breather 5452
Inspect 5452
Battery 5452
Yanmar Engine Oil and Oil Filter 5453
Drive Belt 5454
Yanmar Diesel Engine 5454
Fan and Alternator Drive Belt 5454
PCV Valve, Mazda Engines 5455
Clean Debris From Radiator Core 5455
Transmission Oil Level 5455
Wet Brake Planetary Housing Oil Level Check 5457
Forks 5459
Mast Lubrication 5459
Header Hose Checks 5462
Lift Chain Lubrication 5462
Tilt Cylinder Lubrication 5462
Master Brake Cylinder Rod End Pin Lubrication 5464
Manual Hydraulic Levers Lubrication 5464
Brake Fluid 5465
Tie Rod Lubrication (GP/GLP/GDP040-070VX) 5466
Differential and Drive Axle Oil (Dry Brake) 5466
Maintenance Procedures Every 1000 Hours or 6 Months 5466
Valve Clearance, Check and Adjust 5467
PCV Valve, Kubota Engine 5467
Ignition System 5467
Mazda 2 2L Engines 5467
LPG Fuel Filter Element Replace, Kubota 2 5L Engine 5467
Remove 5467
Install 5468
LPG Vapor Fuel Filter Replace, Mazda Engines 5468
Gasoline Fuel Filter Replacement, Mazda Engines 5469
Remove and Replace 5469
Fuel Filter Replacement, Yanmar Engine 5469
Priming the Fuel System (Yanmar) 5471
Lift Chains Wear Check 5472
Lift Chain Lubrication 5472
Integral Sideshift Carriage, Check Bearings 5473
Integral Sideshift Carriage, Check Lower Mounting Hooks 5473
Steering Axle 5474
Control Levers and Pedals 5474
Maintenance Procedures Every 2000 Hours or Annually 5474
Hydraulic System 5475
Hydraulic Filter, Replace 5475
Hydraulic Tank Breather, Replace 5476
Air Filter 5477
Ignition System 5478
Kubota 2 5L Engine 5478
PCV Valve 5478
Oxygen Sensor 5478
Timing Belt 5479
Mazda Engines 5479
Gasoline Fuel Injector, Mazda Engines 5479
Fuel Injector, Yanmar Engines 5479
Forks 5479
Integral Sideshift Carriage 5479
Bearings, Replace 5479
Transmission Oil and Filter (Dry Brake), Replace 5479
Iron Transmission Housing 5479
Aluminum Transmission Housing 5481
Remove 5481
Clean and Inspect 5482
Install 5482
Transmission Oil Change, Wet Brake Drive Axle 5482
Iron Transmission Housing 5482
Aluminum Transmission Housing 5483
Wet Brake Axle Center Section and Planetary Housing, Oil Change 5486
Brake Fluid (Master Cylinder), Change 5489
Brake Fluid (Dry Brake), Remove 5490
Service Brakes (Dry Brake) 5490
Differential (Dry Brake) 5491
Steering Axle Wheel Bearing Lubrication 5492
Maintenance Procedures Every 4000 Hours or 2 Years 5492
Hydraulic Oil, Replace 5492
Cooling System 5492
Safety Procedures When Working Near Mast 5493
Hood Latch Check 5496
Lift Chain Adjustments 5497
Jump-Starting the Lift Truck 5499
Jump-Starting Using a Battery Charger 5499
Jump-Starting a Lift Truck Using Another Lift Truck 5499
Welding Repairs 5499
Wheel and Tire Replacement 5500
General 5500
Solid Rubber Tire, Change ( Series)GC/GLC 5500
Remove and Install Tire on Wheel 5501
Pneumatic Tire With Tube, Repair 5502
Remove Wheels From Lift Truck 5502
Remove Tire From Wheel 5502
Install Wheel in Tire 5505
Install Tire on Two-Piece Wheel 5507
Add Air to Pneumatic Tires With Tube 5508
Install the Wheels 5509
Dual Drive Wheels, Install 5509
Pneumatic Tubeless Tire, Repair 5510
Remove Wheels From Lift Truck 5510
Add Air to Pneumatic Tubeless Tire 5515
Wheels, Install 5515
Solid Rubber Tires on Pneumatic Wheels, Change 5515
Overhead Guard Changes 5519
Adhesives and Sealants 5519
550096314 0100YRM1672 (04 2014) US EN 5523
550096315 0600YRM1673 (04 2014) US EN 5595
550096316 0600YRM1670 (07 2019) US EN 5635
General 5639
Fan Belt Installation 5639
Remove 5639
Inspect 5639
Installation 5640
Thermostat Repair 5640
Remove 5640
Thermostat Operation Check 5641
Install 5641
Water Pump Repair 5641
Remove 5641
Clean and Inspect 5641
Install 5642
Lubrication System Repair 5642
Oil Pan and Oil Pickup, Remove 5642
Oil Pan and Oil Pickup, Inspection 5642
Oil Pump, Remove 5643
Oil Pump, Inspection 5643
Rotor Lobe Clearance 5643
Rotor Cover Clearance 5644
Oil Pump, Assemble and Install 5644
Oil Pan and Oil Pickup, Assemble and Install 5644
Cylinder Head Repair 5645
Remove and Disassemble 5645
Clean and Inspect 5648
Valve Guides and Seats 5650
Valve Lapping 5650
Valve Guide, Replacement 5650
Valve Seats, Inspection and Repair 5651
Valve and Valve Seat Correction 5651
Valve Springs 5652
Assemble and Install 5653
Valve Clearance Adjustments 5656
Gear Case, Timing Gears, and Camshaft 5658
Gear Case 5658
Fan Drive Pulley, Remove 5658
Fan Drive Pulley, Install 5659
Gear Case, Remove 5659
Gear Case, Install 5659
Timing Gears 5659
Oil Pump, Remove 5659
Oil Pump, Install 5659
Crankshaft Oil Slinger, Remove 5659
Crankshaft Oil Slinger, Install 5660
Idler Gear, Remove 5660
Idler Gear, Install 5660
Camshaft 5660
Camshaft, Remove 5660
Camshaft, Install 5661
Piston and Connecting Rod Assemblies Repair 5661
Disassemble 5661
Piston, Clean and Inspect 5662
Piston Ring Gap 5662
Piston Ring Groove 5663
Connecting Rod and Piston Pin, Clean and Inspect 5663
Cylinder Bores, Clean and Inspect 5664
Cylinder Correction (Oversize) 5666
Assemble 5666
Piston Bore Preparation 5668
Cylinder Wear 5668
Cylinder Correction (Oversize) 5668
Flywheel and Bearing Case Cover 5669
Flywheel, Remove 5669
Bearing Case Cover, Remove 5669
Bearing Case Cover, Install 5670
Flywheel, Install 5670
Crankshaft Repair 5671
Crankshaft, Remove 5671
Inspect and Repair 5672
Crankshaft Journal Oil Clearance Bearing 1 5672
Crankshaft Journal Oil Clearance Bearing 2 5673
Crankshaft Bend 5674
Crankshaft, Install 5674
Crankshaft Side Clearance 5676
Engine Block Cleaning and Inspection 5677
Clean and Inspect 5677
Engine Removal and Installation 5678
Engine Specifications 5678
Engine Data 5678
Torque Specifications 5679
550096317 0700YRM1674 (03 2014) US EN 5681
550096318 0900YRM1675 (04 2018) US EN 5707
General 5711
LPG Tank and Bracket Replacement 5711
Remove LPG Tank 5711
Install LPG Tank 5714
Remove LPG Bracket 5714
Install LPG Bracket 5717
Remove LPG Tank Bracket Alignment Pin 5717
Install LPG Tank Bracket Alignment Pin 5719
Fuel Filter Unit Repair 5720
Fuel Filter Element 5720
Remove 5720
Clean/Inspect 5721
Install 5721
Fuel Filter Housing 5721
Remove 5721
Disassemble 5723
Assemble 5724
Install 5724
Electronic Throttle Body Repair 5725
Remove 5725
Install 5726
Electronic Pressure Regulator (EPR) Repair 5727
Remove 5727
Disassemble 5729
Assemble 5732
Install 5733
LPG Shutoff Valve Assembly 5733
Remove 5733
Install 5735
Fuel Mixer Repair 5736
Remove 5736
Install 5738
Control System 5740
Engine Control Unit (ECU) 5740
Remove 5740
Install 5741
Low LPG Pressure Switch 5742
Remove 5742
Install 5743
LPG Low Level Sensor 5743
Remove 5743
Install 5745
Exhaust System 5746
Counterweight Exhaust System 5746
Remove and Disassemble 5746
Inspect 5748
Assemble and Install 5748
Overhead Exhaust System 5748
Remove and Disassemble 5748
Inspect 5751
Assemble and Install 5751
Exhaust Manifold 5751
Remove 5751
Install 5753
Positive Crankcase Ventilation (PCV) Valve 5753
Remove 5753
Inspect 5753
Install 5753
Oxygen Sensor 5753
Remove 5753
Install 5754
LPG Fuel Testing 5755
General 5755
Available Fuel Tests 5755
Composition Test (ASTM D-2163) 5755
Ammonia Test (ASTM D-4490) 5755
Basic Nitrogen Test (ASTM UOP269-90) 5755
Residues Test (ASTM D-2158) 5755
Vapor Pressure Test (ASTM D-2598) 5755
Sulfur Compounds Test (ASTM D-5623) 5755
Methanol Test (ASTM D-4864) 5756
Copper Corrosion (ASTM D-1838) 5756
Where To Send LPG Fuel Samples For Testing 5756
550096319 0900YRM1676 (04 2014) US EN 5759
550096320 0900YRM1677 (04 2018) US EN 5787
General 5791
LPG Tank and Bracket Replacement 5791
Remove LPG Tank 5791
Install LPG Tank 5794
Remove LPG Bracket 5794
Install LPG Bracket 5797
Remove LPG Tank Bracket Alignment Pin 5797
Install LPG Tank Bracket Alignment Pin 5799
LPG Fuel Filter Unit Repair 5800
LPG Fuel Filter Element 5800
Remove/Disassemble 5800
Clean/Inspect 5801
Assemble/Install 5801
Fuel Filter Housing 5802
Remove 5802
Disassemble 5805
Clean and Inspect 5806
Assemble 5806
Install 5807
Electronic Throttle Body Repair 5807
Remove 5808
Install 5809
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 5810
Remove 5810
Install 5811
Control System 5812
Engine Control Unit (ECU) 5812
Remove 5812
Install 5813
Low LPG Pressure Switch 5813
Remove 5813
Install 5814
LPG Low Level Sensor 5814
Remove 5815
Install 5816
LPG Converter 5817
Remove 5817
Install 5820
LPG Lock-Off Valve 5821
Remove 5821
Install 5823
Exhaust System 5824
Counterweight Exhaust System 5824
Lift Truck Models GLC20-35VX (GLC040-070VX, GLC055SVX) (B910, C910) 5824
Remove and Disassemble 5824
Inspect 5825
Assemble and Install 5825
Lift Truck Models GLP20-35VX (GLP040-070VX) (C875, D875) 5826
Remove and Disassemble 5826
Inspect 5827
Assemble and Install 5828
Overhead Exhaust System 5828
Remove and Disassemble 5828
Inspect 5829
Assemble and Install 5830
Exhaust Manifold 5830
Remove 5830
Install 5831
Oxygen (HEGO) Sensor 5831
Remove 5831
Install 5832
PCV Valve 5832
LPG Fuel Testing 5833
General 5833
Available Fuel Tests 5833
Composition Test (ASTM D-2163) 5833
Ammonia Test (ASTM D-4490) 5833
Basic Nitrogen Test (ASTM UOP269-90) 5833
Residues Test (ASTM D-2158) 5833
Vapor Pressure Test (ASTM D-2598) 5833
Sulfur Compounds Test (ASTM D-5623) 5833
Methanol Test (ASTM D-4864) 5834
Copper Corrosion (ASTM D-1838) 5834
Where To Send LPG Fuel Samples For Testing 5834
550096321 1300YRM1678 (04 2014) US EN 5837
550096322 1400YRM1679 (02 2018) US EN 5905
General 5909
Identification Plate 5909
Drive Axle Removal 5909
Reduction Gear Assembly 5915
Reduction Gear Assembly Repair 5915
Clean and Inspect 5925
Brake Repair 5938
Wet Disc Brake 5938
Clean and Inspect 5954
Wet Brake Noise Reduction 5967
General 5967
Adding Additive To Transmission 5968
Parking Brake Control Lever 5968
General 5968
Clean and Inspect 5971
Differential Repair 5975
Remove 5975
Disassemble 5989
Clean and Inspect 5991
Assemble 5992
Install 5997
Gear Set, Tooth Contact Pattern Check 6011
Drive Axle Installation 6015
Special Tools 6021
Torque Specifications 6024
550096323 1400YRM1680 (01 2023) US EN 6029
General 6035
Drive Axle Repair 6035
Remove and Disassemble 6035
Clean and Inspect 6038
Assemble and Install 6038
Differential Repair 6042
Remove 6042
Disassemble 6054
Clean and Inspect 6061
Install 6072
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 6072
Ring Gear Backlash, Adjust 6089
Ring Gear, Runout Check 6091
Gear Set, Tooth Contact Pattern Check 6091
Torque Specifications 6094
550096323 1400YRM1680 (04 2014) US EN 6097
550096324 1600YRM1681 (04 2014) US EN 6159
550096325 1800YRM1682 (04 2014) US EN 6183
550096326 1900YRM1683 (04 2014) US EN 6217
550096327 2000YRM1684 (01 2016) US EN 6251
General 6255
Electro-Hydraulic Main Control Valve 6256
Description 6256
Remove 6259
Electro-Hydraulic Control Valve Sections 6261
General 6261
Outlet Control Valve Section 6262
Remove 6262
Disassemble 6262
Clean 6264
Inspect 6264
Assemble 6264
Install 6265
Auxiliary Control Valve Sections 6265
Remove 6265
Disassemble 6266
Clean 6266
Inspect 6267
Assemble 6267
Install 6267
Tilt Control Valve Section 6267
Remove 6267
Disassemble 6268
Clean 6269
Inspect 6269
Assemble 6269
Install 6269
Lift/Lower Control Valve Section 6269
Remove 6269
Disassemble 6269
Clean 6271
Inspect 6271
Assemble 6272
Install 6273
Install 6273
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 6275
Lift Pilot Pin 6275
Lower Pilot Pin 6277
Abnormal/Erroneous EHPV Adjustment 6279
Manual Main Control Valve 6279
Description 6279
Remove 6282
OPS Solenoid Assembly 6288
General 6288
Remove 6289
Clean and Inspect 6292
Install 6292
Manual Control Valve Sections 6293
General 6293
Outlet Control Valve Section 6293
Remove 6293
Disassemble 6293
Clean 6296
Inspect 6296
Assemble 6296
Install 6297
Auxiliary Control Valve Sections 6297
Remove 6297
Disassemble 6297
Clean 6300
Inspect 6300
Assemble 6300
Install 6301
Lift/Tilt Control Valve Section 6301
Remove 6301
Disassemble 6301
Clean 6304
Inspect 6304
Assemble 6305
Install 6305
Install 6305
Pressure Relief Valve Check and Adjustment 6310
Primary Relief Valve 6311
Secondary Relief Valve 6311
Steering Control Unit Repair 6312
Steering Control Unit, Remove 6312
Steering Control Unit, Disassemble 6312
Steering Control Unit, Clean 6315
Steering Control Unit, Inspect 6315
Steering Control Unit, Assemble 6315
Relief Valve, Disassemble 6316
Relief Valve, Clean 6316
Relief Valve, Inspect 6317
Relief Valve, Assemble 6317
Steering Control Unit, Install 6317
550096328 2200YRM1685 (04 2014) US EN 6321
550096329 2200YRM1686 (04 2014) US EN 6393
550096330 8000YRM1688 (10 2016) US EN 6423
Lift Truck Lifting Capacity 6427
Counterweight Weights 6427
Tire Sizes 6428
Capacities 6428
Electrical System 6433
Transmission Oil Pressures 6433
Hydraulic System Relief Pressures 6437
Steering System 6438
Stall Speeds (in RPM ±100 rpm) 6439
Mazda 2 2L 6439
Kubota 2 5L 6439
Yanmar 2 6L 6439
Yanmar 3 0L 6439
Yanmar 3 3L 6439
Mast Speeds 6440
Tilt Angles 6444
Front End Equipment – Mast Creep 6445
Mast Creep 6445
Engine Specifications 6446
Torque Specifications 6448
Frame 6448
Mast 6448
Steering System, Cushioned Tire Trucks 6448
Steering System, Pneumatic Tire Trucks 6448
Drive Axle (Dry Brake) 6448
Drive Axle (Wet Brake) 6449
Transmission – Iron Housing 6449
Transmission – Aluminum Housing 6450
Engine – Mazda 2 2L 6450
Engine – Kubota 2 5L 6451
Engine – Yanmar 2 6L, 3 0L and 3 3L Diesel 6452
550096331 8000YRM1689 (03 2020) US EN 6457
General Information About Diagrams and Schematics 6461
Symbol Definitions 6461
Diagrams Manual Applications 6462
Diagrams and Schematics 6464
550096632 1300YRM1690 (04 2014) US EN 6567
550100651 2100YRM1692 (11 2016) US EN 6635
General 6641
Description 6643
Safety Procedures When Working Near Mast 6644
Tilt Cylinder Repair 6646
Remove 6646
Disassemble 6647
Clean 6648
Inspect 6648
Assemble 6649
Install 6649
Tilt Cylinders, Adjust 6650
Tilt Cylinders With Tilt Limit Spacers 6650
Tilt Cylinders Without Tilt Limit Spacers 6650
Tilt Cylinder Leak Check 6651
Main Lift And Free-Lift Cylinders Repair 6651
Main Lift Cylinders 6652
Remove 6652
Two-Stage FFL 6652
Four-Stage FFL 6652
Disassemble 6655
Two-Stage FFL 6655
Four-Stage FFL 6657
Clean 6659
Inspect 6659
Assemble 6659
Two-Stage FFL 6659
Four-Stage FFL 6659
Install 6660
Two-Stage FFL 6660
System Air Bleed Procedures 6660
Four-Stage FFL 6661
Free-Lift Cylinder 6661
Remove 6661
Two-Stage FFL 6661
Four-Stage FFL 6663
Disassemble 6665
Two-Stage FFL 6665
Four-Stage FFL 6666
Clean 6667
Inspect 6667
Assemble 6667
Two-Stage FFL 6667
Four-Stage FFL 6667
Install 6668
Two-Stage FFL 6668
Four-Stage FFL 6668
Lift Cylinder Leak Check 6669
Integral Sideshift Cylinder Repair
Prior to December 2016 6670
Remove 6670
Disassemble 6670
Clean and Inspect 6670
Assemble and Install 6671
Integral Sideshift Cylinder Repair
After December 2016 6673
Remove 6673
Disassemble 6673
Clean and Inspect 6673
Assemble and Install 6674
Fork Positioner Cylinder Repair Prior to December 2016 6676
Remove 6676
Disassemble 6676
Clean 6676
Inspect 6679
Assemble 6679
Install 6680
Fork Positioner Cylinder Adjustment 6680
Fork Positioner Cylinder Repair After December 2016 6681
Remove 6681
Disassemble 6681
Clean 6684
Inspect 6684
Assemble 6685
Install 6685
Fork Positioner Cylinder Adjustment 6685
Seal Kit Installation 6685
External Installation (Seal and Back-Up Ring) 6686
Internal Installation (Piston Rod Assembly) 6686
Torque Specifications 6686
Tilt Cylinders 6686
Piston Rod Nut 6686
Gland 6687
Tilt Cylinder Mounting Capscrew 6687
Tilt Cylinder Rod End Nut 6687
Main Lift and Free-Lift Cylinders 6687
Gland, Main Lift Cylinders 6687
Gland, Free-Lift Cylinder 6687
Piston, Main Lift Cylinders 6687
Main Lift Cylinder Mounting Nut To Outer
Mast 6687
Main Lift Cylinder Mounting Nut To Intermediate
Mast (Four-Stage FFL, Right Cylinder Only) 6687
Retainer Nuts 6687
Chain Guard Capscrew (Free-Lift Cylinder) 6687
Crosshead Mounting Capscrew (Free-Lift Cylinder) 6687
Free-Lift Cylinder Mounting Capscrews 6687
Cylinder Shell Capscrew, Main Lift Cylinders 6687
Fork Positioner 6687
Cylinder Rod Retainer 6687
Fork Positioner Cylinder Mounting Capscrews 6687
Cylinder Rod Anchor Plug 6688
Fork Carrier Capscrews 6688
Hose Guide Capscrews 6688
Integral Sideshift Cylinder 6688
Cylinder Rod Retainer 6688
Gland 6688
550100656 4000YRM1693 (10 2017) US EN 6691
General 6697
Safety Procedures When Working Near Mast 6699
Fork Replacement 6701
Standard Carriage and Integral Sideshift Carriage 6701
Remove 6701
Install 6702
Checks 6702
Fork Positioner Carriage 6704
Remove 6704
Install 6704
Checks 6706
Carriages Repair, Two-Stage FFL Mast 6707
Standard Carriage 6708
Remove 6708
Clean and Inspect 6709
Install 6709
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 6710
Remove 6710
Disassemble 6710
Clean and Inspect 6713
Assemble 6714
Install 6714
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 6715
Remove 6715
Disassemble 6718
Clean and Inspect 6718
Assemble 6718
Install 6719
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 6719
Remove 6719
Install 6720
Fork Positioner Hydraulic Hose Adjustment 6724
Fork Positioner Carriage, Lift Trucks Manufactured After December, 2016 6725
Remove 6725
Disassemble and Assemble 6728
Clean and Inspect 6728
Install 6728
Fork Positioner Hydraulic Hose Adjustment 6729
Two-Stage Mast With Full Free-Lift Repair 6730
Mast With Serial Number E509 6730
Remove 6730
Disassemble 6733
Clean and Inspect 6737
Assemble 6739
Install 6740
Header Hose Procedures 6741
Remove 6741
Installation 6742
Adjustment 6748
Mast With Serial Number E564 6748
Remove 6748
Disassemble 6752
Clean and Inspect 6757
Assemble 6759
Install 6760
Header Hose Procedures 6761
Remove 6761
Installation 6761
Adjustment 6768
Carriages Repair, Four-Stage FFL Mast 6768
Standard Carriage 6768
Remove 6768
Clean and Inspect 6769
Install 6770
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 6771
Remove 6771
Disassemble 6773
Clean and Inspect 6773
Assemble 6774
Install 6774
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 6775
Remove 6775
Disassemble 6775
Clean and Inspect 6778
Assemble 6778
Install 6778
Fork Positioner Carriage 6779
Four-Stage Mast With Full Free-Lift Repair 6780
Mast With Serial Number D515 6780
Remove 6780
Disassemble 6784
Clean and Inspect 6790
Assemble 6792
Install 6795
Header Hose Procedures 6796
Remove 6796
Installation 6796
Adjustment 6804
Carriage Adjustments 6804
Lift Chains Adjustment 6807
Mast Adjustments 6808
Load Roller, Adjust 6809
Mast Side Kicking, Adjust 6811
Hydraulic Quick Disconnect Hoses 6811
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 6811
Lift Trucks Equipped With E-Hydraulic Controls 6811
Lift Trucks Equipped With Manual Hydraulic Controls 6812
Connecting Attachment Hydraulic Quick Disconnect Hoses 6812
Lift Trucks Equipped With E-Hydraulic Controls 6812
Lift Trucks Equipped With Manual Hydraulic Controls 6812