Yale Forklift D810 (GDPGLP030VX, GDPGLP035VX, GDPGLPS040VX) Service Manual PDF

Yale Forklift D810 (GDPGLP030VX, GDPGLP035VX, GDPGLPS040VX) Service Manual – PDF DOWNLOAD

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Yale Forklift D810 (GDPGLP030VX, GDPGLP035VX, GDPGLPS040VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4026
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift D810 (GDPGLP030VX, GDPGLP035VX, GDPGLPS040VX) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797 8000YRM0231 (03 2020) US EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524221866 9000YRM1112 (10 2020) US EN 43
SECTION 9010 Operational Diagnostic Procedures 59
Group 05 – Operational Checkout 61
SECTION 9020 Engine 79
Group 10 – Principles of Operation 89
Group 30 – Observed Symptoms 287
Group 40 – Tests and Adjustments 389
SECTION 9030 Electrical System 421
Group 03 – General Maintenance and Diagnostic Data 445
Group 10 – Principles of Operation 539
Group 20 – Diagnostic Trouble Codes 563
Group 30 – Observed Symptoms 1535
SECTION 9040 Drive Train 1591
Group 10 – Principles of Operation 1595
Group 30 – Observed Symptoms 1651
Group 40 – Tests and Adjustments 1701
SECTION 9050 Hydraulic Systems 1711
Group 10 – Principles of Operation 1715
Group 30 – Observed Symptoms 1773
Group 33 – Observed Symptoms-Gear Pump 1775
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1863
Group 40 – Tests and Adjustments 1907
Group 43 – Tests and Adjustments-Gear Pump 1909
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1933
SECTION 9060 Operators Station 1951
Group 10 – Principles of Operation 1953
SECTION 9070 Front End (Mast) and Chassis 1989
Group 10 – Principles of Operation 1991
Group 30 – Observed Symptoms 2013
SECTION 9080 Supplementary Data 2071
Group 50 – Abbreviations and Acronyms 2073
Group 60 – Special Tools List 2081
Group 70 – Fault Mode Indicator Reference 2091
Group 80 – Supplier Specification Data 2093
524223769 2200YRM1128 (01 2023) US EN 2097
Series Code / Model Designation Reference Table 2105
General 2107
Deutsch Crimping Tool 2108
How to Strip a Wire for Use With Deutsch Crimping Tool 2108
How to Crimp With the Deutsch Crimping Tool 2109
Calibration Test for the Deutsch Crimping Tool 2111
Deutsch Connectors 2113
DT, DTM, and DTP Series Connectors 2113
HD Series Connectors 2156
Metri-Pack Connectors 2178
Remove and Install 2178
Micro-Pack Connectors 2181
Weather-Pack Connectors 2182
AMPSEAL Crimping Tools 2184
AMP Hand Crimping Tool With Certi-Crimp 2184
Description 2184
Stripping Wire for Use with AMP Hand Crimping Tool 2185
Insulation Crimp Adjustment 2186
Maintenance and Inspection for AMP Hand Crimping Tool 2186
AMP Hand Crimping Tool 2186
Crimp Height Inspection 2186
How to use AMP Hand Crimping Tool 2187
AMP Pro-Crimper II Tool 2187
Description 2187
Remove and Install Die Set and Locator Assembly 2188
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2188
Contact Support Adjustment 2189
Crimp Height Adjustment 2190
Maintenance and Inspection Procedures 2190
PRO-CRIMPER II Tool 2190
Crimp Height Inspection 2190
How to Use AMP PRO-CRIMPER II Tool 2191
AMPSEAL Connector Assemblies 2192
Description for Plug Connector Assembly 2192
Seal Plug 2193
Contact Crimping 2193
Description for Plug Connector and Header Assembly 2198
Voltage Reading 2201
Seal Plug 2201
Contact Crimping 2201
AMP Superseal 1 5 Crimping Tools 2208
Mini Mic Receptacle and Tab Contacts 2208
Description 2208
Crimping Conditions and Measurements 2208
Insertion of Rubber Seal on Cable 2210
AMP Hand Application Tool 2215
Description 2215
Maintenance and Inspection 2215
Crimp Height Inspection 2215
Crimp Height Adjustment 2216
How to Use AMP Hand Application Tool 2216
AMP Pro-Crimper II Tool 2217
Description 2217
Remove and Install Die Set and Locator Assembly 2217
Adjustments 2218
Contact Support 2218
Crimp Height 2219
Inspections and Maintenance 2220
Crimp Height Inspection 2220
Visual Inspection 2220
Maintenance 2221
How to Use Pro-Crimper II Tool 2221
AMP Superseal 1 5 Connector Assemblies 2222
Description 2222
Repair and Maintenance 2229
Panel Mount Option 2229
AMP Fastin-Faston Hand Tools 2230
Description – AMP Double Action Hand Tool 2230
Maintenance and Inspection Procedures 2230
Daily Maintenance 2230
Periodic Tool Inspection 2231
Lubrication 2231
Visual Inspection 2231
Crimp Height Inspection 2231
Certi-Crimp Ratchet Inspection 2232
How to Use AMP Double Action Hand Tool 2233
Description – AMP Extraction Tool 2234
Maintenance and Inspection 2235
How to Use AMP Extraction Tool 2235
AMP Fastin-Faston Receptacles and Housings 2237
Description 2237
Wire Repair 2245
Wire Splicing Requirements 2245
Deutsch Jiffy Splice 2246
Twisted/Shielded Cable and Leads Repair 2252
Special Tools 2254
524223769 2200YRM1128 (07 2020) US EN 2263
Series Code / Model Designation Reference Table 2269
General 2272
Deutsch Crimping Tool 2272
How to Strip a Wire for Use With Deutsch Crimping Tool 2272
How to Crimp With the Deutsch Crimping Tool 2273
Calibration Test for the Deutsch Crimping Tool 2275
Deutsch Connectors 2277
DT, DTM, and DTP Series Connectors 2277
HD Series Connectors 2319
Metri-Pack Connectors 2342
Remove and Install 2342
Micro-Pack Connectors 2344
Weather-Pack Connectors 2345
AMPSEAL Crimping Tools 2347
AMP Hand Crimping Tool With Certi-Crimp 2347
Description 2347
Stripping Wire for Use with AMP Hand Crimping Tool 2347
Insulation Crimp Adjustment 2348
Maintenance and Inspection for AMP Hand Crimping Tool 2348
AMP Hand Crimping Tool 2348
Crimp Height Inspection 2348
How to use AMP Hand Crimping Tool 2349
AMP Pro-Crimper II Tool 2349
Description 2349
Remove and Install Die Set and Locator Assembly 2350
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2351
Contact Support Adjustment 2351
Crimp Height Adjustment 2352
Maintenance and Inspection Procedures 2352
PRO-CRIMPER II Tool 2352
Crimp Height Inspection 2352
How to Use AMP PRO-CRIMPER II Tool 2353
AMPSEAL Connector Assemblies 2354
Description for Plug Connector Assembly 2354
Seal Plug 2355
Contact Crimping 2355
Description for Plug Connector and Header Assembly 2360
Voltage Reading 2362
Seal Plug 2362
Contact Crimping 2362
AMP Superseal 1 5 Crimping Tools 2369
Mini Mic Receptacle and Tab Contacts 2369
Description 2369
Crimping Conditions and Measurements 2369
Insertion of Rubber Seal on Cable 2371
AMP Hand Application Tool 2376
Description 2376
Maintenance and Inspection 2376
Crimp Height Inspection 2376
Crimp Height Adjustment 2377
How to Use AMP Hand Application Tool 2377
AMP Pro-Crimper II Tool 2378
Description 2378
Remove and Install Die Set and Locator Assembly 2379
Adjustments 2379
Contact Support 2379
Crimp Height 2380
Inspections and Maintenance 2381
Crimp Height Inspection 2381
Visual Inspection 2381
Maintenance 2382
How to Use Pro-Crimper II Tool 2382
AMP Superseal 1 5 Connector Assemblies 2383
Description 2383
Repair and Maintenance 2390
Panel Mount Option 2390
AMP Fastin-Faston Hand Tools 2391
Description – AMP Double Action Hand Tool 2391
Maintenance and Inspection Procedures 2391
Daily Maintenance 2391
Periodic Tool Inspection 2392
Lubrication 2392
Visual Inspection 2392
Crimp Height Inspection 2392
Certi-Crimp Ratchet Inspection 2393
How to Use AMP Double Action Hand Tool 2394
Description – AMP Extraction Tool 2395
Maintenance and Inspection 2395
How to Use AMP Extraction Tool 2396
AMP Fastin-Faston Receptacles and Housings 2397
Description 2397
Wire Repair 2404
Wire Splicing Requirements 2404
Deutsch Jiffy Splice 2405
Twisted/Shielded Cable and Leads Repair 2410
Special Tools 2413
524223770 2200YRM1130 (03 2020) US EN 2421
General 2425
Description 2425
Dash Display Menu Access 2425
Menu Navigation 2426
Standard Display 2426
Main Menu 2426
Passwords Menu 2427
Password Administration 2427
Add Password 2427
Delete Password 2428
Edit Password 2428
Other Password Functions 2429
Operator Passwords – Enable/Disable 2429
Password Time-Out Delay 2429
Passwords – Number Wrong to Disable 2430
Lockout Reset Password 2430
View Password Log 2431
View Versions 2432
VSM Versions 2432
Dash Display Versions 2433
Engine Controller Version 2434
Transmission (Xmsn) Controller Version 2435
Truck Serial Number 2436
Diagnostics 2437
View Fault Log 2437
Set Travel and Braking 2438
Speed Limit 2438
Acceleration Rate 2439
Auto-Deceleration Rate 2439
Set Power Reversal Rate 2440
Set Inching/Brake Overlap 2441
Setup Display Menu 2442
Set Operator Language 2442
Set Units 2443
Set Time Format (12/24 Hour) 2443
Set Daylight Saving Time 2443
Set Time 2446
Set Date Format 2447
Set Date 2447
Setup Hydraulics 2448
Return to Set Tilt Delay/On/Off 2448
Setup General Items 2449
Light Shutdown Time-Out 2449
Impact Sensor – Enable/Disable 2450
Impact Sensor – Soft Impact Settings 2451
Impact Sensor – Hard Impact Settings 2452
Adjust Impact Sensor Settings 2452
Initial Adjustment of Soft and Hard Impact Settings 2454
Readjustment of Soft and Hard Impact Settings 2454
Impact Sensor – Impact Alarm/Shutdown Reset 2455
Impact Sensor – Alarm Time Duration and Deactivation 2456
Impact Sensor – View Impact Event Log 2457
Engine Mode Indicator 2458
Generation 1 (ECO-eLo ONLY) 2458
Generation 2 2459
Operator Checklist 2460
Operator Checklist Off-On Mode 2460
Edit Operator Checklist 2460
Set Operator Checklist Expiration 2461
View Checklist Log 2461
Clear Operator Checklist Log 2462
Clear Operator Checklist Fault 2462
Calibrations 2463
Set Tilt Stop Point 2463
Calibrate Loaded Weight 2463
524223771 2200YRM1131 (03 2020) US EN 2465
Series Code / Model Designation Reference Table 2471
General 2473
Description 2473
Dash Display Menu Access 2473
Menu Navigation 2474
Main Menu 2474
Passwords 2475
Adding Passwords 2475
Hourmeters 2477
View Versions 2478
VSM Versions 2478
Dash Display Versions 2479
Engine Controller Version 2480
Transmission (Xmsn) Controller Version 2481
Truck Serial Number 2482
Truck Configuration 2483
Diagnostics 2484
Clear Fault Log 2484
View Fault Log 2485
No-Run Data Display 2486
Engine Accelerator and Throttle Data Display 2486
Engine Speeds and Governor Data Display 2487
Engine Fuel and Emissions Data Display 2488
Engine General Data Display 2490
XMSN/Brake Data Display 2491
Hydraulic Data Display 2494
General Truck Data Display 2496
Set Travel and Braking 2497
Speed Limit 2497
Acceleration Rate 2498
Auto-Deceleration Rate 2499
Set Power Reversal Rate 2499
Set Inching/Brake Overlap 2500
Setup Hydraulics 2500
Lift Maximum Speed 2501
Lower Maximum Speed 2501
Tilt Maximum Speed 2502
Auxiliary Function One, Direction A, Maximum Speed 2504
Auxiliary Function One, Direction B, Maximum Speed 2506
Auxiliary Function Two, Direction A, Maximum Speed 2506
Auxiliary Function Two, Direction B, Maximum Speed 2507
Auxiliary Function Three, Direction A, Maximum Speed 2508
Auxiliary Function Three, Direction B, Maximum Speed 2508
Lift/Lower Ramp Rate 2509
Hydraulic Auxiliary Ramp Rate 2509
Return to Set Tilt Delay/On/Off 2510
Hydraulic Input Device 2511
Auxiliary Solenoid 2511
Dual Function 2512
Setup Display 2513
Set Service Language 2513
Setup General Items 2513
Motion Alarm Activation Type 2514
Light Shutdown Time-Out 2515
Restore Default Settings 2515
Restore Engine Controller Default Calibration 2516
Impact Sensor – Enable/Disable 2516
Impact Sensor – Soft Impact Settings 2517
Impact Sensor – Hard Impact Settings 2518
Adjust Impact Sensor Settings 2519
Initial Adjustment of Soft and Hard Impact Settings 2521
Readjustment of Soft and Hard Impact Settings 2521
Impact Sensor – Impact Alarm/Shutdown Reset 2522
Impact Sensor – Alarm Time Duration and Deactivation 2523
Impact Sensor – View Impact Event Log 2524
Engine Mode Indicator 2524
Generation 1 (ECO-eLo ONLY) 2524
Generation 2 2525
Diesel Particulate Filter (DPF) Display 2526
General Description 2526
Passive Regeneration Only 2526
Regeneration Level 0 2526
Auto/Active Regeneration Inhibited 2527
Auto/Active Regeneration 2527
Regeneration Level 1 2527
Parked Regeneration Request 2528
Regeneration Level 2 2528
Warning Level 2528
Regeneration Level 3 2528
Service Level 2529
Regeneration Level 4 2529
Display, Diesel Particulate Filter (DPF), Revised 2529
Operator Interface 2529
Refer to Operator Manual 2529
CAN Communication Lost 2530
Passive Regeneration Only 2530
Regeneration Level 0 2530
Auto/Active Regeneration Inhibited 2530
Auto/Active Regeneration 2531
Regeneration Level 1 2531
Idle-up Auto/Active Regeneration 2531
Parked Regeneration Request 2531
Regeneration Level 2 2531
Warning Level 2533
Regeneration Level 3 2533
Service Level 2533
Regeneration Level 4 2533
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2533
Display, Diesel Particulate Filter (DPF), Stage V Engine 2533
Operator Interface 2534
Refer to Operator Manual 2534
CAN Communication Lost 2534
Passive Regeneration Only 2534
Regeneration Level 0 2534
Auto/Active Regeneration Inhibited 2535
Auto/Active Regeneration 2535
Regeneration Level 1 2535
Idle-up Auto/Active Regeneration 2536
Parked Regeneration Request 2536
Regeneration Level 2 2536
Warning Level 2537
Regeneration Level 3 2537
Service Level 2538
Regeneration Level 4 2538
Stage V Content 2538
Emissions System Malfunction 2538
Ash Load 2538
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2539
Operator Interface 2539
Refer to Operator Manual 2539
CAN Communication Lost 2540
Passive Regeneration Only 2540
Regeneration Level 0 2540
Auto/Active Regeneration Inhibited 2540
Auto/Active Regeneration 2541
Regeneration Level 1 2541
Idle-up Auto/Active Regeneration 2541
Parked Regeneration Request 2541
Regeneration Level 2 2541
Warning Level 2543
Regeneration Level 3 2543
Service Level 2543
Regeneration Level 4 2543
Calibrations 2544
Calibrate Transmission Valve 2546
Set Tilt Stop Point 2546
Calibrate Loaded Weight 2546
Calibrate Travel Speed Sensor 2547
Calibrate Mazda LP and Gas Accelerator Pedal 2547
524223780 8000YRM1134 (03 2020) US EN 2549
Series Code / Model Designation Reference Table 2555
Description 2557
Proc_Cal_001: Service Password Entry 2559
When to Perform 2559
Why Perform 2559
How to Perform 2559
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2560
When to Perform 2560
Calibration Order 2560
Why Perform 2560
How to Perform 2561
Proc_Cal_003: Save and Exit 2562
When to Perform 2562
Why Perform 2562
How to Perform 2562
Proc_Cal_004: Lift Valve Output Threshold 2563
When to Perform 2563
Calibration Order 2563
Why Perform 2563
How to Perform 2564
Proc_Cal_005: Lower Valve Output Threshold 2566
When to Perform 2566
Calibration Order 2566
Why Perform 2566
How to Perform 2566
Proc_Cal_006: Tilt Back Valve Output Threshold 2569
When to Perform 2569
Calibration Order 2569
Why Perform 2569
How to Perform 2569
Proc_Cal_007: Tilt Forward Valve Output Threshold 2572
When to Perform 2572
Calibration Order 2572
Why Perform 2572
How to Perform 2572
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2575
When to Perform 2575
Calibration Order 2575
Why Perform 2575
How to Perform 2575
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2578
When to Perform 2578
Calibration Order 2578
Why Perform 2578
How to Perform 2578
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2581
When to Perform 2581
Calibration Order 2581
Why Perform 2581
How to Perform 2581
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2584
When to Perform 2584
Calibration Order 2584
Why Perform 2584
How to Perform 2584
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2587
When to Perform 2587
Calibration Order 2587
Why Perform 2587
How to Perform 2587
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2590
When to Perform 2590
Calibration Order 2590
Why Perform 2590
How to Perform 2590
Proc_Cal_014: Load Weight Zero Point 2594
When to Perform 2594
Calibration Order 2594
Why Perform 2594
How to Perform 2594
Proc_Cal_015: Loaded Weight Calibration 2596
When to Perform 2596
Calibration Order 2596
Why Perform 2596
How to Perform 2596
Proc_Cal_016: Transmission Valve Calibration 2599
Applicable System/Option 2599
When to Perform 2599
Calibration Order 2599
Why Perform 2599
How to Perform 2599
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2601
Applicable System/Option 2601
When to Perform 2601
Calibration Order 2601
Why Perform 2601
How to Perform 2601
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2603
Applicable System/Option 2603
When to Perform 2603
Calibration Order 2603
Why Perform 2603
How to Perform 2604
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2605
Required Tools 2605
When to Perform 2605
Calibration Order 2605
Why Perform 2606
How to Perform 2606
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2607
When to Perform 2607
Why Perform 2607
How to Perform 2607
Proc_Cal_026: Travel Speed Calibration 2609
When to Perform 2609
Calibration Order 2609
Why Perform 2609
How to Perform 2609
524223780 8000YRM1134 (05 2022) US EN 2613
Series Code / Model Designation Reference Table 2619
Description 2622
Proc_Cal_001: Service Password Entry 2624
When to Perform 2624
Why Perform 2624
How to Perform 2624
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2625
When to Perform 2625
Calibration Order 2625
Why Perform 2625
How to Perform 2625
Proc_Cal_003: Save and Exit 2627
When to Perform 2627
Why Perform 2627
How to Perform 2627
Proc_Cal_004: Lift Valve Output Threshold 2628
When to Perform 2628
Calibration Order 2628
Why Perform 2628
How to Perform 2628
Proc_Cal_005: Lower Valve Output Threshold 2631
When to Perform 2631
Calibration Order 2631
Why Perform 2631
How to Perform 2631
Proc_Cal_006: Tilt Back Valve Output Threshold 2634
When to Perform 2634
Calibration Order 2634
Why Perform 2634
How to Perform 2634
Proc_Cal_007: Tilt Forward Valve Output Threshold 2637
When to Perform 2637
Calibration Order 2637
Why Perform 2637
How to Perform 2637
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2640
When to Perform 2640
Calibration Order 2640
Why Perform 2640
How to Perform 2640
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2643
When to Perform 2643
Calibration Order 2643
Why Perform 2643
How to Perform 2643
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2646
When to Perform 2646
Calibration Order 2646
Why Perform 2646
How to Perform 2646
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2649
When to Perform 2649
Calibration Order 2649
Why Perform 2649
How to Perform 2649
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2652
When to Perform 2652
Calibration Order 2652
Why Perform 2652
How to Perform 2652
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2655
When to Perform 2655
Calibration Order 2655
Why Perform 2655
How to Perform 2655
Proc_Cal_014: Load Weight Zero Point 2658
When to Perform 2658
Calibration Order 2658
Why Perform 2658
How to Perform 2658
Proc_Cal_015: Loaded Weight Calibration 2660
When to Perform 2660
Calibration Order 2660
Why Perform 2660
How to Perform 2660
Proc_Cal_016: Transmission Valve Calibration 2663
Applicable System/Option 2663
When to Perform 2663
Calibration Order 2663
Why Perform 2663
How to Perform 2663
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2665
Applicable System/Option 2665
When to Perform 2665
Calibration Order 2665
Why Perform 2665
How to Perform 2665
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2668
Applicable System/Option 2668
When to Perform 2668
Calibration Order 2668
Why Perform 2668
How to Perform 2668
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2671
Required Tools 2671
When to Perform 2671
Calibration Order 2671
Why Perform 2671
How to Perform 2671
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2673
When to Perform 2673
Why Perform 2673
How to Perform 2673
Proc_Cal_026: Travel Speed Calibration 2675
When to Perform 2675
Calibration Order 2675
Why Perform 2675
How to Perform 2675
524240453 0600YRM1205 (01 2017) US EN 2679
General 2685
Engine Identification 2685
Major Engine Component Identification 2685
Location of Labels 2686
Engine Removal and Installation 2687
Cylinder Head Assembly Repair 2687
Glow Plugs 2690
Remove 2690
Install 2690
Valve Cover 2690
Remove 2690
Clean and Inspect 2691
Install 2691
Rocker Arm Assembly 2691
Remove 2691
Disassemble 2692
Clean and Inspect 2693
Push Rods 2693
Rocker Arm Assembly 2693
Assemble 2693
Install 2694
Valve Clearance Adjustments 2694
Cylinder Head Assembly 2695
Remove 2695
Disassemble 2700
Valves and Valve Springs, Remove 2700
Valve Guides, Remove 2700
Clean and Inspect 2701
Cylinder Head 2701
Valve Guides 2702
Valves 2702
Valve Sink 2702
Valve Seat 2703
Valve Springs 2703
Assemble 2704
Valve Guides, Install 2704
Valves and Valve Springs, Install 2704
Install 2705
Timing Gear Case and Timing Gears Repair 2706
Timing Gear Case Cover 2707
Remove 2707
Clean and Inspect 2707
Install 2708
Timing Gears 2708
Crankshaft Gear 2709
Remove 2709
Install 2709
Idler Gear 2709
Remove 2709
Inspect 2710
Install 2710
Camshaft Gear 2710
Remove 2710
Install 2711
Timing Gear Case 2711
Remove 2711
Clean and Inspect 2712
Install 2712
Drive Train, Camshaft, and Cylinder Block Repair 2713
Remove 2713
Disassemble 2714
Pistons and Connecting Rods 2714
Crankshaft 2714
Camshaft 2717
Clean and Inspect 2718
Cylinder Block 2718
Honing and Boring 2721
Pistons 2722
Piston Pin 2722
Connecting Rod 2723
Tappets 2723
Crankshaft 2724
Camshaft 2725
Camshaft Bushing 2726
Assemble 2726
Camshaft 2726
Crankshaft 2726
Pistons and Connecting Rods 2727
Install 2728
Lubrication System Repair 2729
Engine Oil and Oil Filter Change 2729
Oil Pan 2729
Remove 2729
Install 2730
Oil Suction Tube 2730
Remove 2730
Clean 2731
Install 2731
Oil Pump 2731
Remove 2731
Clean and Inspect 2732
Outer Rotor Outside Clearance 2732
Outer Rotor to Inner Rotor Tip Clearance 2733
Outer Rotor Side Clearance 2733
Rotor Shaft Clearance 2733
Install 2734
Fuel System Repair 2734
Fuel Injectors 2735
Remove 2735
Inspect 2736
Clean 2736
Test 2736
Install 2739
Electronic Throttle System 2739
Remove 2739
Install 2742
Inspect 2743
Adjust 2744
Manual Throttle System 2745
Fuel Injection Pump 2745
Remove 2745
Clean and Inspect 2749
Install 2749
Check/Adjust Fuel Injection Timing 2750
Cooling System Repair 2752
V-Belt 2752
Remove 2752
Inspect 2752
Install 2752
Adjust 2752
Water Pump 2754
4TNE92-NMHA, 4TNE92-NMHA/580090035, 4TNE92-SNMU, and 4TNE98-SNMU Engines 2754
Remove 2754
Install 2755
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/580090036, and 4TNE98-BNMH Engines 2756
Remove 2756
Install 2757
Thermostat 2759
Remove 2759
Inspect 2760
Install 2760
Flywheel and Flywheel Housing 2760
Flywheel 2761
Remove 2761
Install 2762
Flywheel Housing 2762
Remove 2762
Install 2762
Electrical Equipment Repair 2764
Alternator 2764
Remove 2764
Bench Test 2766
Regulate Voltage Check 2766
No Load Test 2768
Output Test 2768
Install 2768
Starter 2769
Remove 2770
No Load Test 2770
Install 2771
Engine Specifications 2772
Engine Data 2772
Engine Tuning 2780
Cylinder Head 2780
Intake/Exhaust Valve and Guide 2781
Valve Spring 2781
Rocker Arm and Shaft 2781
Push Rod 2782
Gear Train and Camshaft 2782
Camshaft 2782
Idle Gear Shaft and Bushing 2782
Backlash of Each Gear 2783
Cylinder Block 2783
Crankshaft 2783
Thrust Bearing 2784
Piston 2784
Piston Ring 2784
Connecting Rod 2785
Rod Small End 2785
Tappet 2785
Oil Pump 2786
Engine Oil Pressure 2786
Outer Rotor Outside Clearance 2786
Outer Rotor Side Clearance 2786
Outer Rotor to Inner Rotor Tip Clearance 2786
Rotor Shaft Clearance 2786
Standard Torque Specifications 2787
Standard Torque Chart 2787
Special Torque Specifications 2788
Special Tools 2789
550073240 1900YRM1620 (01 2023) US EN 2797
Proper Flushing after Major Hydraulic Repairs 2803
Introduction 2803
The Phases of Wear 2803
Causes of Hydraulic System Failure 2803
Progression of Contaminant Caused Hydraulic System Failure 2804
Hydraulic System Flushing Techniques 2804
Double Oil and Filter Change 2804
Mechanical Cleaning 2805
Cleaning of Components 2805
How to Clean Tubes and Hoses 2805
Filter Caddy 2805
Start-Up Procedure for Cleaned System 2806
Contaminated Oil Coolers 2806
Additional Filter Caddy Functions 2807
How to Handle Different Fluids 2807
Water Removal Filters 2807
Fluid Conditioning and System Flushing Procedures 2808
Operation of the Filter Caddy 2808
Filter Caddy operation 2808
Fluid Conditioning Procedure 2808
Filter Caddy Start-Up 2809
System Flushing Procedure 2809
Component Cleaning Procedure 2810
Reservoir Cleaning Procedure 2810
Cylinder Cleaning Procedure 2810
Hose and Tube Cleaning Procedure 2810
Valve Cleaning Procedure 2811
Front-End Attachment Cleaning Procedure 2812
System Flushing Procedure 2812
Filter Caddy Start-Up 2813
System Start-Up and Flushing 2813
Reservoir Fluid Cleaning Times 2814
Dealing With Different Fluid Types 2815
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2815
Filter Caddy Maintenance 2815
Servicing the Strainer 2815
DC Motor 2815
Hydraulic Oil Sampling Method and Procedure 2816
Hydraulic Oil Sampling Method 2816
Objective 2816
General Guidelines 2816
Synopsis 2817
Hydraulic Oil Analysis Report Guidelines 2818
Sampling Conditions 2818
Equipment 2818
Sampling Procedure 2819
Hydraulic Oil Sampling 2819
Sample Labeling 2819
Results Documentation 2819
550073240 1900YRM1620 (03 2020) US EN 2821
Proper Flushing after Major Hydraulic Repairs 2825
Introduction 2825
The Phases of Wear 2825
Causes of Hydraulic System Failure 2825
Progression of Contaminant Caused Hydraulic System Failure 2826
Hydraulic System Flushing Techniques 2826
Double Oil and Filter Change 2826
Mechanical Cleaning 2827
Cleaning of Components 2827
How to Clean Tubes and Hoses 2827
Filter Caddy 2827
Start-Up Procedure for Cleaned System 2828
Contaminated Oil Coolers 2828
Additional Filter Caddy Functions 2828
How to Handle Different Fluids 2828
Water Removal Filters 2829
Fluid Conditioning and System Flushing Procedures 2829
Operation of the Filter Caddy 2829
Filter Caddy operation 2829
Fluid Conditioning Procedure 2830
Filter Caddy Start-Up 2830
System Flushing Procedure 2831
Component Cleaning Procedure 2831
Reservoir Cleaning Procedure 2831
Cylinder Cleaning Procedure 2831
Hose and Tube Cleaning Procedure 2832
Valve Cleaning Procedure 2832
Front-End Attachment Cleaning Procedure 2833
System Flushing Procedure 2833
Filter Caddy Start-Up 2834
System Start-Up and Flushing 2834
Reservoir Fluid Cleaning Times 2835
Dealing With Different Fluid Types 2835
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2835
Filter Caddy Maintenance 2836
Servicing the Strainer 2836
DC Motor 2836
Hydraulic Oil Sampling Method and Procedure 2836
Hydraulic Oil Sampling Method 2836
Objective 2836
General Guidelines 2836
Synopsis 2837
Hydraulic Oil Analysis Report Guidelines 2838
Sampling Conditions 2839
Equipment 2839
Sampling Procedure 2839
Hydraulic Oil Sampling 2839
Sample Labeling 2840
Results Documentation 2840
550108490 0100YRM1735 (04 2015) US EN 2843
550108491 0600YRM1736 (10 2018) US EN 2901
General 2907
Engine Identification 2907
Major Engine Component Identification 2907
Location of Labels 2908
Engine Removal and Installation 2909
Cylinder Head Assembly Repair 2909
Drive Train and Lubrication System 2941
Remove 2942
Disassemble 2942
Oil Pan 2942
Oil Pump (Front Cover) 2944
Clean and Inspect 2945
Front Case 2945
Oil Seal 2945
Counterbalance Shaft 2945
Oil Pump 2945
Assemble 2946
Counterbalance Shaft Bearings 2946
Oil Pump (Front Cover) 2947
Oil Pan 2949
Install 2949
Crankshaft and Cylinder Block Repair 2949
Remove Major Attaching Components 2949
Crankshaft and Cylinder Block 2950
Remove 2950
Clean and Inspect 2951
Boring Cylinder 2952
Install 2953
Piston and Connecting Rod 2955
Remove 2955
Disassemble 2956
Clean and Inspect 2956
Assemble 2957
Install 2959
Piston 2959
Rod Bearing 2960
Install Major Attaching Components 2961
Fuel System Repair 2961
Cooling System Repair 2961
Electrical Equipment Repair 2961
Flywheel and Flywheel Housing 2961
Flywheel 2961
Remove 2961
Install 2962
Flywheel Housing 2962
Remove 2962
Install 2962
Engine Specifications 2962
Engine Data 2962
Engine Tuning 2963
Cylinder Head 2964
Intake/Exhaust Valve and Guide 2964
Valve Spring 2964
Gear Train and Camshaft 2964
Camshaft 2964
Idle Gear Shaft and Bushing 2965
Cylinder Block 2965
Crankshaft 2965
Piston 2965
Piston Ring 2966
Connecting Rod 2966
Oil Pump 2966
Engine Oil Pressure 2966
Drive Gear Clearance 2966
Driven Gear Clearance 2966
Torque Specifications 2967
Special Tools 2968
550108492 0700YRM1737 (12 2014) US EN 2975
550108494 0900YRM1739 (04 2018) US EN 2989
General 2993
LPG Tank and Bracket Replacement 2995
Remove LPG Tank 2995
Install LPG Tank 2998
Remove LPG Tank Bracket 2999
Install LPG Tank Bracket 3001
Remove LPG Tank Bracket Alignment Pin 3001
Install LPG Tank Bracket Alignment Pin 3003
LPG Fuel Filter Unit Repair 3004
LPG Fuel Filter Element 3004
Remove/Disassemble 3004
Clean/Inspect 3005
Assemble/Install 3005
Fuel Filter Housing 3006
Remove 3006
Disassemble 3008
Clean and Inspect 3009
Assemble 3009
Install 3010
Electronic Throttle Body Repair 3011
Remove 3011
Install 3012
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 3013
Remove 3014
Install 3015
Control System 3016
Engine Control Module (ECM) 3016
Remove 3016
Install 3016
Low LPG Pressure Switch 3017
Remove 3017
Install 3018
LPG Low Level Sensor 3019
Remove 3019
Install 3019
LPG Converter 3020
LPG Lock-Off Valve 3024
Remove 3024
Install 3025
Exhaust System 3026
Counterweight Exhaust System 3026
Lift Truck Models GLC030-035VX, GLC040SVX (D809) and GLP16-18VX, GLP20SVX (GLP030-035VX, GLP040SVX) (D810) 3028
Remove and Disassemble 3028
Inspect 3029
Assemble and Install 3030
Overhead Exhaust System 3030
Overhead Exhaust System With Catalytic Converter, Lift Truck Models GLP16-18VX, GLP20SVX (GLP030-035VX, GLP040SVX) (D810) 3032
Remove and Disassemble 3032
Inspect 3032
Assemble and Install 3032
Overhead Exhaust System Without Catalytic Converter, Lift Truck Models GLP16-18VX, GLP20SVX (D810) 3034
Remove and Disassemble 3034
Inspect 3034
Assemble and Install 3034
Exhaust Manifold 3036
Remove 3036
Clean and Inspect 3036
Install 3036
Oxygen (HEGO) Sensor 3037
Remove 3037
Install 3038
PCV Valve 3038
LPG Fuel Testing 3039
General 3039
Available Fuel Tests 3039
Composition Test (ASTM D-2163) 3039
Ammonia Test (ASTM D-4490) 3039
Basic Nitrogen Test (ASTM UOP269-90) 3039
Residues Test (ASTM D-2158) 3039
Vapor Pressure Test (ASTM D-2598) 3039
Sulfur Compounds Test (ASTM D-5623) 3039
Methanol Test (ASTM D-4864) 3040
Copper Corrosion (ASTM D-1838) 3040
Where To Send LPG Fuel Samples For Testing 3040
550108495 1300YRM1740 (06 2018) US EN 3043
General 3047
Serial Number 3047
Hydraulic Gear Pump 3047
Remove 3047
Install 3047
Housing Fittings Replacement 3048
Remove 3048
Install 3050
Charge Pump Repair 3050
Torque Converter Replacement 3053
Remove 3053
Clean and Inspect 3053
Install 3053
Stator Support Assembly Repair 3054
Remove 3054
Disassemble 3061
Clean 3062
Inspect 3062
Assemble 3063
Install 3063
Clutch Packs Repair 3065
Remove 3065
Disassemble 3067
Housings 3067
Clutch Packs 3070
Clean 3081
Inspect 3082
Assemble 3082
Clutch Packs 3082
Housings 3096
Install 3098
Drive Chains and Sprockets 3101
Remove 3101
Clean 3103
Inspect 3104
Install 3104
Proportional and Enable Solenoid Valves 3104
Proportional Valves 3104
Remove 3104
Disassemble 3106
Clean and Inspect 3107
Assemble 3107
Install 3107
Enable Solenoid Valve 3107
Remove 3107
Disassemble 3108
Clean and Inspect 3108
Assemble 3108
Install 3108
Pedal Repair Foot Directional Control 3109
Remove and Disassemble 3109
Clean and Inspect 3112
Assemble and Install 3113
550108496 1400YRM1741 (12 2014) US EN 3117
550108497 1600YRM1742 (12 2014) US EN 3165
550108498 1800YRM1743 (06 2018) US EN 3187
General 3191
Dry Brake System 3191
Wet Brake System 3191
Service Brakes Repair (Dry Brake) 3191
Remove and Disassemble 3192
Clean 3199
Inspect 3200
Assemble and Install 3200
Adjust 3208
Inching Overlap Adjustment 3208
Parking Brake Repair 3209
Remove and Disassemble 3209
Dry Brake System 3209
Wet Brake System 3211
Assemble and Install 3213
Dry Brake System 3213
Wet Brake System 3213
Adjust 3213
Master Cylinder Repair 3214
Remove (Dry Brake) 3214
Disassemble (Dry Brake) 3215
Clean and Inspect (Dry Brake) 3217
Assemble (Dry Brake) 3217
Bench Bleed Master Cylinder (Dry Brake) 3217
Install and Adjust (Dry Brake) 3217
Remove (Wet Brake) 3218
Disassemble (Wet Brake) 3219
Clean and Inspect (Wet Brake) 3220
Assemble (Wet Brake) 3221
Install and Adjust (Wet Brake) 3221
Service Brakes Adjustment (Dry Brake) 3222
Brake System Air Removal 3222
Using Pressure Bleed System 3222
Using Brake Pedal Pressure 3222
Brake Pedal Adjustment 3223
Free Pedal Adjustment 3224
Torque Specifications 3226
550108499 1900YRM1744 (06 2018) US EN 3229
General 3233
Hydraulic Gear Pump Assembly Repair 3234
Remove 3234
Disassemble 3238
Clean 3240
Inspect 3240
Assemble 3240
Install 3240
Quick-Lok™ Hydraulic Hose 3242
Hydraulic Gear Pump Specifications 3243
Variable Displacement Pump Repair 3245
Remove 3245
Disassemble 3250
Clean 3252
Inspect 3252
Assemble 3252
Install 3252
Variable Displacement Pump Checks and Adjustments 3255
Margin Pressure Check 3255
Flow Compensator Adjustment 3256
Pressure Compensator Adjustment 3256
Variable Displacement Pump Specifications 3257
Torque Specifications 3257
Hydraulic Gear Pump 3258
Variable Displacement Pump 3258
550108500 2000YRM1745 (06 2018) US EN 3261
General 3265
Electro-Hydraulic Main Control Valve 3265
Description 3265
Remove 3268
Electro-Hydraulic Control Valve Sections 3271
General 3271
Outlet Control Valve Section 3271
Remove 3271
Disassemble 3271
Clean 3273
Inspect 3273
Assemble 3273
Install 3274
Auxiliary Control Valve Sections 3274
Remove 3274
Disassemble 3276
Clean 3277
Inspect 3277
Assemble 3277
Install 3277
Tilt Control Valve Section 3278
Remove 3278
Disassemble 3278
Clean 3279
Inspect 3279
Assemble 3280
Install 3280
Lift/Lower Control Valve Section 3280
Remove 3280
Disassemble 3280
Clean 3282
Inspect 3282
Assemble 3283
Install 3283
Install 3283
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 3286
Lift Pilot Pin 3286
Lower Pilot Pin 3288
Abnormal/Erroneous EHPV Adjustment 3290
Manual Main Control Valve 3290
Description 3290
Remove 3293
OPS Solenoid Assembly 3299
General 3299
Remove 3300
Clean and Inspect 3302
Install 3302
Manual Control Valve Sections 3303
General 3303
Outlet Control Valve Section 3303
Remove 3303
Disassemble 3303
Clean 3306
Inspect 3306
Assemble 3306
Install 3307
Auxiliary Control Valve Sections 3307
Remove 3307
Disassemble 3307
Clean 3310
Inspect 3310
Assemble 3310
Install 3310
Lift/Tilt Control Valve Section 3311
Remove 3311
Disassemble 3311
Clean 3316
Inspect 3316
Assemble 3316
Install 3317
Install 3317
Pressure Relief Valve Check and Adjustment 3321
Primary Relief Valve 3322
Secondary Relief Valve 3323
Steering Control Unit Repair 3327
Steering Control Unit, Remove 3327
Steering Control Unit, Disassemble 3329
Steering Control Unit, Clean 3331
Steering Control Unit, Inspect 3331
Steering Control Unit, Assemble 3331
Relief Valve, Disassemble 3332
Relief Valve, Clean 3332
Relief Valve, Inspect 3333
Relief Valve, Assemble 3333
Steering Control Unit, Install 3333
550108501 2100YRM1746 (02 2018) US EN 3337
Safety Procedures When Working Near Mast 3341
General 3343
Tilt Cylinder Repair 3344
Remove 3345
Disassemble 3346
Clean 3348
Inspect 3348
Assemble 3348
Install 3349
Adjust Tilt Cylinders 3350
Lift Cylinder Repair 3351
Main Lift Cylinders 3351
Remove 3351
Disassemble 3353
Two-Stage FFL 3353
Three-Stage FFL 3355
Two-Stage LFL 3356
Clean 3356
Inspect 3356
Assemble 3357
Two-Stage FFL 3357
Three-Stage FFL 3357
Two-Stage LFL 3357
Install 3358
System Air Bleed Procedures 3358
Free-Lift Cylinder Repair 3359
Remove 3359
Two-Stage FFL 3359
Three-Stage FFL 3359
Disassemble 3361
Clean 3361
Inspect 3361
Assemble 3362
Install 3362
Two-Stage FFL 3362
Three-Stage FFL 3363
All Free-Lift Cylinders 3363
Sideshift Cylinder Repair Prior to December 2016 3364
Remove 3364
Disassemble 3365
Clean and Inspect 3365
Assemble 3365
Install 3366
Sideshift Cylinder Repair After December 2016 3366
Remove 3366
Disassemble 3368
Clean and Inspect 3368
Assemble 3368
Install 3369
Integral Side-Shift Cylinder Gland Leak Checks 3369
Fork Positioner Cylinder Repair Prior to December 2016 3370
Remove 3370
Disassemble 3370
Clean 3374
Inspect 3374
Assemble 3375
Install 3375
Fork Positioner Cylinder Adjustment 3375
Fork Positioner Cylinder Repair After December 2016 3376
Remove 3376
Disassemble 3376
Clean 3379
Inspect 3380
Assemble 3380
Install 3380
Fork Positioner Cylinder Adjustment 3380
Seal Kit Installation 3381
External Installation (Seal and Back-Up Ring) 3381
Internal Installation (Piston Rod Assembly) 3382
Torque Specifications 3382
Tilt Cylinders 3382
Main Lift Cylinder 3382
Free-Lift Cylinder 3382
Sideshift Cylinder 3382
Fork Positioner Cylinder 3382
550108502 2200YRM1747 (01 2020) US EN 3387
General 3393
Display Switch Cluster 3394
Remove 3394
Install 3396
Direction Control Lever 3396
Remove 3396
Install 3397
Key Switch 3397
Remove 3397
Install 3398
Display Switch Cluster Panel Bezel and Overlay 3398
Remove 3398
Install 3398
Steering Column Repair 3399
Remove 3399
Disassemble 3400
Assemble 3400
Install 3401
Sensors and Switches 3401
General 3401
Dash Panel, Kick Panel, and Seal Plate, Remove and Install 3401
Remove 3401
Install 3402
Accelerator Pedal Position Sensor 3402
Remove 3402
Install 3404
Brake Fluid Level Switch 3404
Remove 3404
Install 3405
Brake Pedal Position Sensor 3406
Remove 3406
Install 3407
Service Brake Pressure Sensor 3407
Remove 3407
Install 3407
Parking Brake Position Sensor 3407
Remove 3407
Install 3408
Seat Sensor (Operator Presence System) 3408
Non-Suspension Seat 3408
Remove 3408
Install 3409
Full Suspension Seats 3410
Remove 3410
Install 3410
Transmission Pressure Sensors (Transducers) 3410
Remove 3410
Install 3411
Transmission Temperature Sensor 3411
Remove 3411
Install 3411
Transmission Speed Sensor 3411
Remove 3411
Install 3411
Rear Horn Button Switch 3411
Remove 3411
Install 3412
Engine and Fuel Sensors and Switches, PSI 2 0L LPG Trucks 3412
Engine and Fuel Sensors, Yanmar 2 6L Diesel Trucks 3412
Engine Speed Sensor 3412
Remove 3412
Install 3414
Oil Pressure Sensor 3414
Remove 3414
Install 3414
Engine Coolant Temperature (ECT) Sensor 3414
Remove 3414
Install 3414
Fuel/Water Separator Sensor 3415
Remove 3415
Install 3415
Glow Plug Relay 3416
Remove 3416
Install 3418
Air Filter Restriction Switch 3418
Remove 3418
Install 3418
Throttle Position Sensor (TPS) 3418
Remove 3418
Install 3419
Sensor MicroswitchFoot Directional Control 3419
Remove 3419
Install 3421
Low Coolant Level Sensor 3421
Remove 3421
Install 3422
Fuel Level Sensor, Diesel Engine Only 3422
Remove 3422
Install 3422
Hydraulic Filter Pressure Switch 3423
Remove 3423
Install 3423
Return To Set Tilt (Tilt Angle) Sensor 3423
Remove 3423
Install 3424
Impact Sensor 3424
Remove 3424
Install 3425
Load Weight Sensor 3427
Remove 3427
Install 3427
Power Distribution Module (PDM) and Component Parts 3429
Power Distribution Module (PDM) as a Unit 3429
Remove 3429
Install 3431
Power Distribution Module (PDM) Components 3431
Remove and Install 3431
Battery 3432
Remove 3432
Install 3432
Lights 3432
Work Lights (Front and Rear) 3432
Remove 3432
Install 3432
Strobe Light 3433
Remove 3433
Install 3433
LED Tail, Backup, and Brake Lights 3434
Remove 3434
Install 3435
Front Marker/Turn Signal Lights 3435
Replacing Whole Front Marker/Turn Signal
Light Assembly 3435
Remove 3435
Install 3435
Replacing Just the Front Marker/Turn Signal
Light LED Light Lens 3435
Remove 3435
Install 3435
Vehicle System Manager (VSM) 3436
General 3436
VSM Replacement 3436
Remove 3436
Install 3437
Programming a New VSM and/or Display Switch Cluster 3438
Data Transferring 3438
New VSM 3438
New (Blank) Display Switch Cluster 3438
Used (Non-Blank) Display Switch Cluster 3438
PC Service Tool Software 3439
Electronic-Hydraulic Controls, Before January, 2020 3440
E-Hydraulic Controls – Test 3440
Mini-Levers 3440
Full Stroke Test 3440
Function Returns to Neutral Test 3441
Push (Override) Button 3441
General 3441
Mini-levers, Remove and Install 3442
Armrest Assembly 3443
Remove 3443
Install 3445
Horn Button 3445
Remove 3445
Install 3445
Direction Control Switch 3446
Remove 3446
Install 3446
Push (Override) Buttons and Toggle Switch 3446
Remove 3447
Install 3448
Electronic-Hydraulic Controls, After January, 2020 3449
E-Hydraulic Controls – TEST 3449
Mini-Levers 3449
Full Stroke Test 3449
Function Returns to Neutral Test 3449
Push (Override) Button 3450
General 3450
Mini-levers, Remove and Install 3450
Armrest Assembly 3451
Remove 3451
Install 3454
Horn Button 3454
Remove 3454
Install 3455
Direction Control Switch 3455
Remove 3455
Install 3455
Push (Override) Buttons 3456
Remove 3456
Install 3457
550108503 2200YRM1748 (05 2017) US EN 3459
General 3463
Ignition System 3463
Ignition Timing Adjustment 3463
Spark Plugs Check 3463
Coil Replacement 3464
Remove 3464
Inspect 3466
Install 3466
Starter Repair 3467
General 3467
Remove 3468
No-Load Test 3468
Magnetic Switch Test 3469
Pull-Out Test 3469
Holding Coil Test 3469
Return Test 3470
Pinion Movement Inspection 3470
Install 3470
Alternator Repair 3471
General 3471
Charging System Inspection 3472
Output Current Check 3472
No-Load Adjusted Voltage Check 3473
Remove 3473
Install 3473
Engine Sensors and Switches 3475
Oil Pressure Sensor 3475
Remove 3475
Install 3475
Air Filter Restriction Switch 3475
Remove 3475
Install 3475
Cam Angle Sensor 3476
Remove 3476
Install 3476
Crankshaft Position Sensor (CKP) 3476
Remove 3476
Install 3476
Temperature Manifold Absolute Pressure (TMAP) Sensor 3478
Remove 3478
Install 3478
Engine Coolant Temperature (ECT) Sensor 3478
Remove 3478
Install 3478
Battery Disconnect Switch, Safety Option 3479
Remove 3479
Install 3480
Electronic Control Module 3480
550108504 4000YRM1749 (10 2017) US EN 3483
General 3489
Safety Procedures When Working Near Mast 3491
Fork Replacement 3492
Remove 3493
Install 3493
Checks 3494
Fork Positioner Carriage 3496
Remove 3496
Install 3498
Checks 3498
Carriages Repair, Two-Stage LFL Mast 3500
Standard Carriage 3500
Remove 3500
Repair 3501
Install 3502
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3502
Remove 3502
Clean and Inspect 3505
Repair 3505
Install 3506
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3507
Remove 3507
Disassemble 3510
Clean and Inspect 3510
Assemble 3510
Install 3511
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 3512
Remove 3512
Disassemble and Assemble 3514
Clean and Inspect 3514
Install 3514
Fork Positioner Hydraulic Hose Adjustment 3516
Fork Positioner, Lift Trucks Manufactured After December, 2016 3517
Remove 3517
Disassemble and Assemble 3519
Clean and Inspect 3519
Install 3519
Fork Positioner Hydraulic Hose Adjustment 3521
Two-Stage LFL Mast Repair 3522
Mast With Serial Number B551 3522
Remove 3522
Disassemble 3524
Clean and Inspect 3525
Assemble 3528
Mast, Install 3529
Two-Stage LFL Mast, Header Hose Arrangement 3531
General 3531
Installation Procedures 3531
Adjustment 3538
Carriages Repair, Two-Stage FFL Mast 3538
Standard Carriage 3538
Remove 3538
Repair 3539
Install 3539
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3540
Remove 3540
Clean and Inspect 3543
Repair 3543
Install 3543
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3544
Remove 3544
Disassemble 3547
Clean and Inspect 3547
Assemble 3547
Install 3548
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 3549
Remove 3549
Clean and Inspect 3549
Disassemble and Assemble 3549
Install 3549
Fork Positioner Hydraulic Hose Adjustment 3553
Fork Positioner, Lift Trucks Manufactured After December, 2016 3554
Remove 3554
Disassemble and Assemble 3556
Clean and Inspect 3556
Install 3556
Fork Positioner Hydraulic Hose Adjustment 3557
Two-Stage FFL Mast Repair 3558
Mast With Serial Number B559 3558
Remove 3558
Disassemble 3561
Clean and Inspect 3564
Assemble 3565
Mast, Install 3566
Two-Stage FFL Mast, Header Hose Arrangement 3568
General 3569
Installation Procedure 3569
Adjustment 3573
Carriages Repair, Three-Stage FFL Mast 3577
Standard Carriage 3577
Remove 3577
Repair 3578
Install 3579
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3579
Remove 3579
Clean and Inspect 3582
Repair 3582
Install 3582
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3583
Remove 3583
Disassemble 3586
Clean and Inspect 3586
Assemble 3586
Install 3587
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 3588
Remove 3588
Clean and Inspect 3588
Disassemble and Assemble 3588
Install 3588
Fork Positioner Hydraulic Hose Adjustment 3591
Fork Positioner, Lift Trucks Manufactured After December, 2016 3592
Remove 3592
Disassemble and Assemble 3596
Clean and Inspect 3596
Install 3596
Fork Positioner Hydraulic Hose Adjustment 3597
Three-Stage FFL Mast Repair 3598
Mast With Serial Number B555 3598
Remove 3598
Disassemble 3600
Clean and Inspect 3601
Assemble 3604
Mast, Install 3605
Three-Stage FFL Mast, Header Hose Arrangement 3607
General 3608
Installation Procedures 3608
Adjustment 3615
Lift Chains Adjustment 3617
Carriage Adjustments 3618
Mast Adjustments 3620
Load Roller Adjustment 3620
Mast Side Kicking Adjustment 3620
550108505 8000YRM1750 (12 2018) US EN 3625
General 3631
Serial Number Data 3631
How to Move a Disabled Lift Truck 3631
How to Tow the Lift Truck 3631
How to Put a Lift Truck on Blocks 3632
How to Raise Drive Tires 3632
How to Raise the Steering Tires 3632
How To Clean A Lift Truck 3633
Maintenance Schedule 3634
Maintenance Procedures Every 8 Hours or Daily 3643
How to Make Checks With Engine Stopped 3643
Tires and Wheels 3643
Safety Labels 3644
Mast, Carriage, Lift Chains, Header Hoses, Attachment 3644
Operator Restraint System 3645
Emergency Locking Retractor (ELR) 3645
Adjust Seat – Full Suspension 3647
Adjust Seat – Internal Suspension 3648
Hood and Seat Latches 3648
Engine Compartment 3649
Paper Application 3649
Fuel, Oil, and Coolant Leaks, Check 3650
Direct Electronic Pressure Regulator (DEPR), Check 3650
Hydraulic Hoses 3650
Coolant Hoses 3650
Steering Column Gas Cylinder 3650
Transmission 3651
Hydraulic System Oil 3651
Engine Oil 3651
Air Filter 3652
Forks 3653
General 3653
Inspect 3653
Remove 3654
Install 3657
Adjust 3657
How to Make Checks With Engine Running 3658
Indicator Lights, Horn, Fuses, and Relays 3658
Service Brakes 3660
Brake Fluid Level 3660
Operation, Check 3660
Parking Brake 3661
Engine Oil Pressure 3661
Cooling System 3662
Steering System 3662
Control Levers and Pedals 3663
Lift System, Operate 3663
First Service After First 100 Hours of Operation 3663
PSI 2 0L LPG Engine Oil and Oil Filter 3663
Yanmar Engine Oil and Oil Filter 3664
Maintenance Procedures Every 250 Hours or 6 Months 3664
PSI 2 0L LPG Engine Oil and Oil Filter 3664
Drain Oil From LPG Vaporizer Regulator (LPG Converter) 3665
Cleaning Carbon Buildup From Intake Valves – PSI 2 0 LPG Engine 3667
Maintenance Procedures Every 500 Hours or 6 Months 3668
Hydraulic System Oil 3668
Battery 3670
Yanmar 2 6L Engine Oil and Oil Filter Change 3670
Yanmar 2 6L Engine Drive Belt 3670
Clean Debris From Radiator Core 3671
Transmission Oil Level 3671
Forks 3672
Inspect 3672
Mast Lubrication 3674
Header Hose Checks 3676
Lift Chain Lubrication 3676
Tilt Cylinder Lubrication 3676
Master Cylinder Rod End Pin Lubrication 3677
Manual Hydraulic Levers Lubrication 3678
Brake Fluid 3678
Parking Brake Adjustment 3678
Tie Rod Lubrication 3679
Differential and Drive Axle Oil 3679
Maintenance Procedures Every 1000 Hours or 6 Months 3680
Valve Clearance, Check and Adjust, Yanmar 2 6L Diesel Engine 3680
Drive Belt Check, PSI Engine 3680
LPG Fuel Filter Element Replace, PSI 2 0L LPG Engine 3680
Remove 3680
Install 3681
Fuel Filter Replacement, Yanmar Engine 3682
Priming the Fuel System (Yanmar) 3683
Lift Chains Wear Check 3684
Lift Chain Lubrication 3684
Integral Sideshift Carriage, Check Bearings 3685
Integral Sideshift Carriage, Check Lower Mounting Hooks 3686
Steering Axle 3686
Control Levers and Pedals 3686
Ignition System, PSI Engine 3686
PCV System, PSI 2 0L LPG Engine 3687
Maintenance Procedures Every 2000 Hours or 1 Year 3687
Hydraulic System 3687
Hydraulic Oil Filter Element, Replace 3687
Remove 3687
Clean and Inspect 3688
Install 3688
Hydraulic Tank Breather, Replace 3689
Air Filter 3690
Oxygen Sensor 3692
PCV System, PSI Engines 3693
Forks, Inspect 3693
Fuel Injector, Yanmar Engines 3695
Integral Sideshift Carriage 3695
Bearings, Replace 3695
Transmission Oil and Oil Filter, Replace 3695
Remove 3695
Clean and Inspect 3696
Install 3696
Brake Fluid Change 3696
Steering Axle Wheel Bearings 3698
Service Brakes 3698
Drive Axle and Differential Oil, Change 3699
Maintenance Procedures Every 4000 Hours or 2 Years 3702
Hydraulic Oil, Change 3702
Cooling System 3703
Maintenance Procedures Every 6000 Hours 3704
Timing Belt Change, PSI Engine 3705
Safety Procedures When Working Near Mast 3705
Hood Latch Check 3708
Lift Chain Adjustments 3709
Jump-Starting the Lift Truck 3710
Jump-Starting Using a Battery Charger 3711
Jump-Starting a Lift Truck Using Another Lift Truck 3711
Welding Repairs 3712
Overhead Guard Changes 3712
Wheel Repair 3712
General 3712
How to Change Solid Rubber Tire (GC Series) 3712
Remove and Install Tire on Wheel 3713
Pneumatic Tire With Tube, Repair 3714
Remove Wheels From Lift Truck 3714
Remove Tire From Wheel 3714
Install Wheel in Tire 3718
Add Air to Pneumatic Tires With Tube 3720
Wheels, Install 3721
Pneumatic Tubeless Tire, Repair 3722
Remove Wheels From Lift Truck 3722
Add Air to Pneumatic Tubeless Tire 3727
Wheels, Install 3727
Solid Rubber Tires on Pneumatic Wheels, Change 3727
Adhesives and Sealants 3731
550108506 8000YRM1751 (08 2018) US EN 3735
Lift Truck Lifting Capacity 3739
Counterweight Weights 3739
Tire Sizes 3739
Capacities 3740
Electrical System 3742
Transmission Oil Pressures 3743
Hydraulic System Relief Pressures 3743
Steering System 3744
Stall Speeds (in RPM ±100 rpm) 3745
PSI 2 0L Engine 3745
Yanmar 2 6L Engine 3745
Mast Speeds 3745
Tilt Angles 3746
Front End Equipment – Mast Creep 3746
Mast Creep 3747
Engine Specifications 3748
Torque Specifications 3749
Frame 3749
Mast 3749
Steering System, Cushion Tire Trucks 3749
Steering System, Pneumatic Tire Trucks 3749
Drive Axle 3749
Transmission 3750
Engine – PSI 2 0L LPG 3750
Engine – Yanmar 2 6L Diesel 3751
550108507 8000YRM1753 (03 2020) US EN 3755
General Information About Diagrams and Schematics 3759
Symbol Definitions 3759
Diagrams Manual Applications 3760
Diagrams and Schematics 3762
550108590 0100YRM1752 (12 2014) US EN 3855
550118420 8000YRM1904 (10 2020) UK EN 3909
General Information About Diagrams and Schematics 3913
Symbol Definitions 3914
Diagrams Manual Applications 3915
Diagrams and Schematics 3917