Yale Forklift (E875) GLPGDPGTP 2.0N, 2.5N, 2.5N6, 3.0N, 3.5N Europe) Service Manual PDF

Yale Forklift E875 (GLPGDPGTP2.0N, GLPGDPGTP2.5N, GLPGDPGTP2.5N6, GLPGDPGTP3.0N, GLPGDPGTP3.5N Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift E875 (GLPGDPGTP2.0N, GLPGDPGTP2.5N, GLPGDPGTP2.5N6, GLPGDPGTP3.0N, GLPGDPGTP3.5N Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1710
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift E875 (GLPGDPGTP2.0N, GLPGDPGTP2.5N, GLPGDPGTP2.5N6, GLPGDPGTP3.0N, GLPGDPGTP3.5N Europe) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
550232091 0100YRM2298 (07 2023) US EN 23
Introduction 31
General 31
Overhead guard and cab repair 32
Overhead guard repair 32
Remove 32
Install 36
Cab components repair 37
Steel Doors 37
Remove 38
Install (Existing) 39
Install (New) 39
PVC Doors 41
Remove 42
Install 45
Screens 46
Front Screen and Wiper 46
Remove 46
Install 49
Top Screen and Wiper 51
Top Screen Remove 52
Top Screen Install 53
Top Wiper Remove 54
Top Wiper Install 56
Rear Screen and Wiper 57
Remove 58
Install 61
Washer Fluid Tank and Supply Lines 62
Remove (Washer Fluid Tank) 63
Install (Washer Fluid Tank) 64
Remove (Supply Lines) 64
Install (Supply Lines) 64
Operator Fan 65
Remove 65
Install 65
Front Grab Handle 65
Remove 65
Install 66
Rear Drive Handle with Horn Button 66
Remove 66
Install 66
12 Volt Power Supply with 2 USB Charging Ports 67
Remove (12 Volt Power Supply) 67
Install (12 Volt Power Supply) 67
Remove (USB Charging Ports) 67
Install (USB Charging Ports) 68
Dome Light 68
Remove 68
Install 68
Noise abatement (sound liners) 69
Hood liners 69
Remove 69
Install 69
Overhead guard liners 69
Remove 69
Install 69
Dash panel liners 70
Remove 70
Install 70
Heater and air conditioner repair 71
Heater repair 71
Heater 72
Remove 72
Install 73
Air conditioner repair 73
Air Conditioning 73
Safety Precautions 74
General Statements for Repairs 74
Residual Pressure 74
Refrigeration Circuit 74
Air Conditioner (A/C) Repair 74
Remove Condenser 76
Install Condenser 77
Remove A/C Compressor 78
Install A/C Compressor 78
Remove Tubes and Expansion Block Valve 79
Install Tubes and Expansion Block Valve 80
Operator station repair 81
Seat repair-Full Suspension 81
Remove 81
Disassemble 82
Armrests 82
Seats 82
Suspension (Seat pan) 84
Assemble 84
Suspension (Seat pan) 84
Seats 84
Armrests 85
Install 86
Seat repair-Non suspension seat 86
Remove 86
Disassemble 87
Operator Presence Sensor 87
Armrests 88
Seat rails 88
Assemble 88
Seat rails 88
Armrests 89
Operator Presence Sensor 89
Install 89
Seat repair-Air suspension 90
Remove 90
Disassemble 91
Armrests 91
Seat cushions 91
Backrest 93
Level adjustment handle 94
Bellows 95
Suspension (Seat pan) 97
Storage box 97
Backrest adjustment 98
Seat switch cable harness 99
Shock absorber 101
Seat plate 101
Static belt 102
Compressor 103
Air spring 104
Swinging structure 105
Assemble 106
Swinging structure 106
Air spring 106
Compressor 106
Seat plate 106
Static belt 106
Shock absorber 107
Seat switch cable harness 107
Backrest adjustment 107
Handles 108
Storage box 108
Bellows 108
Suspension (Seat pan) 108
Backrest 108
Seat cushions 108
Armrests 110
Install 110
Seat repair-value vinyl 111
Remove 111
Bottom seat cushion 112
Disassemble 113
Armrests 113
Assemble 114
Armrests 114
Install 114
Bottom seat cushion 114
Operator restraint system repair 116
Description 116
Seat belt-operational checkout 116
Emergency Locking Retractor (ELR) 116
Remove 116
Install 117
Pedals and linkage repair 117
Brake pedal 117
Remove 117
Install 120
Adjust 121
Throttle pedal (manual) 121
Remove 121
Install 123
Throttle pedal (electronic) 123
Remove 123
Install 124
Foot Directional Control pedal 125
Remove 125
Install 126
Dual pedal 126
Remove 126
Install 127
Park brake 127
Lift trucks with a with a Monotrol®Foot Directional Control pedal: 127
Adjust 127
Releasing the cable adjustment 128
Remove 128
Install 129
Accessories and options 131
Accessory options 131
Monitor holder 131
Tablet holder 131
Phone holder 131
Cup holder 132
Scanner holder 132
Tape dispenser 133
Stretch film roller 133
Accessory bar-fixed 133
Remove 133
Install 134
Accessory bar-swing out (rectangle OHG) 134
Remove 134
Install 135
Accessory bar-swing out (figure 8 OHG) 135
Remove 135
Install 135
Operator fan 136
Remove 136
Install 136
Sun shade 137
Remove 137
Install 137
550232092 0600YRM2299 (05 2023) US EN 139
Introduction 149
General 149
Engine identification 149
Major engine component identification 149
Location of labels 151
Diesel engine labels 151
LPG engine 152
Diesel engine repair 154
Diesel engine specifications 154
Cylinder head specifications 154
Camshaft and timing gear train specifications 156
Crankshaft and piston specifications 157
Cylinder block specifications 159
Special torque chart 160
Diesel cylinder head repair 162
Disassembly of Cylinder Head 162
Remove 168
Glow plugs 168
Valve cover 168
Rocker arm assembly 168
Cylinder head 169
Intake and exhaust valves 170
Valve guides 171
Clean and Inspect 171
Cylinder head components 172
Push rods 172
Push rod bend 172
Rocker arm assembly 172
Rocker arm shaft hole diameter 172
Valve guides 173
Cylinder head 173
Cylinder head distortion 173
Intake and exhaust valves 173
Valve stem diameter 173
Valve stem straightness 173
Valve recession 174
Valve face and valve seat 174
Valve springs 175
Assemble and Install 175
Valve Guides 175
Valves and valve springs 176
Cylinder head 177
Rocker arm assembly 177
Glow plugs 178
Valve cover 178
Engine assembly 178
Diesel timing gear case repair 179
Timing gear case cover 179
Remove 179
Inspect 180
Install 181
Timing gear case 181
Checks 181
Check timing gear backlash 181
Measuring idler gear-to-crankshaft gear backlash 181
Measuring idler gear-to-camshaft gear backlash 182
Remove 182
Install 184
Diesel camshaft and cylinder block repair 187
Remove engine components 188
Disassemble 188
Pistons and connecting rods 188
Remove 190
Crankshaft 190
Inspect 193
Crankshaft oil seals 193
Cylinder Block 194
Honing and Boring 196
Pistons 197
Connecting Rod 199
Tappets 199
Crankshaft 200
Camshaft 201
Camshaft bushing and bores 202
Idler gear and shaft 202
Assemble 203
Camshaft 203
Crankshaft 203
Pistons and Connecting Rods 205
Install 207
Diesel lubrication system repair 208
Check engine lubricating oil pressure 209
Remove 209
Oil pump components 209
Clean and inspect 211
Outer rotor outside clearance 211
Outer rotor to inner rotor tip clearance 211
Outer rotor side clearance 212
Rotor shaft clearance 212
Install 212
Oil pump service information 213
Diesel fuel system repair 214
Fuel system components 214
Remove 214
Injector 214
Common rail 216
Supply pump 217
Install 218
Supply pump 218
Common rail 218
Injector 219
Diesel flywheel repair 220
Remove 220
Install 220
Diesel electrical system repair 221
Starter 221
Remove 221
Disassemble 222
Install 222
Alternator 224
Remove 224
Install 224
Engine Control Unit 225
Remove 225
Install 225
Diesel exhaust and after treatment repair 226
Diesel Particulate Filter (DPF) System 226
Remove 226
DPF assembly 226
Soot filter 228
Inspect 229
Install 230
Soot filter 230
DPF assembly 231
Exhaust Gas Recirculation (EGR) system 232
EGR system configuration 232
Disassemble 232
EGR cooler 232
EGR valve and lead valve 233
Clean 234
EGR cooler 234
EGR pipe and other connecting elbows 234
EGR lead valve 234
Install 235
EGR valve and lead valve 235
EGR Cooler 235
Intake throttle 236
Precautions for handling the intake throttle 236
Exhaust throttle 236
Diesel engine checks, adjustments, and calibrations 237
Valve Clearance Adjustments 237
Alternator checks 238
Test stater coil continuity 238
Test stater coil short to ground 238
Test alternator regulated output 238
Exhaust and aftertreatment 239
EGR valve (check, clean, and test) 239
EGR active control 239
Precautions for cleaning 240
Cleaning the EGR valve 240
Exit the EGR active control 240
Intake throttle 240
Special tools for diesel engines 241
LPG engine repair 245
LPG engine specifications 245
Cylinder head specifications 245
Camshaft and timing gear train specifications 247
Crankshaft and piston specifications 248
Cylinder block specifications 250
Fuel specifications 250
Oil pump service information 251
Special torque chart 253
LPG cylinder head repair 255
Disassemble cylinder head 256
Remove 260
Valve cover 260
Rocker arm 260
Dissassemble rocker arm 260
Cylinder head 261
Intake and exhaust valves 262
Valve guides 262
Clean and Inspect 263
Cylinder head components 263
Push rods 263
Push rod bend 264
Rocker arm assembly 264
Rocker arm shaft hole diameter 264
Valve guides 264
Cylinder head 265
Cylinder head distortion 265
Intake and exhuast valves 265
Valve stem diameter 265
Valve stem straightness 265
Valve recession 265
Valve face and valve seat 266
Valve springs 267
Assemble 267
Valve guides 267
Valves and valve springs 268
Cylinder head 269
Rocker arm assembly 270
Install 271
LPG timing gear case repair 273
Remove 273
Timing gear case cover 273
Timing gear case 274
Idler shaft gear 274
Camshaft and camshaft gear 274
Timing gear case 276
Inspect 276
Install 276
LPG camshaft and cylinder block repair 278
Remove the engine components 279
Disassemble 279
Pistons and connecting rods 279
Remove 281
Crankshaft 281
Inspect 284
Crankshaft oil seals 284
Cylinder block 285
Honing and Boring 285
Pistons 286
Connecting Rod 288
Tappets 288
Crankshaft 289
Camshaft 290
Camshaft bushing and bores 291
Idler gear and shaft 291
Assemble 292
Pistons and Connecting Rods 292
Install 294
Crankshaft 294
Pistons 295
Install the engine components 296
LPG lubrication system repair 297
Check engine lubricating oil pressure 297
Remove 298
Oil pan 298
Oil pump 299
Clean and inspect 299
Outer rotor outside clearance 299
Outer rotor to inner rotor tip clearance 299
Outer rotor side clearance 300
Rotor shaft clearance 300
Assemble 301
Install 301
Oil pump 301
Oil pan 301
Oil pump service information 301
LPG fuel system repair 302
Fuel system components 302
Remove 302
Install 304
LPG flywheel repair 304
Remove 304
Inspect 305
Install 305
LPG electrical system repair 306
Starter 306
Remove 306
Install 306
Alternator 307
Remove 307
Install 307
Engine Control Unit 308
Remove 308
Install 308
LPG exhaust and aftertreatment repair 309
Remove 309
Inspect 311
Install 312
LPG engine checks, adjustments, and calibrations 313
Timing gear checks 313
Check timing gear backlash 313
Measuring idler gear-to-crankshaft gear backlash 313
Measuring idler gear-to-camshaft gear backlash 313
Valve Clearance Adjustments 314
Special tools for LPG engines 316
Bi-fuel engine repair 320
Bi-fuel engine specs 320
Bi-fuel cylinder head repair 320
Bi-fuel timing gear case repair 320
Bi-fuel camshaft and cylinder block repair 320
Bi-fuel lubrication system repair 320
Bi-fuel fuel system repair 320
Bi-fuel flywheel repair 320
Bi-fuel electrical system repair 320
Bi-fuel exhaust and aftertreatment repair 320
Bi-fuel engine checks, adjustments, and calibrations 320
Special tools for bi-fuel engines 320
550232093 0700YRM2300 (05 2023) US EN 323
Introduction 329
General 329
Cooling system repair 330
Fan repair 330
Remove 330
Inspect 332
Install 332
Fan repair (with hydraulic fan drive) 333
Remove 333
Inspect 337
Install 338
Water pump repair 339
Remove 339
Disassemble 342
Install 342
Radiator repair 343
Remove 343
Install 347
Radiator repair (with hydraulic fan drive) 348
Remove 348
Install 351
Cooling system flushing 352
Cooling system checks, adjustments, and calibrations 355
Hose check 355
Flow restriction check 355
Check for water flow restrictions in the radiator 355
Exhaust leak check 355
Thermostat and cooling system sensors check 355
Inspect 355
Temperature switch 355
Water temperature sensor 356
Thermostat 357
Radiator cap 357
550232094 0900YRM2301 (05 2023) US EN 359
Introduction 367
General 367
Engine removal and replacement 368
Diesel engine removal and replacement 368
Remove 368
Install 375
Tool 377
LPG engine removal and replacement 378
Remove 378
Install 388
Tool 390
Bi-fuel engine removal and replacement 391
CNG engine removal and replacement 391
Transmission removal and replacement 392
Powershift transmission removal and replacement 392
Prepare 392
Remove transmission 393
Charge pump 399
Clean 399
Inspect 400
Transmission filter 400
Torque converter 400
Control valve 400
Clutch packs 401
Disassemble 403
Clean 415
Inspect 415
Assemble 416
Stator support assembly 429
Clean 430
Drive chains and sprockets 430
Clean 432
Install 432
Drive chains and sprockets 432
Stator support assembly 432
Clutch pack assemblies 432
Control valve 433
Torque converter 434
Transmission filter 434
Charge pump 434
Install transmission 435
Tool 437
Calibration 437
Hydrostatic transmission removal and replacement 437
Remove transmission 437
Install transmission 437
Drive axle repair (dry brakes) 438
Dry brake axle remove and install 438
Remove 438
Install 441
Wheel ends 442
Servicing Wheel Ends 442
Remove 442
Clean and Inspect 445
Install 445
Service brake 448
Service Brake Repair 448
Remove and Disassemble 448
Clean 451
Inspect 451
Assemble and Install 452
Center section 456
Center Section Repair 456
Differential 478
Differential Repair 478
Park brake 488
Park Brake Repairs 488
Remove 488
Install 489
Special tools 490
Tools 490
End-Stop Plier Settings 490
Retaining Snap Ring for Bores 490
Retaining Snap Ring for Shafts 490
Special Tools 491
T1 491
T2 492
T3 493
T4 494
Drive axle repair (wet brakes) 495
Wet brake axle remove and install 495
Remove 495
Install 496
Wheel ends 498
Service brake 515
Center section 537
Differential 563
Differential Repair 563
Special tools 573
Tools 573
End-Stop Plier Settings 573
Retaining Snap Ring for Bores 573
Retaining Snap Ring for Shafts 573
Special tools 574
T1 574
T2 574
T3 575
T4 575
T5 576
T6 576
T7 577
T8 577
T9 579
T10 581
T11 583
T12 584
T13 585
Brake adjustments 586
Brake pedal adjustment 586
Brake Pedal Adjustment With Single Pedal Option 586
Pedal Adjustment 586
Brake Pedal Adjustment With Dual Pedal Option 588
Pedal Adjustment 588
Service brakes adjustment 590
Brake system 590
Brake System Air Removal 590
Using Pressure Bleed System 590
Using Brake Pedal Pressure 591
Steer axle repair 592
Synchronous steer axle repair 592
Steer Axle Assembly 592
Remove 592
Disassemble 593
Clean 595
Inspect 595
Assemble 595
Install 596
Spindles, Bearings, and Tie Rods 597
Remove 597
Disassemble 597
Clean 598
Inspect 598
Assemble 598
Install 599
Steering Cylinder 599
Remove and Disassemble 599
Clean and Inspect 601
Assemble and Install 601
Non-synchronous steer axle repair 602
Steer axle assembly 602
Remove 602
Disassemble 603
Clean 603
Inspect 604
Assemble 604
Install 605
Spindles, bearings and tie rods 605
Remove 605
Disassemble 606
Clean 606
Inspect 606
Assemble 606
Install 607
Steering cylinder 608
Clean and Inspect 608
Assemble and Install 609
550232095 1900YRM2302 (09 2023) US EN 613
Introduction 623
General 623
Hydraulic system repair 624
Hydraulic pump repair 624
Remove 624
Disassemble 630
Variable Displacement Pump 630
Hydraulic Gear Pump 632
Clean 634
Inspect 634
Assemble 634
Variable Displacement Pump 634
Hydraulic Gear Pump 634
Install 634
Variable Displacement Pump Checks and Adjustments 635
Pump Margin Pressure 635
Hydraulic control valve repair 636
Manual Control Valve 636
Remove 636
Disassemble 639
Clean and Inspect 639
Assemble 640
Install 640
Inlet Valve Section 640
Disassemble 640
Clean 641
Inspect 641
Assemble 641
Fan Drive Control Valve Section 642
Disassemble 642
Clean 643
Inspect 643
Assemble 643
Lift Control Valve Section 643
Disassemble 643
Clean 644
Inspect 644
Assemble 645
Tilt/Auxiliary Control Valve Sections 645
Disassemble 645
Clean 647
Inspect 647
Assemble 648
Outlet Valve Section 648
Disassemble 648
Clean 648
Inspect 649
Assemble 649
Accumulator 649
Remove 649
Install 650
Electronic Control Valve 650
Remove 650
Disassemble 652
Clean and Inspect 653
Assemble 653
Install 653
Inlet Valve Section 653
Disassemble 653
Clean 654
Inspect 654
Assemble 655
Fan Drive Control Valve Section 655
Disassemble 655
Clean 656
Inspect 656
Assemble 657
Lift Control Valve Section 657
Disassemble 657
Clean 658
Inspect 658
Assemble 659
Tilt/Auxiliary Control Valve Sections 659
Disassemble 659
Clean 660
Inspect 660
Assemble 661
Outlet Valve Section 661
Disassemble 661
Clean 661
Inspect 662
Assemble 662
Pressure Relief Valve Check and Adjustment 662
Primary Relief Valve 662
Secondary Relief Valve 663
Hydraulic supply and return repair 664
Hydraulic Supply and Return Hoses 664
Remove 664
Install 667
Mast Hoses 668
Remove 668
Install 672
Hydraulic Tank 672
Inspect 672
Clean 673
Steam Method of Cleaning 673
Chemical Solution Method of Cleaning 673
Additional Preparations for Repair 674
Small Leaks, Repair 674
Large Leaks, Repair 674
Preparations for use After Repair 674
Hydraulic oil cooler 674
Hydraulic Oil Cooler 674
Remove 674
Disassemble 675
Assemble 677
Install 677
Hydraulic calibrations 677
E-Hydraulic controls options 678
Calibration procedures 679
Service password entry 679
Hydraulic valve calibration warmup 680
Lift valve threshold 680
Lower valve threshold 680
Tilt valve threshold (Forward) 681
Tilt valve threshold (Back) 681
Auxiliary 1 Direction A valve output threshold 682
Auxiliary 1 Direction B valve output threshold 682
Auxiliary 2 Direction A valve output threshold 683
Auxiliary 2 Direction B valve output threshold 683
Steer system hydraulics repair 685
Steering pump repair 685
Remove 685
Disassemble 687
Clean 689
Inspect 689
Assemble 689
Install 689
Brake system hydraulics repair 690
Dry brake hydraulics repair 690
Wet brake hydraulics repair 690
Remove 690
Install 692
Cylinder repair 694
Tilt cylinder repair 694
Remove 694
Disassemble 695
Clean 696
Inspect 696
Assemble 697
Install 698
Tilt Cylinders, Adjust 698
Tilt Cylinders With Tilt Limit Spacers 698
Tilt Cylinders Without Tilt Limit Spacers 699
Tilt Cylinder Leak Check 700
Lift cylinder repair 700
Two-Stage Limited-Free-Lift (LFL) 700
Remove 700
Disassemble 701
Clean 702
Inspect 703
Assemble 703
Install 703
Two-Stage Full-Free-Lift (FFL) 704
Remove 704
Disassemble 705
Left-Hand Cylinder 705
Right-Hand Cylinder 706
Clean 707
Inspect 707
Assemble 708
Left-Hand Cylinder 708
Right-Hand Cylinder 709
Install 709
System Air Bleed Procedure 709
Three-Stage Full-Free-Lift (FFL) 710
Remove 710
Disassemble 711
Clean 712
Inspect 712
Assemble 713
Install 714
Four-Stage Full-Free-Lift (FFL) 714
Remove 714
Disassemble 715
Left-Hand main lift cylinder 715
Right-Hand main lift cylinder 716
Clean 717
Inspect 717
Assemble 718
Install 719
Free-Lift cylinder 719
Remove 719
Disassemble 720
Clean 721
Inspect 721
Assemble 722
Install 723
Seal Kit Installation 723
External Installation (Seal and Backup Ring) 723
Internal Installation (Piston Rod Assembly) 724
Lift cylinder leak check 724
Integral sideshift cylinder repair 724
General 724
Remove 724
Clean 726
Inspect 726
Assemble 726
Install 727
Integral Side-Shift Cylinder Gland Leak Checks 727
Hydraulics cleanliness 728
Flushing hydraulics after repair 728
Hydraulic System Flushing Techniques 728
Double Oil and Filter Change 728
Mechanical Cleaning 728
Cleaning of Components 728
Fluid conditioning and system flushing 729
Operation of the Filter Caddy 729
Filter Caddy operation 729
Fluid Conditioning Procedure 730
Filter Caddy Start-Up 730
System Flushing Procedure 731
Component Cleaning Procedure 731
Reservoir Cleaning Procedure 731
Cylinder Cleaning Procedure 731
Hose and Tube Cleaning Procedure 732
Valve Cleaning Procedure 732
Front-End Attachment Cleaning Procedure 733
System Flushing Procedure 733
Filter Caddy Start-Up 734
System Start-Up and Flushing 734
Reservoir Fluid Cleaning Times 735
Dealing With Different Fluid Types 735
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 735
Filter Caddy Maintenance 736
Servicing the Strainer 736
DC Motor 736
Hydraulic oil sampling 736
Hydraulic Oil Sampling Method 736
Objective 736
General Guidelines 736
Synopsis 737
Hydraulic Oil Analysis Report Guidelines 738
Sampling Conditions 739
Equipment 739
Sampling Procedure 739
Hydraulic Oil Sampling 739
Sample Labeling 740
Results Documentation 740
550232096 4000YRM2303 (06 2023) US EN 743
Introduction 751
General 751
Safety Procedures When Working Near Mast 751
Fork and carriage repair 753
Fork removal and replacement 753
Integral Sideshift Carriage 753
Remove 753
Install 754
Checks 754
Carriage repair, 2-stage limited free lift 756
Standard Carriage 756
Remove 756
Clean and Inspect 757
Install 758
Integral Sideshift Carriage 759
Remove 759
Disassemble 762
Clean and Inspect 762
Assemble 763
Install 763
Auxiliary extension tubes (standard carriage) 764
Remove 764
Install 764
Auxiliary extension tubes (ISS carriage) 764
Remove 764
Install 764
Carriage repair, 2-stage full free lift 765
Standard Carriage 765
Remove 765
Clean and Inspect 766
Install 766
Integral Sideshift Carriage 767
Remove 767
Disassemble 770
Clean and Inspect 770
Assemble 771
Install 771
Auxiliary extension tubes (standard carriage) 772
Remove 772
Install 772
Auxiliary Extension Tubes (ISS Carriage) 772
Remove 772
Install 772
Carriage repair, 3-stage full free lift 773
Standard Carriage 773
Remove 773
Clean and Inspect 774
Install 774
Integral Sideshift Carriage 775
Remove 775
Disassemble 777
Clean and Inspect 778
Assemble 779
Install 779
Auxiliary extension tubes (standard carriage) 780
Remove 780
Install 780
Auxiliary extension tubes (ISS carriage) 780
Remove 780
Install 780
Carriage repair, 4-Stage Full Free Lift 781
Standard Carriage 781
Remove 781
Clean and Inspect 782
Install 783
Integral Sideshift Carriage 783
Remove 783
Disassemble 786
Clean and Inspect 786
Assemble 786
Install 787
Auxiliary Extension Tubes (Standard Carriage) 788
Remove 788
Install 788
Auxiliary Extension Tubes (ISS Carriage) 788
Remove 788
Install 789
Fork positioner 789
Mast repair 790
2-stage limited free lift (LFL) mast repair 790
Repair mast with serial number G507/G562 790
Remove 790
Disassemble 793
Clean and Inspect 798
Assemble 800
Install 801
2-stage full free lift (FFL) mast repair 803
Repair mast with serial number F509/F564 803
Remove 803
Disassemble 806
Clean and Inspect 808
Assemble 811
Install 812
3-stage full free lift (FFL) mast repair 813
Repair mast with serial number G508/G563 813
Remove 813
Disassemble 816
Clean and Inspect 820
Assemble 822
Install 823
4-Stage full free lift (FFL) Mast Repair 825
Repair Mast With Serial Number E515/B954 825
Remove 825
Disassemble 828
Clean and Inspect 834
Assemble 837
Install 838
Header Hose Repair 841
Header Hoses, 2-stage limited free lift (LFL) 841
Remove 841
Installation 841
Adjustment 843
Header Hoses, 2-stage full free lift (FFL) 843
Remove 843
Installation 844
Adjustment 848
Header Hoses, 3-stage full free lift (FFL) 849
Remove 849
Installation 849
Adjustment 853
Header Hose, 4-Stage Full Free Lift (FFL) 854
Remove 854
Install 855
Header Hose Tension Measurement Instructions 864
Adjustment 866
Adjustment Procedures 867
Carriage Adjustments 867
Lift Chains Adjustment 867
Lift Chains 867
Lift Trucks Equipped with Forks 868
Lift Trucks Equipped with Hook-Type Carriage and Attachment Without Forks 868
Mast Adjustments 868
Mast 868
Load Roller, Adjust 868
Mast Side Kicking, Adjust 871
Bolzoni attachment installation 872
Paper roll clamp installation 872
Bale clamp installation 872
Rotator installation 872
550232097 2200YRM2304 (07 2023) US EN 875
Introduction 889
General 889
Electrical system repair 890
Wire harness repair 890
Molex MX150 Series Connectors 890
MX150 Locations 895
Molex MX150 Series Terminals 895
Inspecting Wiring Terminals and Connectors 895
Removing Terminated Wires from Plug Connector 896
Removing Terminated Wires from Receptacle Connector 897
Installing Terminated Wires into Plug or Receptacle Connector 898
Wire Terminals 898
Unused Cavity Circuit Plug 898
Stripping Wire for Molex MX150 Series Terminals 898
Poor Wire Stripping Examples 899
Crimping Molex MX150 Series Terminals 900
Sensors, relays, and other electrical components repair 901
Sensors, Relays, and Other Electrical Components Repair 901
Accelerator Pedal Position Sensor 901
Remove 901
Install 902
Engine and Fuel Sensors and Switches, Yanmar Diesel Engine 902
Air Filter Restriction Switch 902
Remove 902
Install 902
Oil Pressure Sensor 902
Remove 902
Install 902
Engine Speed Sensor 902
Remove 902
Install 903
Engine Coolant Temperature (ECT) Sensor 903
Remove 903
Install 903
Throttle Position Sensor (TPS) 905
Remove 905
Install 906
Fuel/Water Separator Sensor 906
Remove 906
Install 906
Glow Plug Relay 907
Remove 907
Install 909
Engine Block Heater (2 1L Engine) 909
Remove 909
Install 909
Engine Block Heater (2 2L Engine) 910
Remove 910
Install 910
Exhaust Gas Sensors 910
Heated O2 Sensor 910
Remove 910
Install 911
Exhaust EGT Sensor 912
Remove 912
Install 912
Dynamic Stability System (DSS) 912
Mast Height Sensor (Discrete) 912
Remove 912
Install 913
Mast Height Sensor (Continuous) 913
Remove 913
Install 914
Mast Tilt Sensor 914
Remove 914
Install 915
Speed Sensor 915
Steer Axle Position Sensor 915
Remove 915
Install 916
Fuel Quality Sensor (FQS) – LPG/Dual Fuel Engines 916
Remove 916
Install 917
Synchronous Steering Column Sensor 917
Remove 917
Install 918
Service Brake Pedal Position Sensor – Single Pedal 918
Remove 918
Install 918
Brake Fluid Level Sensor 919
Remove 919
Install 919
Parking Brake Position Sensor 920
Remove 920
Install 920
Service Brake (Hydraulic) Pressure Transducer 920
Remove 920
Install 921
Service Brake (E-Brake) Position Sensor 921
Remove 921
Install 921
Monotrol Sensor 921
Remove 921
Install 922
Low Coolant Level Sensor 922
Remove 922
Install 923
Fuel Level Sensor, Gas and Diesel Engines Only 923
Remove 923
Install 923
Operator Presence Sensor 924
Remove 924
Install 924
Transmission Sensors 924
Speed Sensor 924
Remove 924
Install 925
Pressure Sensor 925
Remove 925
Install 925
Temperature Sensor 925
Remove 925
Install 925
Impact Sensor 925
Remove 925
Install 926
Load Weight Sensor 926
Remove 926
Install 926
Ambient Light Sensor 926
Remove 926
Install 928
Proximity Sensor 928
Remove 928
Install 928
Object Detection Sensors (Side) 929
Remove 929
Install 929
Object Detection Sensor (Rear) 929
Remove 929
Install 930
LPG Tank Interlock 930
Remove 930
Install 930
Smart Antenna 931
Remove 931
Install 931
Power distribution module (PDM) repair 931
Power Distribution Module 931
Remove 931
Install 932
Replacing PDM components (fuses and relays) 933
Battery service 936
Battery Remove and Install 936
Remove 936
Install 937
Battery Disconnect Switch (Optional) 937
Remove 938
Install 938
Light repair 938
Light Repair 938
LED Mast Lights 938
Remove 938
Install 939
LED Strobe Light 939
Remove 939
Install 939
Fork Laser Level Line 940
Remove 940
Install 940
Red or Blue Front Spot Light 940
Remove 940
Install 941
Red or Blue Rear Spot Light 941
Remove 941
Install 941
Front Work Lights 941
Remove 942
Install 942
Rear Work Light 942
Remove 942
Install 942
Rear Work Light with Red Line 943
Pedestrian Awareness Lights (PAL), Perimeter 943
Remove (Right Side) 943
Install (Right Side) 943
Remove (Rear) 943
Install (Rear) 944
Front LED Work Light with Marker Light 944
Remove 944
Install 945
Tail Light with Stop, Brake, Reverse, Hazard, and Turn Lights 945
Remove 945
Install 946
Controller removal and replacement 946
Controller Remove and Replace 946
VSM 946
Remove 946
Install 947
O-Box (E-Hydraulic) Controller 947
Remove 947
Install 948
Hydro Static Transmission (HST) controller 948
Remove 948
Install 949
I-Box (Accessory 1) 949
Remove 949
Install 949
I-Box (Accessory 2) 950
Remove 950
Install 950
Telemetry Wireless Asset Management System 950
Level 1 – Wireless Monitoring (WIFI Group) 950
Remove Telemetry Module 951
Install Telemetry Module 953
Remove Antenna 953
Install Antenna 954
Level 2 – Wireless Access 954
Telemetry Module 955
Antenna 955
RF-ID Reader 955
Remove 956
Install 956
Level 3 – Wireless Verification 956
Telemetry Module 957
Antenna 957
RF-ID Reader 957
Display Panel (Checklist) 957
Software 959
Loading and updating VSM software and truck Configuration Data Files (CDF)s with HYG Field Prog software 959
Installing the Field Prog software 959
Minimum system requirements 959
Open the Field Prog Tool 960
Using the Field Prog tool 961
Error behavior 965
CAN-based operations 966
Display programming 966
Programming the Display via USB 967
Setup 968
Run the Field Prog tool 968
Language 968
Loading and updating display and application software 969
Loading and Updating Display and Application Software 969
Minimum System Requirements 969
Configure Communications Settings 971
Installing Axcess Software 973
Using the Axcess Software 974
Programming the VSM 975
Begin Programming 976
Programming the Display via USB 976
Setup 977
Run the Tool 977
Transfer 978
Programming other controllers 978
Transmission Valve Calibration 979
Language 980
User interface (display) 980
User interface display 980
Navigation Key 980
Startup sequence 981
Side View Operator Screens 985
Switched Inputs and Preset Heights 986
Home screen 988
Loggin in 990
Log In or Out 990
Main Menu 991
View the Fault List 991
Fault List 991
Fault Filter 992
View hardware and software versions 993
Calibrations 993
Alarms 994
Diagnostics 995
Settings 998
Hydraulics 998
H1 Lift/Lower 998
H2 Tilt 999
H3 Third Hyd Function 999
H4 Fourth Hyd Function 999
H5 Fifth Hyd Function 999
H8 Pump 999
Drive 999
D1 Engine 999
D8 Traction 999
Sensors/Presets 999
Impact 1000
Mast presets 1000
Telemetry 1000
Operators 1000
Password Enabled 1000
Add New 1000
Existing User 1000
Maintenance 1001
M 1 Reminder 1001
M 2 Checklist 1001
Truck Setup 1001
T1 Display 1001
T2 Lights 1001
T3 Time Out 1001
T4 Alarms 1001
T5 Alarms 1002
T6 Inputs 1002
Powertrain Protection System with Engine Shutdown 1002
Powertrain Empty Seat Engine Shutdown 1002
Display Icons 1003
Service Display Menu Structure 1025
Calibrations 1050
Transmission warm-up 1050
Hydraulic valve calibration warm-up 1050
Calibrations 1050
DSS calibrations 1050
Return To Set Tilt Calibration 1050
Synchronous Steering Calibration 1051
Lift valve calibration 1053
Lift valve threshold calibration 1053
Lower valve calibration 1055
Lower valve threshold calibration 1055
Tilt back valve calibration 1056
Tilt back valve output threshold calibration 1056
Tilt forward valve calibration 1057
Tilt forward valve output threshold calibration 1057
Auxiliary valve direction A calibration 1058
Auxiliary 1 or 2 direction A valve output threshold calibration 1058
Auxiliary valve direction B calibration 1060
Auxiliary 1 or 2 direction B valve output threshold calibration 1060
Transmission calibration (Basic) 1061
Prepare 1061
Calibrations procedures 1061
Transmission calibration (Advanced) 1062
Calibrations procedures 1062
Operator controls repair 1067
Steering column repair 1067
Description 1067
Steering column assembly, remove 1068
Battery disconnect 1068
Remove operator controls from steering column 1068
Remove covers, tilt only steering column 1068
Remove covers, tilt and telescope steering column 1069
Remove steering pump 1070
Remove steering column assembly from truck 1070
Steering column, disassemble 1070
Tilt only 1070
Tilt and telescope 1070
Steering column, assemble 1072
Tilt only 1072
Tilt and telescope 1072
Steering column assembly, install 1072
Install steering column assembly in truck 1072
Install steering pump 1072
Install covers, tilt only steering column 1072
Install covers, tilt and telescope steering column 1072
Install operator controls on steering column 1073
Connect battery 1073
Display repair 1073
Display remove and install 1073
Remove 1073
Install 1074
Pinout descriptions for the 2 8-inch display 1074
Pinout descriptions for the 5-inch display 1075
Pinout descriptions for the 7-inch display 1077
Operator buttons and switches repair 1079
Park brake rocker switch 1079
Remove 1079
Install 1079
Dash panel control module 1079
Remove 1079
Install 1080
Cab Panel Control Module 1080
Remove 1080
Install 1081
Mini-Lever Module 1081
Remove 1082
Install 1082
Armrest assembly 1082
Remove 1082
Install 1085
Rear drive handle with horn button 1085
Remove 1085
Install 1086
Steering wheel horn switch 1086
Remove 1086
Install 1087
Direction control lever (steering column) 1087
Remove 1087
Install 1088
Turn signal lever 1088
Remove 1088
Install 1090
Wiper control lever 1090
Remove 1090
Install 1091
Battery disconnect switch 1091
Remove 1091
Install 1092
Truck start switch 1092
Keyed switch 1092
Remove 1092
Install 1093
Keyless switch with Knob 1093
Push button switch 1094
Remove 1094
Install 1094
Push button with remote key switch 1095
Remove 1095
Install 1095
Dome light switch 1095
Remove 1095
Install 1096
E-hydraulic controls repair 1096
E-hydraulic controls – TEST 1096
Mini-levers 1096
Full stroke test 1096
Function returns to neutral test 1096
Push (override) button 1096
General 1097
Mini-levers, remove and install 1097
Armrest assembly 1098
Remove 1098
Install 1100
Horn button 1100
Remove 1100
Install 1100
Direction control switch 1100
Remove 1100
Install 1101
Push (override) button 1101
Remove 1101
Install 1102
Joystick controls repair 1102
Joystick controls – TEST 1102
Joystick levers 1102
Full stroke test 1102
Function returns to neutral test 1103
General 1104
Armrest assembly 1104
Remove 1104
Install 1106
Joystick control levers 1106
Remove 1106
Install 1106
Horn button 1107
Remove 1107
Install 1107
Direction Control Switch 1107
Remove 1107
Install 1108
550232099 8000YRM2305 (09 2023) US EN 1111
Introduction 1119
General 1119
Truck handling and transport 1120
How to move a disabled lift truck 1120
How to Tow Lift Truck 1120
How to put a lift truck on blocks 1121
How to Raise Drive Tires 1121
How to Raise Steering Tires 1121
How to clean a lift truck 1122
Putting a lift truck into storage 1123
How to Put Internal Combustion Engine (ICE) Lift Trucks in Storage 1123
Short-Term Storage 1123
Long-Term Storage 1124
While the Lift Truck is in Storage 1124
How to Put Batteries in Storage 1124
Preparing a stored lift truck for use 1125
Putting a Stored Lift Truck Back Into Service 1125
Wheels and tires 1125
Periodic maintenance (PM) schedule 1126
Daily periodic maintenance (PM) task schedule 1126
First 150 hours periodic maintenance (PM) schedule 1132
Every 500 hour periodic maintenance (PM) schedule 1136
Every 1000 hour periodic maintenance (PM) schedule 1142
Every 2000 hour periodic maintenance (PM) schedule 1147
Every 3000 hour periodic maintenance (PM) schedule 1152
Every 4000 hour periodic maintenance (PM) schedule 1155
Every 5000 hour periodic maintenance (PM) schedule 1159
Every 6000 hour periodic maintenance (PM) schedule 1163
Periodic maintenance (PM) procedures 1165
Daily periodic maintenance (PM) task procedures 1165
How to make checks with engine stopped 1165
Tires and wheels 1165
Safety labels 1165
Mast, carriage, lift chains, header hoses, attachment 1166
Visual Inspection of Mast, Mast Hardware, and Tilt Cylinder Hardware 1166
Operator restraint system 1167
Seat belt-operational checkout 1167
Emergency Locking Retractor (ELR) 1167
Seat adjustments 1167
Non-Suspension Seat 1167
Full-Suspension Seat 1167
Air-Suspension Seat 1167
Hood and seat latches 1169
Engine compartment 1169
Fuel, oil, and coolant leaks, check 1169
Hydraulic hoses 1169
Coolant hoses 1169
Steering column gas cylinder 1169
Transmission (Powershift) 1170
Hydraulic system oil 1170
Engine oil 1170
Air filter 1172
Forks 1173
Inspect 1173
Fuel Filter/Water Separator 1175
How to make checks with engine running 1175
Indicator lights, horn, fuses, and relays 1176
Service brakes 1177
Brake fluid level 1177
Operation, check 1177
Park brake, Dry Brake Axle 1177
Park Brake, Wet Brake Axle 1178
Engine oil pressure 1178
Cooling system 1179
Lift system, operate 1180
Check lift height sensor 1180
First 150 hours periodic maintenance (PM) procedures 1180
Yanmar engine oil and oil filter, Yanmar 2 1L, 3 0L, 3 3L Diesel and Yanmar 2 2L LPG 1180
Transmission oil level (Powershift) 1183
Transmission oil filter (Powershift) 1183
Dry brake axle differential and drive axle oil 1184
Wet brake axle differential (center section) and wheel end oil 1184
Drive shaft inspection 1186
Tilt cylinder mounting hardware inspection 1187
Every 500 hour periodic maintenance (PM) procedures 1188
Hydraulic tank breather 1188
Inspect 1188
Battery 1188
Yanmar LPG engine oil and oil filter 1189
Yanmar diesel engine oil and oil filter 1190
Clean debris from radiator core and oil cooler 1192
Transmission oil level (Powershift) 1193
Mast Lubrication 1194
Mast pivot pins and bushings 1195
Tilt Cylinder Adjustments 1196
Header Hose Checks 1197
Lift Chain Lubrication 1198
Tilt Cylinder Lubrication 1198
Master brake cylinder rod end pin lubrication 1199
Manual control levers lubrication 1199
Steer axle tie rod lubrication 1199
Differential and drive axle oil 1200
Park brake 1201
Brake pedal linkage 1201
Tilt cylinder mounting hardware inspection 1201
Every 1000 hour periodic maintenance (PM) procedures 1202
Yanmar 2 2L LPG engine oil and oil filter 1202
Pedals 1203
Manual hydraulic control levers 1204
Levers and linkage 1204
Hood 1205
Hinges 1205
Hood latch 1205
Integral sideshift carriage, check bearings 1206
Check bearings 1206
Check lower mounting hooks 1206
Lift Chain Lubrication 1207
Measure chain wear 1207
LPG vaporizer and fuel filter 1209
LPG vaporizer 1209
LPG fuel filter element replace 1211
Remove 1211
Install 1211
Engine electrical system 1212
Check connectors 1212
Fuel filter/water separator 1212
Intake and exhaust throttle valves, Yanmar 3 0L and 3 3L engines 1212
Valve clearance adjustments, Yanmar 3 0L and 3 3L engines 1212
Steer axle king pin lubrication 1214
Dry brake axle differential and drive axle oil 1214
Wet brake axle differential (center section) oil 1215
Park brake inspection 1216
LPG tank bracket latch lubrication 1216
LPG tank bracket release 1217
Drive shaft inspection 1217
Every 2000 hour periodic maintenance (PM) procedures 1218
Hydraulic Filter 1218
Hydraulic tank breather 1220
Inspect 1220
Air cleaner 1220
Transmission oil drain and fill (Powershift) 1221
Transmission oil filter (Powershift) 1221
Integral Sideshift Carriage 1222
Remove bearings 1222
Brake fluid change (master cylinder) 1223
Service brakes (dry brake drive axle) 1223
Check thickness 1223
Dry brake axle differential and drive axle oil 1224
Wet brake axle differential (center section) and wheel end oil 1224
EGR cooler 1225
EGR pipe and other connecting elbows 1226
Dry brake drive axle wheel bearing 1226
Steer axle wheel bearing 1226
Every 3000 hour periodic maintenance (PM) procedures 1226
Intake and exhaust throttle valves, Yanmar 2 1L Diesel and 2 2L LPG Engines 1226
Valve Clearance Adjustments, Yanmar 2 1L Diesel and 2 2L LPG Engines 1226
Every 4000 hour periodic maintenance (PM) procedures 1228
Cooling system 1228
Coolant drain and flush 1228
Coolant fill 1229
Hydraulic Oil, Replace 1230
Spark plugs, Yanmar 2 2L LPG engine 1230
Every 5000 hour periodic maintenance (PM) procedures 1230
V-belt (drive belt) 1230
Auto tensioner 1231
Every 6000 hour periodic maintenance (PM) procedures 1232
DPF, Yanmar 2 1L diesel engine 1232
PCV valve 1232
550232100 8000YRM2306 (09 2023) US EN 1235
Introduction 1241
General 1241
Covers, floorplates, and counterweight 1242
Covers repair 1242
Hood 1242
Remove 1242
Install 1243
Steering column covers 1244
Remove 1244
Install 1245
Kick panels 1245
Remove 1245
Install 1247
Floormats and floorplates 1247
Remove 1247
Install 1248
Dash covers 1248
Remove 1248
Install 1249
Heating, Ventilation and Air Conditioning (HVAC) unit covers 1249
Remove 1249
Install 1251
Counterweight repair 1251
Counterweight Repair 1251
Remove 1251
Install 1255
LPG tank bracket repair 1256
LPG Tank Bracket Repair 1256
Fixed Bracket 1256
Remove 1256
Install 1257
Swing-Out Bracket 1257
Remove 1257
Install 1258
Swing-Out and Drop-Down Bracket 1259
Remove 1259
Install 1259
Frame repair 1261
Frame module repair 1261
Fuel tank repair 1261
Inspect 1261
Clean 1261
Steam method of cleaning 1262
Chemical solution method of cleaning 1262
Additional preparations for repair 1263
Small leaks, repair 1263
Large leaks, repair 1263
Preparations for use after repair 1263
Hydraulic oil tank repair 1263
Inspect 1263
Clean 1264
Steam method of cleaning 1264
Chemical solution method of cleaning 1265
Additional preparations for repair 1265
Small leaks, repair 1265
Large leaks, repair 1265
Preparations for use after repair 1265
Frame checks and adjustments 1265
Paint and labels 1266
General painting concerns 1266
Label replacement 1266
Tires and wheels 1271
Wheel and tire overview 1271
Snap-on wheel removal and replacement 1271
Snap-On-Tire, Change 1271
Remove Snap-On-Tire, Solid Tire From Wheel 1272
Install Snap-On-Tire, Solid Tire on Wheel 1273
Pneumatic tire removal and replacement (with tube) 1274
Remove wheels from lift truck 1274
Remove tire from wheel 1274
Remove Tire From Two-Piece Wheel 1275
Remove Tire From Three and Four-Piece Wheels 1276
Install wheel in tire 1277
Install Three-Piece or Four-Piece Wheel in Tire 1277
Add air to pneumatic tires with tube 1279
Install the wheels 1280
Pneumatic tire removal and replacement (without tube) 1281
Remove wheels from lift truck 1281
Remove Tire From Wheel 1281
Install Tire on Wheel 1283
Add Air to Pneumatic Tubeless Tire 1285
Wheels, Install 1286
Solid pneumatic tire repair and replacement 1286
Solid Rubber Tires on Pneumatic Wheels, Change 1286
Remove Tire From Wheel 1286
Install Tire on Wheel 1287
Optional features 1290
Debris screen 1290
Remove 1290
Install 1290
String cutter 1290
Remove 1290
Install 1291
550232101 8000YRM2307 (06 2023) US EN 1293
Introduction 1299
General 1299
Electrical schematics and diagrams 1300
Electrical schematics 1300
Hydraulic schematics 1338
Hydraulic Schematics – Transmission 1338
Hydraulic schematics – manual hydraulics with Powershift transmission 1343
Hydraulic schematics – e-hydraulics with Powershift transmission 1345
Hydraulic schematics – manual hydraulics with Hydrostatic transmission 1347
Hydraulic schematics – e-hydraulics with Hydrostatic transmission 1347
550232102 8000YRM2308 (08 2023) US EN 1349
Introduction 1363
General 1363
Frame 1364
Frame modular design description 1364
Frame attaching hardware description 1365
Hydraulics 1367
Hydraulic supply and return description 1367
Hydraulic Supply and Return 1367
Hydraulic pump description 1370
Hydraulic Pump 1370
Control valve description 1373
Control Valve 1373
Manual Control Valve 1373
Electro-Hydraulic Control Valve 1374
Manual Valve Main Components 1376
Control Valve Schematic 1376
Valve Section Breakdowns 1377
Inlet/Steer Section – Neutral/Steering Idle 1377
Inlet Section – Steering 1378
Lift Section – Neutral 1378
Lift Section – Neutral 1378
Lift Section – Lower 1379
Lift Section – Lower 1379
Lift Section – Raise 1380
Lift Section – Raise 1380
Tilt Section – Neutral 1381
Tilt Section – Spool IN 1381
Tilt Section – Spool OUT 1382
AUX 1 Section – Neutral 1382
AUX 1 Section – Spool IN 1383
AUX 1 Section – Spool OUT 1383
AUX 2 Section – Neutral 1384
AUX 2 Section – Spool IN 1384
AUX 2 Section – Spool OUT 1385
Unloader in Neutral – FDP 1385
Unloader in Function – FDP 1386
Anti-Stall Functionality 1386
Steering control unit description 1387
Steering Control Unit (SCU) 1387
Operation 1388
Brake system description 1391
Brake System Description 1391
Dry Brakes 1391
Master Cylinder 1393
Brake Position Sensor 1394
Wet Brakes 1394
Park Brake 1396
MONOTROL® Directional Control 1397
Inch Brake/Service Brake Pedal 1397
Electrical system 1399
Controller description 1399
Controller Description 1399
VSM 1399
OBox (Output Box) 1404
IBox (Input Box) 1406
Display (User Interface) 1409
Smart Antenna 1414
Impact Sensor 1416
Dash and Cab Switch Bank (Control Module) 1417
Mini-Lever Module (MLM) 1418
Hydro Static Transmission (HST) Controller 1420
Main Power Distribution Module (PDM) 1421
Power distribution module (PDM) description 1423
Power Distribution Module (PDM) 1423
Fuse and Relay Descriptions 1426
PDM Pin Out 1427
PDM Electrical Schematic 1429
Sensors description 1431
Sensors 1431
Operator Compartment 1431
Operator Presence Sensor (OPS) 1431
Steering Wheel Sensor 1432
Ambient Light Sensor 1432
Proximity Sensor 1433
Object Detection Sensors (Side) 1435
Objection Detection Sensor (Rear) 1435
Brake Pressure Sensor 1436
Service Brake Pedal Position Sensor 1437
E-Brake Position Sensor 1437
Park Brake Position Sensor 1438
Brake Fluid Level Sensor 1439
Accelerator Pedal Position (APP) Sensor 1439
Load Weight Sensor 1440
Frame 1440
Impact Sensor 1441
Steer Axle Position Sensor 1441
Mast 1442
Mast Lift Height Sensor (Discrete) 1442
Mast Height Sensor (Continuous) 1443
Mast Tilt Sensor 1443
Transmission Sensors 1444
Transmission Output Shaft Sensor (TOSS) 1444
Pressure Sensor 1445
Temperature Sensor 1445
Fuel 1446
Fuel Water Separator Sensor 1446
Fuel Level Sensor (Gas and Diesel Engines) 1446
LPG Tank Bracket Sensor 1447
Fuel Quality Sensor (FQS) – LPG and Dual Fuel Engines 1448
Engine 1449
Air Filter Restriction Sensor 1451
Throttle Position Sensor (TPS) 1451
Oil Pressure Sensor 1451
Engine Coolant Temperature (ECT) Sensor 1451
Engine Speed Sensor 1452
Low Coolant Level Sensor 1452
Exhaust System 1453
Heated Oxygen Sensor 1453
Exhaust Gas Temperature (EGT) Sensor 1453
EGR Temperature Sensor 1453
EGR Pressure Sensor 1453
Controller area network (CAN) description 1454
Controller Area Network (CAN) 1454
Operation 1454
Standard CAN 1455
Identifier Fields 1455
Message Types 1456
Multiple CANs 1456
CAN1 (Vehicle Bus) 1456
CAN2 (DriveTrain Bus) 1457
CAN3 (Front End) 1457
CAN4 (Service) 1458
CAN Failure 1458
Display description 1458
Display Description 1458
2 8-Inch Display 1458
5- or 7-Inch Display 1459
Electrical Specifications 1460
Wake Up 1460
Wake Up Output 1460
Memory Support 1460
Display Viewing 1461
Ambient Light Sensor 1461
Video Inputs 1461
Controller CAN Communications 1461
5-Button Keypad 1461
Male Connector Polarities 1462
2 8-Inch Display 1462
5-Inch Display 1464
7-Inch Display 1466
Battery description 1468
Battery Overview 1468
Battery Types 1469
Conventional 1469
Maintenance-Free 1469
Battery Charging 1469
Fast Charging 1470
Slow Charging 1470
Battery Disconnect Switch (Optional) 1470
Battery Charge Dongle (Optional) 1471
Lights description 1472
Lights 1472
Pedestrian Awareness Lights 1472
Orange Strobe Light 1472
Red or Blue Spot Lights 1473
Red LED Pedestrian Awareness Perimeter Lights 1474
Work Lights 1475
Front or Rear or Both 1475
Mast Mounted 1476
Brake, Tail, Reverse, Turn Signals, Hazard 1477
Brake Lights (Red) 1478
Tail Lights (Red) 1478
Turn Signals (Amber) 1478
Hazard 1478
Reverse Lights (White) 1478
Fork Laser Level Light (Line) 1478
Interior Reading Light (Cab Only) 1479
Software description 1479
Software Description 1480
Configuration Data File (CDF) 1480
Display Application (Program) 1480
Vehicle System Manager (VSM) Application (Program) 1480
Service Tools 1480
PC Service Tool (PCST) 1480
System Requirements 1481
Main Screen 1481
Field Prog Programming Tool 1482
Yanmar Smart Assist Direct (SAD) Tool (Engine) 1484
System Requirements 1484
ECU Replacement or Update 1485
Telemetry system description 1486
General 1486
Telemetry Module 1490
Basic Operations 1491
ID Card / ID Reader 1491
Interlock Relay 1492
Buzzer 1492
Wakeup 1492
Checklist 1492
Dynamic Stability System (DSS) 1492
Components of the DSS 1493
Vehicle System Manager (VSM) 1493
Lift Height Sensor 1493
Hydraulic Load Sensor 1493
Tilt Angle Sensor 1494
Tilt Override Button 1494
Speed Sensor 1494
Steer Angle Sensor 1494
DSS Subsystems 1494
Lateral Stability System 1494
High-Lift Traction Control 1494
High-Lift Tilt Control 1494
Corner Control 1495
DSS indicators and events 1495
Visual indicators 1496
Audible indicator 1497
Telemetry 1497
Operator’s cab 1498
Overhead guard description 1498
Overhead Guard 1498
Cab components description 1500
Cab Components 1500
Doors 1500
Steel Doors 1501
PVC Doors 1501
Screens 1503
Front Screen 1503
Top (Roof) Screen 1503
Rear Screen 1503
Wipers 1504
Front Screen and Wiper 1504
Top Screen and Wiper 1505
Rear Screen and Wiper 1506
Washer Fluid Tank and Supply Lines 1507
Heating and Cooling 1508
HVAC Controls 1514
Front and Rear Work Lights 1515
Strobe Light 1515
Operator Fan 1515
Front Grab Handle 1515
Rear Drive Handle with Horn Button 1516
12 Volt Power Supply with 2 USB Charging Ports 1516
12 Volt Auxiliary Wire Harness 1517
Reading (Dome) Light 1518
Seat description 1518
Seat Description 1518
Non-Suspension 1519
Semi-Suspension 1519
Full Suspension 1520
Air Ride Full Suspension 1520
Serviceable Parts 1520
Seat Belts 1520
Operator Presence Sensor (OPS) 1520
Operator controls description 1522
Operator Controls Description 1523
LCD Display (User Interface) 1523
Radio Frequency IDentification (RFID) Card Reader 1523
Steering Wheel and Horn 1524
Manual Hydraulic Levers 1524
Mini-Lever Module (MLM) Hydraulic Levers 1525
Joystick Hydraulic Controls 1525
Wiper Lever 1526
Turn Signal Lever 1527
Direction (FNR) Lever 1528
Dash and Cab Control Modules 1528
Manual Park Brake and Release 1529
Park Brake Rocker Switch (Optional) 1530
Accelerator Pedal 1530
Foot Direction Control (FDC) 1530
Dual Pedal Direction Control 1531
Keyed Ignition Switch 1531
Keyless Ignition Switch 1532
Pushbutton Ignition Switch 1532
Operator Seat 1533
Dome Light and Rocker Switch 1533
Rear Drive Handle with Horn Button 1534
Driver’s Fan and Fire Extinguisher 1534
Drivetrain 1535
Diesel engine description 1535
General Engine Information 1535
Combustion Theory 1535
Engine Block 1536
Camshaft and Timing Set 1538
Cylinder Head 1539
Valve Train 1541
Manifolds 1541
Intake 1541
Exhaust 1541
Air Cleaner/Filter 1542
Diesel Fuel System 1542
Electronic Fuel Injection (EFI) 1543
Positive Crankcase Ventilation (PCV) 1543
Battery Construction 1544
Conventional Standard Battery 1544
Maintenance-Free Battery 1545
Battery Charging 1545
Battery Fast Charging 1545
Battery Slow Charging 1546
Starting System Principles of Operation 1546
Starting System Components – Ignition Switch 1546
Starting System Components – Starter Solenoid 1546
Starting System Components – Flywheel and Ring Gear 1547
Starting System Components – Starter and Motor Drive 1547
Charging System – General 1549
Charging System – Regulator 1549
Charging System – Theory 1549
Exhaust Aftertreatment 1550
Description and Operation 1550
Diesel Particulate Filter (DPF) – Yanmar 1550
Yanmar Diesel Engine 1552
Yanmar Diesel Fuel System 1553
Fuel Water Separator 1554
Supply Pump 1555
Common Rail 1555
Injector 1555
Crankshaft Rotation Sensor and Gear Speed Sensor 1555
ECU 1555
Engine Mechanical 1556
Engine Cooling 1557
Engine Oil 1559
Engine Main Electronic Control Components 1560
Engine Control Unit (ECU) 1561
Fuel Feed Pump 1561
Fuel Pump (Supply Pump) 1561
Common Rail 1562
Fuel Injector 1562
Exhaust Gas Recirculation (EGR) valve 1562
Diesel Particulate Filter (DPF) 1563
Intake Throttle 1563
Exhaust Throttle (Optional) 1563
Accelerator Pedal Position (APP) Sensor 1564
Engine Coolant Temperature Sensor 1564
Crankshaft Rotation Sensor 1564
Gear Speed Sensor 1564
New Air Temperature Sensor 1565
Exhaust Gas Recirculation (EGR) Temperature Sensor 1565
EGR (EGR) Pressure Sensor 1565
Intake Air Temperature Sensor 1566
Engine Coolant Thermostat 1566
DPF Inside/Inlet Temperature Sensors 1567
DPF Differential Pressure Sensor 1567
Fuel Rail Pressure Sensor 1568
Engine ECU Management Controls 1568
Cold Start Assist 1568
Droop Control 1568
Isochronous Control 1568
Low-Idle Speed Up 1569
Turbocharger Protection (at low temperature) 1569
High-Idle Speed Reduction at Low Temperature (optional) 1569
Auto Idle Speed Reduction (optional) 1569
DPF Regeneration Control 1569
Self-Regeneration 1569
Assisted Regeneration 1569
Reset Regeneration 1569
Manual (Stationary) Regeneration 1569
Diagnostic Tool Tests and Adjustments 1569
EGR Active Control 1569
Exhaust Gas Throttle Active Control 1569
Intake Air Throttle Active Control 1569
LPG engine description 1569
Engine coolant system 1569
Engine oil 1570
Fuel system 1571
Vaporizer 1574
Balancing line 1574
Fuel rail 1574
Injector 1574
Crankshaft speed sensor and cam speed sensor 1574
Gas temperature pressure sensor 1574
ECU 1574
Engine trouble caused by improper fuel 1574
Fuel properties and engine performance 1574
Bi-fuel engine description 1575
CNG engine description 1575
Powershift transmission description 1575
Powershift Transmission 1575
Mechanical Overview 1575
Engine 1575
Torque Converter 1575
Stator 1576
Turbine 1576
Transmission 1577
Single-Speed 1579
Clutch Packs 1580
Forward Operation 1582
Reverse Operation 1582
Transmission Hydraulic Schematic 1582
Transmission Oil Flow 1586
Control Valve Oil Flow 1586
Control Valve 1587
Torque Converter Regulator 1589
Electrical System Architecture 1589
Transmission Input Shaft Speed (TISS) 1591
Transmission Output Shaft Speed (TOSS) 1592
Transmission Oil Temperature Sensor 1593
Accelerator Pedal Position (APP) Sensor 1593
Electrical Control Schematic 1594
Transmission Operational Modes 1596
Powered Off Mode 1596
Neutral Interlock Mode 1596
Normal Mode 1596
Fault Mode 1596
Pack Braking Mode 1596
Inching Mode 1596
Transmission Output Gear Yoke and Driveshaft 1596
Transmission, Driveshaft, and Drive Axle 1597
Hydrostatic transmission description 1598
Wet brake axle description 1598
Dry brake axle description 1598
Dry Brake Axle 1598
Synchronous steer axle description 1603
Synchronous Steering 1603
Operation 1604
Components 1604
Steering Wheel Sensor 1604
Steer Axle Position Sensor 1604
Calibration 1605
Synchronous Steering Hydraulic Schematic 1605
Non-synchronous steer axle description 1606
Non-Synchronous Steer Axle 1606
Steer Axle Components 1607
Top Bushing Blocks 1608
Center Pivot Mount Bushings 1608
Steer Axle Mounting Brackets 1608
Steering Cylinder 1608
Tie Rods 1608
Spindle Assembly 1609
Wheel Hub 1609
Powertrain Protection System 1609
Cooling 1611
Fan description 1611
Fan (Radiator Cooling) 1611
Crankshaft Belt Drive Fan 1611
Hydraulic Belt Drive Fan 1611
Cooling system description 1612
Cooling System 1612
Radiator 1613
Radiator Cap 1614
Cooling Fan 1614
Thermostat 1614
Coolant Pump 1615
Coolant Recovery Reservoir 1615
Coolant 1616
Radiator description 1616
Radiator 1616
Radiator Cap 1617
Charge Air Cooler (CAC) 1617
Radiator Screen (Optional) 1617
Front end 1618
Fork description 1618
Fork Description 1618
Fork Inspections and Service 1619
Fork Classification 1619
Fork Terminology 1620
Fork Tip Options 1622
Fork Bevel Options 1623
Fork Taper Options 1623
Fork Identification 1624
Miscellaneous Forks 1624
Standard Carriage and Forks 1624
Carriage description 1625
Carriage Description 1625
Carriage Classification 1625
Standard Carriage 1626
Load Backrest (LBR) Extension 1627
Integral Sideshift (ISS) Carriage 1629
Integral Sideshift Carriage with Fork Positioner (ISSFP) 1630
Mast description 1631
Mast Overview 1631
2-stage limited free lift (LFL) mast description 1632
2-stage LFL mast description 1632
Basic Operation 1634
Two Stage Limited Free-Lift 1635
Mast Hydraulic Components 1640
Two Stage LFL Header Hose 1640
Main Lift Cylinders 1642
Mast Hose Manifold 1643
Velocity Fuse 1643
Hoses and Hose Assemblies 1643
Hose Fittings 1643
Mast Mechanical Components 1644
Lift Chain 1644
Chain Anchors 1644
Chain Sheaves 1645
Load Rollers 1645
Wear Strips 1646
Mast Mounting Bushings 1646
2-stage full free lift (FFL) mast description 1646
2-stage FFL mast description 1646
Basic Operation 1648
Two Stage Full Free-Lift 1649
Mast Hydraulic Components 1655
Two Stage FFL Header Hose 1655
Free-Lift and Main Lift Cylinders 1657
Mast Hose Manifold 1658
Velocity Fuse 1659
Hoses and Hose Assemblies 1659
Hose Fittings 1659
Mast Mechanical Components 1659
Lift Chain 1659
Chain Anchors 1660
Chain Sheaves 1661
Load Rollers 1661
Wear Strips 1662
Mast Mounting Bushings 1662
3-stage full free lift (FFL) mast description 1663
3-Stage FFL mast description 1663
Basic Operation 1665
Three Stage Full Free-Lift 1666
Mast Hydraulic Components 1674
Three Stage FFL Header Hose 1674
Free-Lift and Main Lift Cylinders 1676
Mast Hose Manifold 1677
Velocity Fuse 1678
Hoses and Hose Assemblies 1678
Hose Fittings 1678
Mast Mechanical Components 1678
Lift Chain 1678
Chain Anchors 1679
Chain Sheaves 1680
Load Rollers 1680
Wear Strips 1681
Mast Mounting Bushings 1681
4-stage full free lift (FFL) mast description 1682
Paper roll clamp description 1682
Bale clamp description 1682
Rotator description 1682
550232103 8000YRM2309 (06 2023) US EN 1685
Introduction 1691
General 1691
Truck vital measurements 1692
Weight specifications 1692
Lift truck lifting capacity 1692
Counterweight weights 1692
Speed specifications 1692
Engine speeds 1692
Mast lower speeds 1693
Carriage lifting speeds with metric rated load at governed RPM and 55°C oil temperature (+/- 5%) 1693
Front end equipment max drift speeds* 1693
Dimension specifications 1694
Tire sizes 1694
Mast tilt specifications 1695
Pressure specifications 1695
Hydraulic system pressure specifications 1695
Coolant system pressure specifications 1695
Steering system pressure specifications 1695
Tire pressure specifications 1696
Transmission oil specifications 1696
Engine operation specifications 1697
Engine operation specifications 1697
Fluid specifications and capacities 1698
Fuel specifications and capacities 1698
Fuel tank capacity 1698
Lubricant specifications and capacities 1699
Engine oil 1699
Hydraulic tank oil 1699
Transmission oil 1700
Brake fluid 1700
Dry brake axle 1700
Wet brake axle 1700
Coolant specifications and capacities 1701
Cooling capacity 1701
Torque specifications 1702
Frame torque specifications 1702
Energy, electrical, and controls systems torque specifications 1702
Front end torque specifications 1702
Carriage 1702
Mast 2 stage FFL 1703
Mast 3 Stage FFL 1703
Mast 2 stage LFL 1703
Hydraulic torque specifications 1703
Operator station torque specifications 1704
Rectangle overhead guard 1704
Figure 8 overhead guard 1704
Drivetrain torque specifications 1705
Engine – Yanmar 2 1L Diesel 1705
Engine – Yanmar 2 2L LPG 1706
Transmission 1707
Drive axle (Dry Brake) 1707
Drive axle (Wet Brake) 1708
Brakes 1708
Park brake 1708
Steering axle 1708