Yale Forklift A910 (GC_GLC040-GLC070VX) Service Manual – PDF DOWNLOAD

Description

Yale Forklift A910 (GC_GLC040-GLC070VX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A910 (GC_GLC040-GLC070VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 6218
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift A910 (GC_GLC040-GLC070VX) 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
524223754-0100YRM1120-(12-2012)-US-EN 2097
toc 2097
Frame 2097
Safety Precautions Maintenance and Repair 2098
General 2101
Description 2101
Hood, Seat, and Side Covers Replacement 2102
Remove 2102
Install 2108
Steering Column 2113
Description 2113
Steering Column Repair 2113
Remove 2113
Disassemble 2115
Clean 2115
Inspect 2115
Assemble 2115
Install 2118
LPG Tank and Bracket Assembly 2118
Counterweight Replacement 2119
Remove 2119
Install 2122
Tow Pin, Remove and Install 2123
Overhead Guard Replacement 2123
Remove and Install 2123
LED Tail, Backup, and Brake Lights, Replace 2124
Operator Restraint System Replacement 2125
Description 2125
Automatic Locking Retractor (ALR) 2125
Emergency Locking Retractor (ELR) 2125
Engine Replacement 2127
Remove 2127
Install 2132
Transmission Replacement 2134
Remove Transmission with Iron Housing 2134
Install Transmission with Iron Housing 2136
Remove Transmission with Aluminum Housing 2136
Install Transmission with Aluminum Housing 2141
Throttle Pedal and Cable Adjustment 2144
Mazda Gas/LPG Engines With Basic Power Shift Transmission and El 2144
Mazda Gasoline Engine With Electronic Transmission 2146
Throttle Pedal Stop Adjustment 2147
Yanmar Diesel Engine With Basic Power Shift Transmission 2148
Yanmar Diesel Engine With Electronic Throttle 2148
Exhaust System Repair 2149
Lift Trucks With Counterweight Exhaust System 2149
Mazda Gas and LPG Engines 2149
Remove and Disassemble 2149
Inspect 2149
Assemble and Install 2149
Yanmar Diesel Engine 2151
Remove and Disassemble 2151
Inspect 2151
Assemble and Install 2151
Lift Trucks With Overhead Exhaust System 2153
Yanmar Diesel Engine 2153
Remove and Disassemble 2153
Inspect 2153
Assemble and Install 2154
Mazda Gas and LPG Engines 2156
Remove and Disassemble 2156
Inspect 2156
Assemble and Install 2156
Cooling System 2158
Description 2158
Hydraulic Filter Assembly Repair 2158
Remove 2158
Clean and Inspect 2159
Install 2159
Fuel and Hydraulic Tanks Repair 2160
Inspect 2160
Clean 2160
Steam Method of Cleaning 2160
Chemical Solution Method of Cleaning 2161
Additional Preparations for Repair 2161
Small Leaks, Repair 2161
Large Leaks, Repair 2161
Preparations for Use After Repair 2162
Safety Labels 2162
tables 2097
Table 1 Gas Spring Installation, Lift Truck Models GLP/GDP16VX, 2109
Table 2 Gas Spring Installation, Lift Truck Models GLP/GDP20-35 2111
Table 3 Weight of Counterweights, Lift Truck Models GLC20-35VX 2121
Table 4 Weight of Counterweights, Lift Truck Models GC/GLC030VX 2121
Table 5 Weight of Counterweights, Lift Truck Models GLP/GDP16-1 2121
Table 6 Weight of Counterweights, Lift Truck Models GLP/GDP20-3 2121
524223755-0600YRM1121-(12-2012)-US-EN 2169
toc 2169
GM Engine Repair 2169
Safety Precautions Maintenance and Repair 2170
General 2175
Engine Serial Number 2175
Engine Removal and Installation 2177
Intake Manifold 2177
Remove 2177
Clean and Inspect 2178
Install 2178
Exhaust Manifold 2179
Remove 2179
Clean and Inspect 2179
Install 2179
Camshaft and Cylinder Head Repair 2180
Rocker Arm Cover 2180
Remove 2180
Install 2180
Camshaft Timing Pulley and/or Front Seal 2180
Remove 2180
Install 2181
Camshaft Carrier and Cylinder Head 2182
Remove 2182
Disassemble 2183
Camshaft Carrier 2183
Cylinder Head 2184
Clean and Inspect 2185
Camshaft Carrier 2185
Cylinder Head 2185
Valve and Valve Seat 2187
Assemble 2188
Cylinder Head 2188
Camshaft Carrier 2188
Install 2188
Timing Belt 2190
Timing Belt Front Cover 2190
Remove 2190
Install 2191
Timing Belt and Timing Belt Tensioner 2191
Remove 2191
Install 2192
Timing Belt Rear Cover 2193
Remove 2193
Install 2193
Lubrication System Repair 2194
Oil Pan 2194
Remove 2194
Install 2194
Oil Pump 2196
Remove 2196
Clean and Inspect 2197
Install 2198
Piston and Piston Rod Assemblies Repair 2198
Piston Rod Bearings, Replace 2198
Piston and Piston Rod Assemblies 2200
Remove 2200
Disassemble 2201
Pistons, Clean and Inspect 2202
Cylinder Bores, Inspect and Repair 2202
Piston Rings, Inspect 2203
Assemble 2204
Install 2204
Crankshaft and Main Bearings 2205
Crankshaft Timing Pulley and/or Front Seal 2205
Remove 2205
Install 2206
Crankshaft Rear Main Oil Seal 2207
Remove 2207
Install 2207
Crankshaft/RPM Sensor 2207
Remove 2207
Install 2208
Crankshaft Reluctor Wheel 2208
Remove and Install 2208
Crankshaft and Main Bearings 2208
Remove 2208
Inspect and Repair 2209
Bearing Selection 2210
Main Bearings and Journal Clearance, Check 2211
Install 2212
Flywheel and Flywheel Housing 2213
Remove 2213
Install 2213
Cooling System Repair 2214
Serpentine Belt 2214
Remove 2214
Inspect 2214
Install 2214
Water Pump 2215
Remove 2215
Inspect 2215
Install 2217
Thermostat 2218
Remove 2218
Check 2218
Install 2219
Thermostat Housing 2220
Remove 2220
Clean and Inspect 2220
Install 2220
Sensors and Switches 2222
Crankshaft Position (CKP) Sensor 2222
Remove 2222
Install 2222
Camshaft Position (CMP) Sensor 2222
Remove for Lift Trucks Built Before January, 2010 2222
Assembly 2222
Sensor Only 2222
Install for Lift Trucks Built Before January, 2010 2223
Assembly 2223
Sensor Only 2223
Remove for Lift Trucks Built After January, 2010 2224
Install for Lift Trucks Built After January, 2010 2224
Oil Pressure Sensor 2224
Remove 2224
Install 2224
Ignition System 2225
Spark Plug Wire Inspection 2225
Spark Plug Wire Replacement 2225
Remove 2225
Install 2226
Spark Plug Replacement 2226
Remove 2226
Install 2227
Spark Plug Inspection 2227
Usage 2227
Inspect 2227
Visual Inspection 2229
Coil Pack 2229
Remove 2229
Install 2229
Alternator Repair 2230
Alternator 2230
Remove 2230
Install 2230
Alternator Fuse, Replace 2230
Starter Repair 2231
Remove 2231
Install 2231
Engine Specifications 2232
Engine Data 2232
Cylinder Bore 2232
Piston 2232
Piston Rings 2233
Wrist Pin 2233
Crankshaft 2233
Piston Rod 2234
Camshaft and Camshaft Carrier 2234
Valve System 2234
Cylinder Head Warpage 2235
Lubrication System 2235
Cooling System 2235
Torque Specifications 2236
Special Tools 2237
524223756-0600YRM1122-(03-2020)-US-EN 2243
General 2247
Serial Number 2248
Engine Removal and Installation 2248
Cylinder Head, Camshaft, and Valve Mechanism Repair 2248
Remove 2248
Clean 2251
Inspect and Repair 2251
Cylinder Head 2251
Rocker Shaft Assembly 2251
Camshaft 2252
Valve Guides 2253
Valve Seats 2253
Valves 2254
Valve Springs 2254
Install 2255
Crankshaft and Main Bearings Repair 2259
Remove 2259
Inspect and Repair 2260
Crankshaft 2260
Main Bearings 2260
Install 2261
Pistons and Connecting Rods Repair 2262
Remove and Disassemble 2262
Clean 2262
Inspect and Repair 2262
Pistons 2262
Piston Rings 2262
Connecting Rods and Bearings 2263
Assemble and Install 2263
Cylinder Block Repair 2265
Oil Pump Repair 2266
Remove 2266
Disassemble 2267
Clean 2267
Inspect 2267
Assemble 2268
Install 2268
Cooling System Repair 2270
Thermostat 2270
Replace 2270
Fan Assembly 2270
Remove and Disassemble 2270
Assemble and Install 2271
Water Pump 2271
Remove 2271
Install 2272
Flywheel and Ring Gear Repair 2273
Remove 2273
Install 2273
Valve Adjustment 2273
Compression Pressure Check 2275
Engine Timing Adjustment 2276
Engine Specifications 2276
Engine Data 2276
Engine Speeds 2276
2007, and Later, Emission Compliant Engines 2276
All Engines Except 2007, and Later, Emission Compliant Engines 2277
Thermostat 2277
Cylinder Head 2277
Valve Mechanism 2277
Camshaft 2278
Crankshaft 2278
Connecting Rods 2278
Cylinder Block 2279
Pistons 2279
Oil Pump 2279
Torque Specifications 2280
524223757-0700YRM1123-(06-2016)-US-EN 2283
General 2287
Cooling System Checks 2287
Exhaust Leaks Into Cooling System 2287
Water Flow Restrictions in Radiator 2287
Radiator Hoses 2287
Water Pump 2288
Flushing the Cooling System 2288
Cooling System, Clean 2288
Radiator Replacement 2289
Radiator, Remove GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2290
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2305
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2308
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 2311
Radiator, Install for Lift Truck Models GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2318
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2323
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2325
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2328
Fan Assembly Replacement 2340
Fan Removal 2340
Inspect 2355
Fan Installation 2355
524223757-0700YRM1123-(06-2021)-US-EN 2361
General 2365
Cooling System Checks 2365
Exhaust Leaks Into Cooling System 2365
Water Flow Restrictions in Radiator 2365
Radiator Hoses 2365
Water Pump 2365
Flushing the Cooling System 2367
Cooling System, Clean 2367
Radiator Replacement 2369
Radiator, Remove GC/GLC030VX,GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX (GP/GLP/GDP030VX,GP/GLP/GDP035VX, GP/GLP/GDP040SVX)(C810); GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910); GLC050LX(A967); GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875);GLP/GDP20-25LX (GLP/GDP050LX)(A974); GLC40, 45, 55VX, GLC55SVX,(GC/GLC080, 100, 120VX, GC/GLC080,100VXBCS, GC/GLC120SVX,GC/GLC120VXPRS) (E818, F818) ANDGLP/GDP40VX5/VX6, GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) 2369
Radiator, Remove for Lift Trucks Models Equipped with Oil CoolerGC/GLC030VX, GC/GLC035VX,GC/GLC040SVX (C809); GLP/GDP16VX,GLP/GDP18VX, GLP/GDP20SVX(GP/GLP/GDP030VX, GP/GLP/GDP035VX,GP/GLP/GDP040SVX) (C810); GLC050LX(A967) AND GLP/GDP20-25LX(GLP/GDP050LX) (A974) 2384
Radiator, Remove for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2387
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX(GP/GLP/GDP135VX, GP/GLP/GDP155VX)(C878, D878, E878) and GLP/GDP80VX,GLP/GDP80VX9, GLP/GDP90VX(GLP/GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (A909, B909) 2390
Radiator, Install for Lift Truck Models GC/GLC030VX,GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX (GP/GLP/GDP030VX,GP/GLP/GDP035VX, GP/GLP/GDP040SVX)(C810); GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910); GLC050LX(A967); GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875);GLP/GDP20-25LX (GLP/GDP050LX)(A974); GLC40, 45, 55VX; GLC55SVX;(GC/GLC080, 100, 120VX; GC/GLC080,100VXBCS; GC/GLC120SVX;GC/GLC120VXPRS) (E818, F818) andGLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) 2396
Radiator, Install for Lift Truck Models Equipped with Oil CoolerGC/GLC030VX, GC/GLC035VX,GC/GLC040SVX (C809); GLP/GDP16VX,GLP/GDP18VX, GLP/GDP20SVX(GP/GLP/GDP030VX, GP/GLP/GDP035VX,GP/GLP/GDP040SVX) (C810); GLC050LX(A967) and GLP/GDP20-25LX(GLP/GDP050LX) (A974) 2400
Radiator, Install for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2401
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2404
Fan Assembly Replacement 2415
Fan Removal 2415
Inspect 2429
Fan Installation 2430
524223758-0900YRM1124-(04-2018)-US-EN 2435
General 2439
Hoses Replacement 2439
LPG Tank and Bracket Replacement 2439
Remove LPG Tank 2439
Install LPG Tank 2441
Remove LPG Bracket 2442
Install LPG Bracket 2444
Remove LPG Tank Bracket Alignment Pin 2444
Install LPG Tank Bracket Alignment Pin 2446
Fuel Filter Unit Repair 2446
Fuel Filter Element 2446
Remove 2446
Clean/Inspect 2447
Install 2447
Fuel Filter Housing 2447
Remove 2447
Disassemble 2448
Assemble 2448
Install 2449
Electronic Throttle Body Repair 2449
Electronic Throttle Body 2449
Remove 2449
Install 2450
Electronic Throttle Body Adapter Plate 2450
Remove 2450
Install 2450
Fuel Injector Repair 2450
Fuel Rail 2451
Remove for Lift Trucks Built Before January, 2010 2451
Install for Lift Trucks Built Before January, 2010 2452
Remove for Lift Trucks Built After January, 2010 2452
Install for Lift Trucks Built After January, 2010 2453
Fuel Injector for Lift Trucks Built Before January, 2010 2454
Remove 2454
Clean 2454
Install 2454
Fuel Injector Adapters for Lift Trucks Built Before January, 2010 2455
Remove 2455
Install 2457
Fuel Injectors and Adapters for Lift Trucks Built After January, 2010 2457
Remove 2457
Clean 2457
Install 2458
LPG Regulator Repair 2458
LPG Regulator 2458
Remove 2458
Install 2459
LPG Regulator Fuel Filter 2459
Remove 2459
Install 2460
Lock-Off Solenoid and Cartridge 2460
Remove 2460
Install 2461
Control System 2461
Electronic Control Unit (ECU) 2461
Remove 2461
Install 2463
Fuel Pump Relay 2463
Remove 2463
Install 2464
Injector Driver Module 2464
Remove 2464
Install 2465
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 2465
Remove 2465
Install 2465
Engine Coolant Temperature (ECT) Sensor 2466
Remove 2466
Install 2466
Oxygen Sensor 2466
Remove 2466
Install 2467
Low LPG Pressure Switch 2467
Remove 2467
Install 2468
Exhaust System Repair 2469
Remove and Disassemble 2469
Inspect 2470
Assemble and Install 2470
LPG Fuel Testing 2471
General 2471
Available Fuel Tests 2471
Composition Test (ASTM D-2163) 2471
Ammonia Test (ASTM D-4490) 2471
Basic Nitrogen Test (ASTM UOP269-90) 2471
Residues Test (ASTM D-2158) 2471
Vapor Pressure Test (ASTM D-2598) 2472
Sulfur Compounds Test (ASTM D-5623) 2472
Methanol Test (ASTM D-4864) 2472
Copper Corrosion (ASTM D-1838) 2472
Where To Send LPG Fuel Samples For Testing 2472
524223759-0900YRM1125-(05-2005)-US-EN 2475
toc 2475
LPG Fuel System 2475
Safety Precautions Maintenance and Repair 2476
General 2479
Hoses Replacement 2479
LPG Tank Replacement 2479
Remove 2479
Install 2481
Fuel Filter 2482
Remove 2482
Clean and Inspect 2482
Install 2483
Relief Valve Replacement 2484
Remove and Install 2484
Carburetor Repair 2484
Remove 2484
Disassemble 2484
Clean 2486
Assemble 2486
Install 2486
Fuel Injector Repair 2487
Remove 2487
Clean and Inspect 2487
Install 2487
Governor Repair 2487
Remove 2487
Install 2487
Regulator Repair 2488
Remove 2488
Install 2488
Control System 2489
Engine Control Unit (ECU) 2489
Remove 2489
Install 2490
Engine Coolant Temperature (ECT) Sensor 2490
Remove 2490
Install 2490
Camshaft Position (CMP) Sensor 2490
Voltage Check 2490
Intake Air Temperature (IAT) Sensor 2491
Remove 2491
Install 2491
Manifold Absolute Pressure (MAP) Sensor 2492
Remove 2492
Install 2492
Oxygen Sensor 2492
Remove 2492
Install 2492
Throttle Position (TP) Sensor 2493
Remove 2493
Install 2493
524223760-0900YRM1126-(02-2010)-US-EN 2497
toc 2497
Gasoline Fuel System 2497
Safety Precautions Maintenance and Repair 2498
General 2501
Electronic Throttle Body Repair 2501
Electronic Throttle Body 2501
Remove 2501
Install 2501
Fuel System Repair 2502
Before Repair Procedure 2502
After Repair Procedure 2502
Fuel Leakage Check for Lift Trucks Built Before January, 2010 2502
Fuel Leakage Check for Lift Trucks Built After January, 2010 2503
Fuel Line Pressure Check 2504
Fuel Injectors 2505
Remove 2505
Install 2507
Pressure Regulator 2508
Remove 2508
Install 2508
Control System 2508
Electronic Control Unit (ECU) 2508
Remove 2508
Install 2510
Power Latch Relay 2510
Remove 2510
Install 2510
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) 2511
Remove 2511
Install 2511
Engine Coolant Temperature (ECT) Sensor 2511
Remove 2511
Install 2512
Oxygen Sensor 2512
Remove 2512
Install 2512
Exhaust System Repair 2513
Remove and Disassemble 2513
Inspect 2513
Assemble and Install 2513
524223761-0900YRM1127-(05-2005)-US-EN 2517
toc 2517
Gasoline Fuel System 2517
Safety Precautions Maintenance and Repair 2518
General 2521
Abbreviations 2521
Engine Tune-up 2521
Engine Tune-Up Preparation 2521
Idle Speed Adjustment 2521
Idle-Up Speed Check 2521
Intake-Air System 2523
Intake-Air System Manifold Vacuum Check 2523
Throttle Body 2524
Remove 2524
Install 2524
Electronic Governor 2524
Remove 2524
Install 2524
Intake-Air Control (IAC) Valve 2524
Remove 2524
Install 2524
Intake Manifold 2526
Remove 2526
Install 2526
Fuel System 2527
Before Repair Procedure 2527
Fuel Line Safety Procedure 2527
After Repair Procedure 2527
Fuel Hose, Install 2527
Fuel Leakage Check 2528
Fuel Line Pressure Check 2528
Fuel Injector 2529
Remove 2529
Install 2530
Pressure Regulator 2530
Remove 2530
Install 2531
Exhaust System 2531
Exhaust System, Inspect 2531
Three-Way Catalytic (TWC) Converter 2531
Remove and Install 2531
Exhaust Manifold 2531
Remove 2531
Install 2531
Positive Crankcase Ventilation (PCV) Valve 2533
Remove 2533
Inspect 2533
Install 2533
Control System 2533
Engine Control Unit (ECU) 2533
Remove 2533
Install 2535
Intake Air Temperature (IAT) Sensor 2536
Remove 2536
Install 2536
Mass Air Flow (MAF) Sensor 2536
Remove 2536
Install 2536
Throttle Position (TP) Sensor 2537
TP Sensor, Adjust 2537
Remove 2538
Install 2538
Engine Coolant Temperature (ECT) Sensor 2538
Remove 2538
Install 2538
Camshaft Position (CMP) Sensor 2539
Voltage Check 2539
Oxygen Sensor 2540
Remove 2540
Install 2540
Manifold Absolute Pressure (MAP)/Boost Sensor 2540
Remove 2540
Install 2540
Technical Data 2541
tables 2517
Table 1 PCV Valve Specifications 2533
Table 2 Closed Throttle Position Specifications 2538
Table 3 Gasoline Fuel Systems Technical Data 2541
524223762-1300YRM1129-(11-2018)-US-EN 2545
General 2549
Serial Number 2549
Charge Pump Repair 2549
Remove 2549
Inspect 2550
Install 2550
Torque Converter Replace 2550
Remove 2550
Install 2558
Front Cover Housing and Chain Drive Repair 2564
Remove 2564
Clean 2573
Inspect 2573
Install 2573
Clutch Packs Repair 2582
Remove and Disassemble 2582
Transmission, Remove and Disassemble 2582
Clean 2601
Inspect 2601
Assemble and Install 2602
Transmission, Assemble and Install 2610
Control Valve Repair 2616
Remove and Disassemble 2616
Clean 2620
Inspect 2620
Assemble and Install 2620
Foot Directional Control Pedal Repair 2621
Remove and Disassemble 2621
Assemble and Install 2625
Direction Control Lever 2626
Remove 2626
Install 2626
524223763-1400YRM1132-(11-2008)-US-EN 2631
toc 2631
Drive Axle and Differential Assembly Repair 2631
Safety Precautions Maintenance and Repair 2632
General 2635
Drive Axle Repair 2635
Remove and Disassemble 2635
Clean and Inspect 2635
Assemble and Install 2637
Differential Repair 2639
Remove 2639
Differential Assembly From Center Section 2639
Drive Pinion, Pinion Gear, and Bearings From Center Section 2643
Disassemble 2647
Differential Assembly 2647
Drop Box Housing 2650
Center Section 2651
Clean and Inspect 2653
Assemble 2653
Center Section 2653
Drop Box Housing 2656
Differential Assembly 2657
Install 2661
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 2661
Drive Pinion, Pinion Gear, and Bearings Into Center Section 2663
Differential Assembly Into Center Section 2666
Ring Gear Backlash, Adjust 2672
Ring Gear, Runout Check 2673
Gear Set, Tooth Contact Pattern Check 2673
Torque Specifications 2676
tables 2631
Table 1 Pinion Variation Numbers Examples 2662
Table 2 Ring and Pinion Tooth Contact Adjustment 2673
Table 3 Correct Tooth Contact 2674
Table 4 Incorrect Tooth Contact 2675
524223764-1600YRM1133-(07-2013)-US-EN 2679
toc 2679
Steering Axle 2679
Safety Precautions Maintenance and Repair 2680
General 2683
Steering Axle Assembly Repair 2685
Remove 2685
Disassemble 2686
Clean 2694
Inspect 2694
Assemble 2694
Install 2700
Spindles, Bearings, and Tie Rods Repair 2702
Spindles and Bearings 2702
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2702
Remove 2702
Disassemble 2704
Clean 2705
Inspect 2705
Assemble 2705
Install 2706
Spindles and Bearings 2709
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2709
Remove and Disassemble 2709
Assemble and Install 2710
Tie Rods 2710
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2710
Remove 2710
Install 2711
Tie Rods 2712
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2712
Remove 2712
Install 2718
Steering Cylinder Repair 2718
Remove and Disassemble 2718
Clean and Inspect 2719
Assemble and Install 2719
Torque Specifications 2720
524223765-1800YRM1135-(09-2018)-US-EN 2725
General 2729
Dry Brake System 2729
Wet Brake System 2729
Service Brakes Repair (Dry Brake) 2729
Remove and Disassemble 2730
Clean 2738
Inspect 2738
Assemble and Install 2739
Adjust 2746
Inching Overlap Adjustment 2746
Parking Brake Repair 2747
Remove and Disassemble 2747
Assemble and Install 2750
Adjust 2750
Master Cylinder Repair 2751
Remove (Dry Brake) 2751
Disassemble (Dry Brake) 2752
Clean and Inspect (Dry Brake) 2754
Assemble (Dry Brake) 2754
Bench Bleed Master Cylinder (Dry Brake) 2754
Install and Adjust (Dry Brake) 2754
Remove (Wet Brake) 2755
Disassemble (Wet Brake) 2757
Clean and Inspect (Wet Brake) 2758
Assemble (Wet Brake) 2759
Install and Adjust (Wet Brake) 2759
Service Brakes Adjustment (Dry Brake) 2760
Brake System Air Removal 2760
Using Pressure Bleed System 2760
Using Brake Pedal Pressure 2761
Brake Pedal Adjustment 2761
Free Pedal Adjustment 2762
Torque Specifications 2764
524223766-1900YRM1136-(01-2022)-US-EN 2767
General 2771
Hydraulic Gear Pump Assembly 2772
Variable Displacement Pump Assembly 2773
Single Gear Pump Assembly Repair 2774
Remove 2774
Disassemble 2780
Clean 2782
Inspect 2782
Assemble 2782
Install 2782
Tandem Gear Pump Assembly 2787
Remove 2787
Disassemble 2788
Clean 2791
Inspect 2791
Assemble 2791
Install 2792
Gear Pump Specifications 2793
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2799
Remove 2799
Disassemble 2809
Clean 2812
Inspect 2813
Assemble 2813
Install 2813
63 0 cc/rev – Variable Displacement Pump Repair 2818
Remove 2818
Disassemble 2821
Clean 2823
Inspect 2823
Assemble 2823
Install 2823
Variable Displacement Pump Checks and Adjustments (Single Pump) 2827
Margin Pressure Check 2827
Flow Compensator Adjustment 2828
Pressure Compensator Adjustment 2828
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2830
Variable Displacement Pump Specifications 2833
Torque Specifications 2835
Hydraulic Gear Pump 2835
Variable Displacement Pump 2836
Special Tools 2837
524223766-1900YRM1136-(11-2017)-US-EN 2839
General 2843
Hydraulic Gear Pump Assembly 2844
Variable Displacement Pump Assembly 2845
Single Gear Pump Assembly Repair 2845
Remove 2845
Disassemble 2852
Clean 2852
Inspect 2854
Assemble 2854
Install 2854
Tandem Gear Pump Assembly 2858
Remove 2859
Disassemble 2861
Clean 2863
Inspect 2863
Assemble 2863
Install 2864
Gear Pump Specifications 2864
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2870
Remove 2870
Disassemble 2880
Clean 2883
Inspect 2883
Assemble 2883
Install 2884
63 0 cc/rev – Variable Displacement Pump Repair 2887
Remove 2887
Disassemble 2890
Clean 2890
Inspect 2890
Assemble 2892
Install 2892
Variable Displacement Pump Checks and Adjustments (Single Pump) 2894
Margin Pressure Check 2894
Flow Compensator Adjustment 2895
Pressure Compensator Adjustment 2895
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2896
Variable Displacement Pump Specifications 2899
Torque Specifications 2900
Hydraulic Gear Pump 2901
Variable Displacement Pump 2902
Special Tools 2902
524223767-2000YRM1137-(01-2017)-US-EN 2907
General 2913
Electro-Hydraulic Main Control Valve 2914
Description 2914
Remove 2922
Electro-Hydraulic Control Valve Sections 2927
General 2927
Outlet Control Valve Section 2927
Remove 2927
Disassemble 2928
Clean 2930
Inspect 2930
Assemble 2930
Install 2931
Auxiliary Control Valve Sections 2931
Remove 2931
Disassemble 2938
Clean 2939
Inspect 2940
Assemble 2940
Install 2942
Tilt Control Valve Section 2943
Remove 2943
Disassemble 2943
Clean 2949
Inspect 2949
Assemble 2949
Install 2950
Lift/Lower Control Valve Section 2951
Remove 2951
Disassemble 2951
Clean 2960
Inspect 2960
Assemble 2960
Install 2961
Mid-Inlet Section 2961
Remove 2961
Clean 2962
Inspect 2962
Install 2962
Install 2962
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2967
Lift Pilot Pin 2967
Lower Pilot Pin 2971
Abnormal/Erroneous EHPV Adjustment 2973
Manual Main Control Valve 2974
Description 2974
Remove 2978
OPS Solenoid Assembly 2986
General 2986
Remove 2987
Clean and Inspect 2990
Install 2990
Manual Control Valve Sections 2991
General 2991
Outlet Control Valve Section 2991
Remove 2991
Disassemble 2991
Clean 2994
Inspect 2994
Assemble 2994
Install 2995
Auxiliary Control Valve Sections 2995
Remove 2995
Disassemble 2995
Clean 2998
Inspect 2998
Assemble 2998
Install 2999
Lift/Tilt Control Valve Section 2999
Remove 2999
Disassemble 2999
Clean 3006
Inspect 3006
Assemble 3007
Install 3008
Mid-Inlet Section 3009
Remove 3009
Clean 3009
Inspect 3009
Install 3009
Install 3010
Pressure Relief Valve Check and Adjustment 3016
Primary Relief Valve 3017
Secondary Relief Valve 3021
Steering Control Unit Repair 3028
Steering Control Unit, Remove 3028
Steering Control Unit, Disassemble 3032
Steering Control Unit, Clean 3034
Steering Control Unit, Inspect 3034
Steering Control Unit, Assemble 3034
Relief Valve, Disassemble 3035
Relief Valve, Clean 3035
Relief Valve, Inspect 3036
Relief Valve, Assemble 3036
Steering Control Unit, Install 3036
524223767-2000YRM1137-(06-2021)-US-EN 3041
General 3045
Electro-Hydraulic Main Control Valve 3046
Description 3046
Remove 3054
Electro-Hydraulic Control Valve Sections 3059
General 3059
Outlet Control Valve Section 3059
Remove 3059
Disassemble 3059
Clean 3062
Inspect 3062
Assemble 3063
Install 3063
Auxiliary Control Valve Sections 3063
Remove 3064
Disassemble 3069
Clean 3071
Inspect 3071
Assemble 3071
Install 3073
Tilt Control Valve Section 3074
Remove 3074
Disassemble 3075
Clean 3079
Inspect 3079
Assemble 3080
Install 3081
Lift/Lower Control Valve Section 3081
Remove 3081
Disassemble 3081
Clean 3087
Inspect 3087
Assemble 3087
Install 3088
Mid-Inlet Section 3088
Remove 3088
Clean 3089
Inspect 3089
Install 3089
Install 3089
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 3094
Lift Pilot Pin 3094
Lower Pilot Pin 3097
Abnormal/Erroneous EHPV Adjustment 3099
Manual Main Control Valve 3100
Description 3100
Remove 3104
OPS Solenoid Assembly 3112
General 3112
Remove 3113
Clean and Inspect 3115
Install 3115
Manual Control Valve Sections 3116
General 3116
Outlet Control Valve Section 3116
Remove 3116
Disassemble 3116
Clean 3119
Inspect 3119
Assemble 3119
Install 3119
Auxiliary Control Valve Sections 3120
Remove 3120
Disassemble 3120
Clean 3123
Inspect 3123
Assemble 3123
Install 3123
Lift/Tilt Control Valve Section 3124
Remove 3124
Disassemble 3124
Clean 3130
Inspect 3130
Assemble 3130
Install 3132
Mid-Inlet Section 3132
Remove 3132
Clean 3133
Inspect 3133
Install 3133
Install 3133
Pressure Relief Valve Check and Adjustment 3141
Primary Relief Valve 3141
Secondary Relief Valve 3144
Steering Control Unit Repair 3149
Steering Control Unit, Remove 3149
Steering Control Unit, Disassemble 3153
Steering Control Unit, Clean 3155
Steering Control Unit, Inspect 3155
Steering Control Unit, Assemble 3155
Relief Valve, Disassemble 3156
Relief Valve, Clean 3156
Relief Valve, Inspect 3157
Relief Valve, Assemble 3157
Steering Control Unit, Install 3157
524223768-2100YRM1139-(02-2014)-US-EN 3161
524223769-2200YRM1128-(01-2023)-US-EN 3209
Series Code / Model Designation Reference Table 3217
General 3219
Deutsch Crimping Tool 3220
How to Strip a Wire for Use With Deutsch Crimping Tool 3220
How to Crimp With the Deutsch Crimping Tool 3221
Calibration Test for the Deutsch Crimping Tool 3223
Deutsch Connectors 3225
DT, DTM, and DTP Series Connectors 3225
HD Series Connectors 3268
Metri-Pack Connectors 3290
Remove and Install 3290
Micro-Pack Connectors 3293
Weather-Pack Connectors 3294
AMPSEAL Crimping Tools 3296
AMP Hand Crimping Tool With Certi-Crimp 3296
Description 3296
Stripping Wire for Use with AMP Hand Crimping Tool 3297
Insulation Crimp Adjustment 3298
Maintenance and Inspection for AMP Hand Crimping Tool 3298
AMP Hand Crimping Tool 3298
Crimp Height Inspection 3298
How to use AMP Hand Crimping Tool 3299
AMP Pro-Crimper II Tool 3299
Description 3299
Remove and Install Die Set and Locator Assembly 3300
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3300
Contact Support Adjustment 3301
Crimp Height Adjustment 3302
Maintenance and Inspection Procedures 3302
PRO-CRIMPER II Tool 3302
Crimp Height Inspection 3302
How to Use AMP PRO-CRIMPER II Tool 3303
AMPSEAL Connector Assemblies 3304
Description for Plug Connector Assembly 3304
Seal Plug 3305
Contact Crimping 3305
Description for Plug Connector and Header Assembly 3310
Voltage Reading 3313
Seal Plug 3313
Contact Crimping 3313
AMP Superseal 1 5 Crimping Tools 3320
Mini Mic Receptacle and Tab Contacts 3320
Description 3320
Crimping Conditions and Measurements 3320
Insertion of Rubber Seal on Cable 3322
AMP Hand Application Tool 3327
Description 3327
Maintenance and Inspection 3327
Crimp Height Inspection 3327
Crimp Height Adjustment 3328
How to Use AMP Hand Application Tool 3328
AMP Pro-Crimper II Tool 3329
Description 3329
Remove and Install Die Set and Locator Assembly 3329
Adjustments 3330
Contact Support 3330
Crimp Height 3331
Inspections and Maintenance 3332
Crimp Height Inspection 3332
Visual Inspection 3332
Maintenance 3333
How to Use Pro-Crimper II Tool 3333
AMP Superseal 1 5 Connector Assemblies 3334
Description 3334
Repair and Maintenance 3341
Panel Mount Option 3341
AMP Fastin-Faston Hand Tools 3342
Description – AMP Double Action Hand Tool 3342
Maintenance and Inspection Procedures 3342
Daily Maintenance 3342
Periodic Tool Inspection 3343
Lubrication 3343
Visual Inspection 3343
Crimp Height Inspection 3343
Certi-Crimp Ratchet Inspection 3344
How to Use AMP Double Action Hand Tool 3345
Description – AMP Extraction Tool 3346
Maintenance and Inspection 3347
How to Use AMP Extraction Tool 3347
AMP Fastin-Faston Receptacles and Housings 3349
Description 3349
Wire Repair 3357
Wire Splicing Requirements 3357
Deutsch Jiffy Splice 3358
Twisted/Shielded Cable and Leads Repair 3364
Special Tools 3366
524223769-2200YRM1128-(07-2020)-US-EN 3375
Series Code / Model Designation Reference Table 3381
General 3384
Deutsch Crimping Tool 3384
How to Strip a Wire for Use With Deutsch Crimping Tool 3384
How to Crimp With the Deutsch Crimping Tool 3385
Calibration Test for the Deutsch Crimping Tool 3387
Deutsch Connectors 3389
DT, DTM, and DTP Series Connectors 3389
HD Series Connectors 3431
Metri-Pack Connectors 3454
Remove and Install 3454
Micro-Pack Connectors 3456
Weather-Pack Connectors 3457
AMPSEAL Crimping Tools 3459
AMP Hand Crimping Tool With Certi-Crimp 3459
Description 3459
Stripping Wire for Use with AMP Hand Crimping Tool 3459
Insulation Crimp Adjustment 3460
Maintenance and Inspection for AMP Hand Crimping Tool 3460
AMP Hand Crimping Tool 3460
Crimp Height Inspection 3460
How to use AMP Hand Crimping Tool 3461
AMP Pro-Crimper II Tool 3461
Description 3461
Remove and Install Die Set and Locator Assembly 3462
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3463
Contact Support Adjustment 3463
Crimp Height Adjustment 3464
Maintenance and Inspection Procedures 3464
PRO-CRIMPER II Tool 3464
Crimp Height Inspection 3464
How to Use AMP PRO-CRIMPER II Tool 3465
AMPSEAL Connector Assemblies 3466
Description for Plug Connector Assembly 3466
Seal Plug 3467
Contact Crimping 3467
Description for Plug Connector and Header Assembly 3472
Voltage Reading 3474
Seal Plug 3474
Contact Crimping 3474
AMP Superseal 1 5 Crimping Tools 3481
Mini Mic Receptacle and Tab Contacts 3481
Description 3481
Crimping Conditions and Measurements 3481
Insertion of Rubber Seal on Cable 3483
AMP Hand Application Tool 3488
Description 3488
Maintenance and Inspection 3488
Crimp Height Inspection 3488
Crimp Height Adjustment 3489
How to Use AMP Hand Application Tool 3489
AMP Pro-Crimper II Tool 3490
Description 3490
Remove and Install Die Set and Locator Assembly 3491
Adjustments 3491
Contact Support 3491
Crimp Height 3492
Inspections and Maintenance 3493
Crimp Height Inspection 3493
Visual Inspection 3493
Maintenance 3494
How to Use Pro-Crimper II Tool 3494
AMP Superseal 1 5 Connector Assemblies 3495
Description 3495
Repair and Maintenance 3502
Panel Mount Option 3502
AMP Fastin-Faston Hand Tools 3503
Description – AMP Double Action Hand Tool 3503
Maintenance and Inspection Procedures 3503
Daily Maintenance 3503
Periodic Tool Inspection 3504
Lubrication 3504
Visual Inspection 3504
Crimp Height Inspection 3504
Certi-Crimp Ratchet Inspection 3505
How to Use AMP Double Action Hand Tool 3506
Description – AMP Extraction Tool 3507
Maintenance and Inspection 3507
How to Use AMP Extraction Tool 3508
AMP Fastin-Faston Receptacles and Housings 3509
Description 3509
Wire Repair 3516
Wire Splicing Requirements 3516
Deutsch Jiffy Splice 3517
Twisted/Shielded Cable and Leads Repair 3522
Special Tools 3525
524223770-2200YRM1130-(03-2020)-US-EN 3533
General 3537
Description 3537
Dash Display Menu Access 3537
Menu Navigation 3538
Standard Display 3538
Main Menu 3538
Passwords Menu 3539
Password Administration 3539
Add Password 3539
Delete Password 3540
Edit Password 3540
Other Password Functions 3541
Operator Passwords – Enable/Disable 3541
Password Time-Out Delay 3541
Passwords – Number Wrong to Disable 3542
Lockout Reset Password 3542
View Password Log 3543
View Versions 3544
VSM Versions 3544
Dash Display Versions 3545
Engine Controller Version 3546
Transmission (Xmsn) Controller Version 3547
Truck Serial Number 3548
Diagnostics 3549
View Fault Log 3549
Set Travel and Braking 3550
Speed Limit 3550
Acceleration Rate 3551
Auto-Deceleration Rate 3551
Set Power Reversal Rate 3552
Set Inching/Brake Overlap 3553
Setup Display Menu 3554
Set Operator Language 3554
Set Units 3555
Set Time Format (12/24 Hour) 3555
Set Daylight Saving Time 3555
Set Time 3558
Set Date Format 3559
Set Date 3559
Setup Hydraulics 3560
Return to Set Tilt Delay/On/Off 3560
Setup General Items 3561
Light Shutdown Time-Out 3561
Impact Sensor – Enable/Disable 3562
Impact Sensor – Soft Impact Settings 3563
Impact Sensor – Hard Impact Settings 3564
Adjust Impact Sensor Settings 3564
Initial Adjustment of Soft and Hard Impact Settings 3566
Readjustment of Soft and Hard Impact Settings 3566
Impact Sensor – Impact Alarm/Shutdown Reset 3567
Impact Sensor – Alarm Time Duration and Deactivation 3568
Impact Sensor – View Impact Event Log 3569
Engine Mode Indicator 3570
Generation 1 (ECO-eLo ONLY) 3570
Generation 2 3571
Operator Checklist 3572
Operator Checklist Off-On Mode 3572
Edit Operator Checklist 3572
Set Operator Checklist Expiration 3573
View Checklist Log 3573
Clear Operator Checklist Log 3574
Clear Operator Checklist Fault 3574
Calibrations 3575
Set Tilt Stop Point 3575
Calibrate Loaded Weight 3575
524223770-2200YRM1130-(05-2021)-US-EN 3577
General 3581
Description 3581
Dash Display Menu Access 3581
Menu Navigation 3582
Standard Display 3582
Main Menu 3582
Passwords Menu 3583
Password Administration 3583
Add Password 3583
Delete Password 3583
Edit Password 3584
Other Password Functions 3585
Operator Passwords – Enable/Disable 3585
Password Time-Out Delay 3585
Passwords – Number Wrong to Disable 3585
Lockout Reset Password 3586
View Password Log 3586
View Versions 3587
VSM Versions 3587
Dash Display Versions 3588
Engine Controller Version 3589
Transmission (Xmsn) Controller Version 3590
Truck Serial Number 3591
Diagnostics 3592
View Fault Log 3592
Set Travel and Braking 3593
Speed Limit 3593
Acceleration Rate 3594
Auto-Deceleration Rate 3594
Set Power Reversal Rate 3595
Set Inching/Brake Overlap 3596
Setup Display Menu 3597
Set Operator Language 3597
Set Units 3598
Set Time Format (12/24 Hour) 3598
Set Daylight Saving Time 3599
Set Time 3602
Set Date Format 3602
Set Date 3603
Setup Hydraulics 3604
Return to Set Tilt Delay/On/Off 3604
Setup General Items 3605
Light Shutdown Time-Out 3605
Impact Sensor – Enable/Disable 3606
Impact Sensor – Soft Impact Settings 3607
Impact Sensor – Hard Impact Settings 3607
Adjust Impact Sensor Settings 3608
Initial Adjustment of Soft and Hard Impact Settings 3610
Readjustment of Soft and Hard Impact Settings 3610
Impact Sensor – Impact Alarm/Shutdown Reset 3611
Impact Sensor – Alarm Time Duration and Deactivation 3612
Impact Sensor – View Impact Event Log 3613
Engine Mode Indicator 3613
Generation 1 (ECO-eLo ONLY) 3613
Generation 2 3614
Operator Checklist 3615
Operator Checklist Off-On Mode 3615
Edit Operator Checklist 3615
Set Operator Checklist Expiration 3615
View Checklist Log 3616
Clear Operator Checklist Log 3617
Clear Operator Checklist Fault 3617
Calibrations 3618
Set Tilt Stop Point 3618
Calibrate Loaded Weight 3618
524223771-2200YRM1131-(03-2020)-US-EN 3621
Series Code / Model Designation Reference Table 3627
General 3629
Description 3629
Dash Display Menu Access 3629
Menu Navigation 3630
Main Menu 3630
Passwords 3631
Adding Passwords 3631
Hourmeters 3633
View Versions 3634
VSM Versions 3634
Dash Display Versions 3635
Engine Controller Version 3636
Transmission (Xmsn) Controller Version 3637
Truck Serial Number 3638
Truck Configuration 3639
Diagnostics 3640
Clear Fault Log 3640
View Fault Log 3641
No-Run Data Display 3642
Engine Accelerator and Throttle Data Display 3642
Engine Speeds and Governor Data Display 3643
Engine Fuel and Emissions Data Display 3644
Engine General Data Display 3646
XMSN/Brake Data Display 3647
Hydraulic Data Display 3650
General Truck Data Display 3652
Set Travel and Braking 3653
Speed Limit 3653
Acceleration Rate 3654
Auto-Deceleration Rate 3655
Set Power Reversal Rate 3655
Set Inching/Brake Overlap 3656
Setup Hydraulics 3656
Lift Maximum Speed 3657
Lower Maximum Speed 3657
Tilt Maximum Speed 3658
Auxiliary Function One, Direction A, Maximum Speed 3660
Auxiliary Function One, Direction B, Maximum Speed 3662
Auxiliary Function Two, Direction A, Maximum Speed 3662
Auxiliary Function Two, Direction B, Maximum Speed 3663
Auxiliary Function Three, Direction A, Maximum Speed 3664
Auxiliary Function Three, Direction B, Maximum Speed 3664
Lift/Lower Ramp Rate 3665
Hydraulic Auxiliary Ramp Rate 3665
Return to Set Tilt Delay/On/Off 3666
Hydraulic Input Device 3667
Auxiliary Solenoid 3667
Dual Function 3668
Setup Display 3669
Set Service Language 3669
Setup General Items 3669
Motion Alarm Activation Type 3670
Light Shutdown Time-Out 3671
Restore Default Settings 3671
Restore Engine Controller Default Calibration 3672
Impact Sensor – Enable/Disable 3672
Impact Sensor – Soft Impact Settings 3673
Impact Sensor – Hard Impact Settings 3674
Adjust Impact Sensor Settings 3675
Initial Adjustment of Soft and Hard Impact Settings 3677
Readjustment of Soft and Hard Impact Settings 3677
Impact Sensor – Impact Alarm/Shutdown Reset 3678
Impact Sensor – Alarm Time Duration and Deactivation 3679
Impact Sensor – View Impact Event Log 3680
Engine Mode Indicator 3680
Generation 1 (ECO-eLo ONLY) 3680
Generation 2 3681
Diesel Particulate Filter (DPF) Display 3682
General Description 3682
Passive Regeneration Only 3682
Regeneration Level 0 3682
Auto/Active Regeneration Inhibited 3683
Auto/Active Regeneration 3683
Regeneration Level 1 3683
Parked Regeneration Request 3684
Regeneration Level 2 3684
Warning Level 3684
Regeneration Level 3 3684
Service Level 3685
Regeneration Level 4 3685
Display, Diesel Particulate Filter (DPF), Revised 3685
Operator Interface 3685
Refer to Operator Manual 3685
CAN Communication Lost 3686
Passive Regeneration Only 3686
Regeneration Level 0 3686
Auto/Active Regeneration Inhibited 3686
Auto/Active Regeneration 3687
Regeneration Level 1 3687
Idle-up Auto/Active Regeneration 3687
Parked Regeneration Request 3687
Regeneration Level 2 3687
Warning Level 3689
Regeneration Level 3 3689
Service Level 3689
Regeneration Level 4 3689
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3689
Display, Diesel Particulate Filter (DPF), Stage V Engine 3689
Operator Interface 3690
Refer to Operator Manual 3690
CAN Communication Lost 3690
Passive Regeneration Only 3690
Regeneration Level 0 3690
Auto/Active Regeneration Inhibited 3691
Auto/Active Regeneration 3691
Regeneration Level 1 3691
Idle-up Auto/Active Regeneration 3692
Parked Regeneration Request 3692
Regeneration Level 2 3692
Warning Level 3693
Regeneration Level 3 3693
Service Level 3694
Regeneration Level 4 3694
Stage V Content 3694
Emissions System Malfunction 3694
Ash Load 3694
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3695
Operator Interface 3695
Refer to Operator Manual 3695
CAN Communication Lost 3696
Passive Regeneration Only 3696
Regeneration Level 0 3696
Auto/Active Regeneration Inhibited 3696
Auto/Active Regeneration 3697
Regeneration Level 1 3697
Idle-up Auto/Active Regeneration 3697
Parked Regeneration Request 3697
Regeneration Level 2 3697
Warning Level 3699
Regeneration Level 3 3699
Service Level 3699
Regeneration Level 4 3699
Calibrations 3700
Calibrate Transmission Valve 3702
Set Tilt Stop Point 3702
Calibrate Loaded Weight 3702
Calibrate Travel Speed Sensor 3703
Calibrate Mazda LP and Gas Accelerator Pedal 3703
524223771-2200YRM1131-(05-2021)-US-EN 3705
Series Code / Model Designation Reference Table 3711
General 3713
Description 3713
Dash Display Menu Access 3713
Menu Navigation 3714
Main Menu 3715
Passwords 3715
Adding Passwords 3715
Hourmeters 3717
View Versions 3718
VSM Versions 3718
Dash Display Versions 3719
Engine Controller Version 3720
Transmission (Xmsn) Controller Version 3721
Truck Serial Number 3722
Truck Configuration 3723
Diagnostics 3724
Clear Fault Log 3724
View Fault Log 3725
No-Run Data Display 3726
Engine Accelerator and Throttle Data Display 3727
Engine Speeds and Governor Data Display 3729
Engine Fuel and Emissions Data Display 3730
Engine General Data Display 3732
XMSN/Brake Data Display 3733
Hydraulic Data Display 3735
General Truck Data Display 3738
Set Travel and Braking 3740
Speed Limit 3740
Acceleration Rate 3741
Auto-Deceleration Rate 3741
Set Power Reversal Rate 3742
Set Inching/Brake Overlap 3742
Setup Hydraulics 3743
Lift Maximum Speed 3743
Lower Maximum Speed 3744
Tilt Maximum Speed 3744
Auxiliary Function One, Direction A, Maximum Speed 3746
Auxiliary Function One, Direction B, Maximum Speed 3749
Auxiliary Function Two, Direction A, Maximum Speed 3749
Auxiliary Function Two, Direction B, Maximum Speed 3750
Auxiliary Function Three, Direction A, Maximum Speed 3751
Auxiliary Function Three, Direction B, Maximum Speed 3751
Lift/Lower Ramp Rate 3752
Hydraulic Auxiliary Ramp Rate 3752
Return to Set Tilt Delay/On/Off 3753
Hydraulic Input Device 3754
Auxiliary Solenoid 3754
Dual Function 3755
Setup Display 3756
Set Service Language 3756
Setup General Items 3756
Motion Alarm Activation Type 3757
Light Shutdown Time-Out 3758
Restore Default Settings 3758
Restore Engine Controller Default Calibration 3759
Impact Sensor – Enable/Disable 3759
Impact Sensor – Soft Impact Settings 3760
Impact Sensor – Hard Impact Settings 3760
Adjust Impact Sensor Settings 3761
Initial Adjustment of Soft and Hard Impact Settings 3763
Readjustment of Soft and Hard Impact Settings 3763
Impact Sensor – Impact Alarm/Shutdown Reset 3764
Impact Sensor – Alarm Time Duration and Deactivation 3765
Impact Sensor – View Impact Event Log 3766
Engine Mode Indicator 3766
Generation 1 (ECO-eLo ONLY) 3766
Generation 2 3767
Diesel Particulate Filter (DPF) Display 3768
General Description 3768
Passive Regeneration Only 3768
Regeneration Level 0 3768
Auto/Active Regeneration Inhibited 3769
Auto/Active Regeneration 3769
Regeneration Level 1 3769
Parked Regeneration Request 3770
Regeneration Level 2 3770
Warning Level 3771
Regeneration Level 3 3771
Service Level 3771
Regeneration Level 4 3771
Display, Diesel Particulate Filter (DPF), Revised 3771
Operator Interface 3772
Refer to Operator Manual 3772
CAN Communication Lost 3772
Passive Regeneration Only 3772
Regeneration Level 0 3772
Auto/Active Regeneration Inhibited 3773
Auto/Active Regeneration 3773
Regeneration Level 1 3773
Idle-up Auto/Active Regeneration 3773
Parked Regeneration Request 3774
Regeneration Level 2 3774
Warning Level 3775
Regeneration Level 3 3775
Service Level 3775
Regeneration Level 4 3775
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3776
Display, Diesel Particulate Filter (DPF), Stage V Engine 3776
Operator Interface 3776
Refer to Operator Manual 3776
CAN Communication Lost 3777
Passive Regeneration Only 3777
Regeneration Level 0 3777
Auto/Active Regeneration Inhibited 3777
Auto/Active Regeneration 3778
Regeneration Level 1 3778
Idle-up Auto/Active Regeneration 3778
Parked Regeneration Request 3778
Regeneration Level 2 3778
Warning Level 3780
Regeneration Level 3 3780
Service Level 3780
Regeneration Level 4 3780
Stage V Content 3780
Emissions System Malfunction 3780
Ash Load 3781
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3782
Operator Interface 3782
Refer to Operator Manual 3782
CAN Communication Lost 3783
Passive Regeneration Only 3783
Regeneration Level 0 3783
Auto/Active Regeneration Inhibited 3783
Auto/Active Regeneration 3784
Regeneration Level 1 3784
Idle-up Auto/Active Regeneration 3784
Parked Regeneration Request 3784
Regeneration Level 2 3784
Warning Level 3786
Regeneration Level 3 3786
Service Level 3786
Regeneration Level 4 3786
Calibrations 3787
Calibrate Transmission Valve 3789
Set Tilt Stop Point 3789
Calibrate Loaded Weight 3790
Calibrate Travel Speed Sensor 3790
Calibrate Mazda LP and Gas Accelerator Pedal 3791
524223772-2200YRM1142-(01-2020)-US-EN 3793
General 3803
Display Switch Cluster 3806
Remove 3806
Install 3809
Direction Control and Turn Signal Levers 3809
Remove 3809
Install 3811
Key Switch 3811
Remove 3811
Install 3812
Display Switch Cluster Panel Bezel and Overlay 3812
Remove 3812
Install 3812
Steering Column Repair 3812
Remove 3812
Disassemble 3815
Assemble 3815
Install 3815
Sensors and Switches 3816
General 3816
Dash and Kick Panel, Remove and Install 3816
Remove 3816
Install 3817
Accelerator Pedal Position Sensor 3818
Remove 3818
Install 3821
Brake Fluid Level Switch 3822
Remove 3822
Install 3824
Service Brake Pedal Position Sensor 3825
Remove 3825
Install 3828
Parking Brake Sensor 3829
Remove 3829
Install 3830
Service Brake Pressure Sensor 3831
Remove 3831
Install 3833
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3834
Remove 3834
Install 3834
Sensor Microswitch (Foot Directional Control Pedal) 3835
Remove 3835
Install 3838
Low Coolant Level Sensor 3839
Remove 3839
Install 3842
Fuel Level Sensor, Gas and Diesel Engines Only 3843
Remove 3843
Install 3844
Armrest Switch 3844
Remove 3844
Install 3846
Seat Sensor (Operator Presence System) 3846
Non-Suspension and Semi-Suspension Seats; For Lift truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-8VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (C879, D879, E879, F879) 3846
Remove 3846
Install 3847
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3847
Remove 3847
Install 3848
Full Suspension Seats; All Lift Truck Models 3848
Remove 3848
Install 3848
Hood Shut Off Switch 3848
Remove 3848
Install 3851
Remote Key Switch 3852
Remove 3852
Install 3852
Hydraulic Filter Pressure Switch 3853
Remove 3853
Install 3855
Transmission Speed Sensor 3855
Remove 3855
Install 3858
Transmission Pressure Sensors 3859
Remove 3859
Install 3861
Transmission Temperature Sensor 3862
Remove 3862
Install 3864
Engine Speed Sensor 3866
Remove 3866
Install 3866
Intermediate Speed Sensor 3867
Remove 3867
Install 3867
Return to Set Tilt (Tilt Angle) Sensor 3867
Lift Truck Models GLC20-35VX (GC/GCL040-070VX, GC/GLC055SVX) (A910); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP30VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) 3867
Remove 3867
Install 3868
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3869
Remove 3869
Install 3870
Rear Horn Button Switch 3870
Remove 3870
Install 3871
Impact Sensor 3872
Lift Truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX,) (C879, D879, E879, F879) 3872
Remove 3872
Install 3875
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3875
Remove 3875
Install 3876
Load Weight Sensor 3877
Remove 3877
Install 3878
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3879
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3879
Crankshaft Position (CKP) Sensor 3879
Camshaft Position (CMP) Sensor 3879
Oil Pressure Sensor 3879
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3879
Engine Coolant Temperature (ECT) Sensor 3880
Air Flow Restriction Switch 3880
Remove for GM 2 4L Gas and LPG Trucks 3880
Install for GM 2 4L Gas and LPG Trucks 3880
Oxygen Sensor 3881
Remove 3881
Install 3884
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3885
Crankshaft Position (CKP) Sensor 3885
Camshaft Position (CMP) Sensor 3885
Oil Pressure Sensor 3885
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3885
Engine Coolant Temperature (ECT) Sensor 3885
Air Flow Restriction Switch 3885
Oxygen Sensor 3885
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3885
Low LPG Pressure Switch 3885
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3886
Air Filter Restriction Switch 3886
Remove 3886
Install 3886
Oil Pressure Sensor 3886
Remove 3886
Install 3886
Engine Speed Sensor 3886
Remove 3886
Install 3886
Engine Coolant Temperature (ECT) Sensor 3886
Remove 3886
Install 3886
Throttle Position Sensor (TPS) 3889
Remove 3889
Install 3890
Fuel/Water Separator Sensor 3890
Remove 3890
Install 3890
Glow Plug Relay 3891
Remove 3891
Install 3893
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3893
Air Filter Restriction Switch 3893
Remove 3893
Install 3893
Engine Oil Pressure Sensor 3898
Remove 3898
Install 3898
Engine Speed Sensor 3898
Remove 3898
Install 3899
Engine Coolant Temperature (ECT) Sensor 3899
Remove 3899
Install 3900
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3901
Remove 3901
Install 3901
Fuel/Water Separator Sensor 3902
Remove 3902
Install 3902
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3903
Intake Air Temperature Sensor 3903
Remove 3903
Install 3904
Intake Air Pressure Sensor 3904
Remove 3904
Install 3904
Air Inlet Heater 3904
Remove 3904
Install 3905
Engine Oil Pressure Sensor 3905
Remove 3905
Install 3905
Engine Coolant Temperature (ECT) Sensor 3905
Remove 3905
Install 3905
Crankshaft Position Sensor 3906
Remove 3906
Install 3906
Adjust Shim Procedure 3907
Camshaft Position Sensor 3908
Remove 3908
Install 3908
Air Flow Restriction Sensor 3909
Remove 3909
Install 3909
Fuel/Water Separator 3909
Remove 3909
Install 3910
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3910
Intake Air Temperature Sensor 3914
Remove 3914
Install 3915
Boost Sensor 3915
Remove 3915
Install 3916
Throttle Valve Assembly and Air Intake Heater 3916
Remove 3916
Install 3916
Engine Coolant Temperature (ECT) Sensor 3917
Remove 3917
Install 3917
Engine Oil Pressure Sensor 3917
Remove 3917
Install 3918
Crankshaft Position Sensor 3918
Remove 3918
Install 3918
Adjust Shim Procedure 3919
Camshaft Position Sensor 3920
Remove 3920
Install 3921
Differential Pressure Sensor 3921
Remove 3921
Install 3921
Mass Air Flow Sensor 3922
Remove 3922
Install 3923
Fuel/Water Separator 3923
Remove 3923
Install 3924
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3924
Engine Coolant Temperature (ECT) Sensor 3925
Remove 3925
Install 3925
Throttle Position Sensor 3926
Engine Oil Pressure Sensor 3926
Remove 3926
Install 3926
Engine Speed Sensor 3926
Remove 3926
Install 3926
Fuel Shut Off Solenoid 3926
Remove 3926
Install 3926
Vehicle System Manager (VSM) 3927
General 3927
VSM Replacement 3927
Remove 3927
Install 3929
Programming a New VSM and/or Display Switch Cluster 3929
General 3929
PC Service Tool Software 3930
Data Transferring 3930
New VSM 3930
New (Blank) Display Switch Cluster 3930
Used (Non-Blank) Display Switch Cluster 3930
Power Distribution Module (PDM) and Component Parts 3932
Remove 3932
PDM as a Unit 3932
Install 3936
PDM as a Unit 3936
Remove and Install 3937
PDM Component Parts 3937
Transmission Control Unit 3937
Remove 3937
Install 3941
Battery 3943
Remove 3943
Install 3943
Lights 3944
Work Lights (Front and Rear) 3944
Remove 3944
Install 3944
Strobe Light 3945
Remove 3945
Install 3945
LED Tail, Backup, and Brake Lights 3946
Remove 3946
Install 3947
Front Marker/Turn Signal Lights 3948
Replacing Whole Front Marker/Turn Signal Light Assembly 3948
Remove 3948
Install 3948
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3949
Remove 3949
Install 3949
Diesel Particulate Filter (DPF) Display 3949
Remove 3949
Clean and Inspect 3950
Install 3950
Electronic-Hydraulic Controls – Generation 1 3951
E-Hydraulic Controls – Test 3951
Mini-Levers 3951
Full Stroke Test 3951
Function Returns to Neutral Test 3951
Push Button Switch 3951
General 3952
Mini-Lever Replacement 3952
Remove 3952
Clean and Inspect 3953
Install 3953
Push Button Switch Replacement 3954
Remove 3954
Install 3956
Mini-Lever Module (MLM) 3956
Remove 3956
Install 3956
Joystick 3957
Remove and Disassemble 3957
Inspect 3957
Assemble and Install 3957
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3958
General 3958
Mini-levers, Remove and Install 3958
Armrest Assembly 3959
Remove 3959
Install 3962
Horn Button 3962
Remove 3962
Install 3962
Direction Control Switch 3963
Remove 3963
Install 3963
push (override) buttons and Toggle Switch 3963
Remove 3964
Install 3965
Joystick 3966
Remove and Disassemble 3966
Inspect 3966
Assemble and Install 3966
Joystick Armrest Slider Assembly 3967
Remove 3967
Install 3968
Electronic-Hydraulic Controls, After January, 2020 3968
E-Hydraulic Controls – TEST 3968
Mini-Levers 3968
Full Stroke Test 3968
Function Returns to Neutral Test 3968
Push (Override) Button 3969
General 3969
Mini-levers, Remove and Install 3969
Armrest Assembly 3970
Remove 3970
Install 3973
Horn Button 3973
Remove 3973
Install 3973
Direction Control Switch 3973
Remove 3973
Install 3974
Push (Override) buttons and Toggle Switch 3974
Remove 3975
Install 3977
Special Tools 3978
524223772-2200YRM1142-(08-2021)-US-EN 3981
General 3991
Display Switch Cluster 3995
Remove 3995
Install 3997
Direction Control and Turn Signal Levers 3997
Remove 3997
Install 3998
Key Switch 3999
Remove 3999
Install 4000
Display Switch Cluster Panel Bezel and Overlay 4000
Remove 4000
Install 4000
Steering Column Repair 4001
Remove 4001
Disassemble 4004
Assemble 4004
Install 4004
Sensors and Switches 4005
General 4005
Dash and Kick Panel, Remove and Install 4005
Remove 4005
Install 4006
Accelerator Pedal Position Sensor 4006
Remove 4006
Install 4010
Brake Fluid Level Switch 4011
Remove 4011
Install 4012
Service Brake Pedal Position Sensor 4014
Remove 4014
Install 4016
Parking Brake Sensor 4017
Remove 4017
Install 4019
Service Brake Pressure Sensor 4019
Remove 4019
Install 4021
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4023
Remove 4023
Install 4023
Sensor Microswitch (Foot Directional Control Pedal) 4023
Remove 4023
Install 4026
Low Coolant Level Sensor 4027
Remove 4027
Install 4030
Fuel Level Sensor, Gas and Diesel Engines Only 4031
Remove 4031
Install 4032
Armrest Switch 4032
Remove 4032
Install 4034
Seat Sensor (Operator Presence System) 4034
Non-Suspension and Semi-Suspension Seats; For Lift truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-8VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (C879, D879, E879, F879) 4034
Remove 4034
Install 4035
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4035
Remove 4035
Install 4035
Full Suspension Seats; All Lift Truck Models 4036
Remove 4036
Install 4036
Hood Shut Off Switch 4037
Remove 4037
Install 4039
Remote Key Switch 4040
Remove 4040
Install 4040
Hydraulic Filter Pressure Switch 4041
Remove 4041
Install 4043
Transmission Speed Sensor 4043
Remove 4043
Install 4046
Transmission Pressure Sensors 4047
Remove 4047
Install 4049
Transmission Temperature Sensor 4050
Remove 4050
Install 4052
Engine Speed Sensor 4054
Remove 4054
Install 4055
Intermediate Speed Sensor 4055
Remove 4055
Install 4055
Return to Set Tilt (Tilt Angle) Sensor 4056
Lift Truck Models GLC20-35VX (GC/GCL040-070VX, GC/GLC055SVX) (A910); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP30VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) 4056
Remove 4056
Install 4056
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4056
Remove 4057
Install 4058
Rear Horn Button Switch 4059
Remove 4059
Install 4059
Impact Sensor 4060
Lift Truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX,) (C879, D879, E879, F879) 4060
Remove 4060
Install 4062
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4062
Remove 4062
Install 4063
Load Weight Sensor 4063
Remove 4063
Install 4065
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 4066
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 4066
Crankshaft Position (CKP) Sensor 4066
Camshaft Position (CMP) Sensor 4066
Oil Pressure Sensor 4066
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 4066
Engine Coolant Temperature (ECT) Sensor 4067
Air Flow Restriction Switch 4067
Remove for GM 2 4L Gas and LPG Trucks 4067
Install for GM 2 4L Gas and LPG Trucks 4067
Oxygen Sensor 4068
Remove 4068
Install 4071
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 4072
Crankshaft Position (CKP) Sensor 4072
Camshaft Position (CMP) Sensor 4072
Oil Pressure Sensor 4072
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 4072
Engine Coolant Temperature (ECT) Sensor 4072
Air Flow Restriction Switch 4072
Oxygen Sensor 4072
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 4072
Low LPG Pressure Switch 4072
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 4073
Air Filter Restriction Switch 4073
Remove 4073
Install 4073
Oil Pressure Sensor 4073
Remove 4073
Install 4073
Engine Speed Sensor 4073
Remove 4073
Install 4073
Engine Coolant Temperature (ECT) Sensor 4073
Remove 4073
Install 4073
Throttle Position Sensor (TPS) 4076
Remove 4076
Install 4077
Fuel/Water Separator Sensor 4077
Remove 4077
Install 4077
Glow Plug Relay 4078
Remove 4078
Install 4080
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 4080
Air Filter Restriction Switch 4080
Remove 4080
Install 4081
Engine Oil Pressure Sensor 4085
Remove 4085
Install 4085
Engine Speed Sensor 4085
Remove 4085
Install 4086
Engine Coolant Temperature (ECT) Sensor 4086
Remove 4086
Install 4087
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 4088
Remove 4088
Install 4088
Fuel/Water Separator Sensor 4089
Remove 4089
Install 4089
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 4090
Intake Air Temperature Sensor 4090
Remove 4090
Install 4091
Intake Air Pressure Sensor 4091
Remove 4091
Install 4091
Air Inlet Heater 4091
Remove 4091
Install 4092
Engine Oil Pressure Sensor 4092
Remove 4092
Install 4092
Engine Coolant Temperature (ECT) Sensor 4092
Remove 4092
Install 4092
Crankshaft Position Sensor 4093
Remove 4093
Install 4093
Adjust Shim Procedure 4094
Camshaft Position Sensor 4095
Remove 4095
Install 4095
Air Flow Restriction Sensor 4095
Remove 4095
Install 4096
Fuel/Water Separator 4096
Remove 4096
Install 4097
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 4097
Intake Air Temperature Sensor 4101
Remove 4101
Install 4102
Boost Sensor 4102
Remove 4102
Install 4103
Throttle Valve Assembly and Air Intake Heater 4103
Remove 4103
Install 4103
Engine Coolant Temperature (ECT) Sensor 4104
Remove 4104
Install 4104
Engine Oil Pressure Sensor 4105
Remove 4105
Install 4105
Crankshaft Position Sensor 4105
Remove 4105
Install 4105
Adjust Shim Procedure 4106
Camshaft Position Sensor 4108
Remove 4108
Install 4108
Differential Pressure Sensor 4108
Remove 4108
Install 4109
Mass Air Flow Sensor 4109
Remove 4109
Install 4110
Fuel/Water Separator 4111
Remove 4111
Install 4112
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 4113
Engine Coolant Temperature (ECT) Sensor 4114
Remove 4114
Install 4114
Throttle Position Sensor 4114
Engine Oil Pressure Sensor 4114
Remove 4114
Install 4114
Engine Speed Sensor 4114
Remove 4114
Install 4114
Fuel Shut Off Solenoid 4115
Remove 4115
Install 4115
Vehicle System Manager (VSM) 4116
General 4116
VSM Replacement 4116
Remove 4116
Install 4118
Programming a New VSM and/or Display Switch Cluster 4118
General 4118
PC Service Tool Software 4119
Data Transferring 4119
New VSM 4119
New (Blank) Display Switch Cluster 4119
Used (Non-Blank) Display Switch Cluster 4119
Power Distribution Module (PDM) and Component Parts 4122
Remove 4122
PDM as a Unit 4122
Install 4125
PDM as a Unit 4125
Remove and Install 4126
PDM Component Parts 4126
Transmission Control Unit (TCU) 4127
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4127
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4127
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 4128
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 4128
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) Equipped with 3-Speed Transmission and Manufactured Before December, 2018 4128
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) Equipped With 3-Speed Transmission and Manufactured Before December, 2018 4129
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) Equipped with 3-Speed Transmission and Manufactured Between December, 2018 and July, 2021 4130
Install, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) Equipped with 3-Speed Transmission and Manufactured Between December, 2018 and July, 2021 4132
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) Equipped with 3-Speed Transmission and Manufactured After July, 2021 4132
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) Equipped With 3-Speed Transmission and Manufactured After July, 2021 4132
Battery 4133
Remove 4133
Install 4133
Lights 4134
Work Lights (Front and Rear) 4134
Remove 4134
Install 4134
Strobe Light 4135
Remove 4135
Install 4135
LED Tail, Backup, and Brake Lights 4136
Remove 4136
Install 4137
Front Marker/Turn Signal Lights 4138
Replacing Whole Front Marker/Turn Signal Light Assembly 4138
Remove 4138
Install 4138
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 4139
Remove 4139
Install 4139
Diesel Particulate Filter (DPF) Display 4140
Remove 4140
Clean and Inspect 4141
Install 4141
Electronic-Hydraulic Controls – Generation 1 4142
E-Hydraulic Controls – Test 4142
Mini-Levers 4142
Full Stroke Test 4142
Function Returns to Neutral Test 4142
Push Button Switch 4142
General 4143
Mini-Lever Replacement 4143
Remove 4143
Clean and Inspect 4144
Install 4144
Push Button Switch Replacement 4145
Remove 4145
Install 4147
Mini-Lever Module (MLM) 4147
Remove 4147
Install 4147
Joystick 4148
Remove and Disassemble 4148
Inspect 4148
Assemble and Install 4148
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 4149
General 4149
Mini-levers, Remove and Install 4149
Armrest Assembly 4150
Remove 4150
Install 4153
Horn Button 4153
Remove 4153
Install 4153
Direction Control Switch 4154
Remove 4154
Install 4154
push (override) buttons and Toggle Switch 4154
Remove 4155
Install 4156
Joystick 4157
Remove and Disassemble 4157
Inspect 4157
Assemble and Install 4157
Joystick Armrest Slider Assembly 4158
Remove 4158
Install 4159
Electronic-Hydraulic Controls, After January, 2020 4160
E-Hydraulic Controls – TEST 4160
Mini-Levers 4160
Full Stroke Test 4160
Function Returns to Neutral Test 4160
Push (Override) Button 4160
General 4161
Mini-levers, Remove and Install 4161
Armrest Assembly 4162
Remove 4162
Install 4165
Horn Button 4165
Remove 4165
Install 4165
Direction Control Switch 4165
Remove 4165
Install 4166
Push (Override) buttons and Toggle Switch 4166
Remove 4167
Install 4169
Special Tools 4170
524223773-2200YRM1143-(05-2005)-US-EN 4173
toc 4173
Electrical System 4173
Safety Precautions Maintenance and Repair 4174
Ignition System 4177
General 4177
Ignition Timing Adjustment, Gasoline and LPG 4177
Spark Plugs Check 4177
Spark Plug Wires Check 4177
Distributor Repair 4180
Remove 4180
Disassemble 4181
Inspect 4181
Assemble 4182
Install 4182
Igniter 4183
Remove 4183
Test 4183
Install 4183
Camshaft Position (CMP) Sensor 4184
Voltage Check 4184
Ignition Coil Check 4185
Primary Coil Winding 4185
Secondary Coil Winding 4185
Starter Repair 4186
General 4186
Remove 4186
No-Load Test 4187
Magnetic Switch Test 4187
Pull-Out Test 4187
Holding Coil Test 4188
Return Test 4188
Pinion Movement Inspection 4188
Install 4188
Alternator Repair 4189
General 4189
Charging System Inspection 4189
Output Current Check 4190
No-Load Adjusted Voltage Check 4190
Remove 4191
Inspect 4191
Rectifier Check 4191
Install 4192
tables 4173
Table 1 Spark Plug Wire 4177
Table 2 Starter Specifications 4186
Table 3 Problem Diagnosis Chart 4187
Table 4 Specifications 4190
Table 5 Rectifier Check Table 4191
524223776-4000YRM1148-(09-2015)-US-EN 4195
General 4199
Safety Procedures When Working Near Mast 4200
Fork Replacement 4202
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4202
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4204
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4205
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4205
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4206
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4207
Carriages Repair 4208
Standard Carriage 4208
Remove 4208
Repair 4209
Install 4209
Standard Carriage, Remove 4210
Hang-On Sideshift Carriage, Remove 4211
Standard Carriage and Hang-On Sideshift Carriage, Repair 4212
Standard Carriage, Install 4213
Hang-On Sideshift Carriage, Install 4213
Integral Sideshift Carriage 4214
Remove 4214
Clean and Inspect 4217
Repair 4218
Install 4218
Fork Positioner 4219
Remove 4219
Clean and Inspect 4224
Disassemble and Assemble 4224
Install 4224
Fork Positioner Hydraulic Hose Adjustment 4225
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4227
Connecting Attachment Hydraulic Quick Disconnect Hoses 4227
Mast Repair 4228
Mast, Remove 4228
Two-Stage LFL and Two-Stage FFL Masts 4231
Disassemble 4231
Clean and Inspect 4241
Three-Stage FFL Mast 4242
Disassemble 4242
Clean and Inspect 4250
Two-Stage LFL and Two-Stage FFL Mast 4252
Assemble 4252
Three-Stage FFL Mast 4255
Assemble 4255
Four-Stage FFL Mast – Manufactured Before July, 2009 4257
Disassemble 4257
Clean and Inspect 4262
Assemble 4264
Four-Stage FFL Mast – Manufactured After July, 2009 4265
Disassemble 4265
Clean and Inspect 4272
Assemble 4275
Mast, Install 4276
Header Hose Arrangement 4279
Two-Stage LFL 4279
Two-Stage FFL 4287
Three-Stage FFL 4302
Standard 4302
Optional Equipment Lift Truck GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4319
Four-Stage FFL Mast – Manufactured Before July, 2009 4327
Four-Stage FFL Mast – Manufactured After July, 2009 4336
Adjustment 4343
Lift Chains Adjustment 4343
Carriage Adjustments 4346
Mast Adjustments 4346
Load Roller Adjustment 4346
Mast Side Kicking Adjustment 4349
524223777-8000YRM1150-(12-2017)-US-EN 4353
General 4359
Serial Number Data 4359
How to Move Disabled Lift Truck 4359
How to Tow Lift Truck 4359
How to Put Lift Truck on Blocks 4360
How to Raise Drive Tires 4360
How to Raise Steering Tires 4361
How to Clean a Lift Truck 4362
Maintenance Schedule 4362
Maintenance Procedures Every 8 Hours or Daily 4387
How to Make Checks With Engine Stopped 4388
Tires and Wheels 4388
Safety Labels 4389
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4389
Operator Restraint System 4390
Automatic Locking Retractor (ALR) 4390
Emergency Locking Retractor (ELR) 4390
Adjust Seat – Full Suspension 4390
Adjust Seat – Internal Suspension 4392
Hood and Seat Latches 4393
Engine Compartment 4393
Paper Application 4393
Fuel, Oil, and Coolant Leaks, Check 4394
Hydraulic Hoses 4394
Coolant Hoses 4394
Steering Column Gas Cylinder 4394
Transmission 4394
Hydraulic System Oil 4394
Engine Oil 4395
Air Filter 4401
Forks 4401
Remove 4401
Inspect 4403
Install 4404
Adjust 4404
How to Make Checks With Engine Running 4405
Indicator Lights, Horn, Fuses, and Relays 4405
Service Brakes 4408
Brake Fluid Level 4408
Operation, Check 4408
Parking Brake 4408
Engine Oil Pressure 4409
Cooling System 4409
Steering System 4410
Control Levers and Pedals 4410
Lift System, Operate 4410
First Service After First 100 Hours of Operation 4411
Mazda and GM Engine Oil and Oil Filter 4411
Yanmar Engine Oil and Oil Filter 4412
Maintenance Procedures Every 250 Hours or 6 Months 4412
Mazda and GM Engine Oil and Oil Filter 4412
Drive Belt 4413
Mazda 2 0L and 2 2L Engines 4413
Fan and Alternator Drive Belt 4413
GM 2 4L Engine 4413
Fan and Alternator Drive Belt 4413
Drain Tar From LPG Regulator (Except 2007 Mazda Emission Compliant Engines) 4414
Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engines Only) 4415
Maintenance Procedures Every 500 Hours or 6 Months 4415
Hydraulic System Oil 4416
Hydraulic Tank Breather 4416
Inspect 4416
Battery 4417
Yanmar Engine Oil and Oil Filter 4417
Drive Belt 4418
Yanmar Diesel Engine 4418
Fan and Alternator Drive Belt 4418
Timing Belt, Checks and Inspection 4419
PCV Valve 4421
Clean Debris From Radiator Core 4421
Transmission Oil Level 4421
Wet Brake Planetary Housing Oil Level Check 4423
Forks 4424
Mast Lubrication 4424
Header Hose Checks 4428
Lift Chain Lubrication 4428
Tilt Cylinder Lubrication 4429
Master Brake Cylinder Rod End Pin Lubrication 4430
Manual Hydraulic Levers Lubrication 4430
Brake Fluid 4431
Tie Rod Lubrication (GP/GLP/GDP040-070VX) 4432
Differential and Drive Axle Oil (Dry Brake) 4432
Maintenance Procedures Every 1000 Hours or 6 Months 4432
Valve Clearance, Check and Adjust 4432
Ignition System 4433
GM 2 4L Engine 4433
Mazda Engines 2 0L and 2 2LFE and F2 4433
LPG Fuel Filter Element Replace, GM 2 4L Engine 4433
Remove 4433
Install 4433
LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 4434
LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines Only 4434
Remove 4434
Clean/Inspect 4435
Install 4435
Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant Engines Only 4435
Remove and Replace 4435
Fuel Filter Replacement, Yanmar Engine 4436
Priming the Fuel System (Yanmar) 4438
Lift Chains Wear Check 4438
Lift Chain Lubrication 4439
Integral Sideshift Carriage, Check Bearings 4439
Integral Sideshift Carriage, Check Lower Mounting Hooks 4440
Steering Axle 4440
Control Levers and Pedals 4440
Maintenance Procedures Every 2000 Hours or Annually 4440
Hydraulic System 4441
Hydraulic Filter, Replace 4441
Hydraulic Tank Breather, Replace 4442
Air Filter 4443
PCV Valve 4444
Oxygen Sensor 4445
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 4447
Remove and Replace 4447
LPG Regulator Fuel Filter, GM Engines 4447
Remove 4447
Install 4448
Gasoline Fuel Filter 4448
Remove and Replace for Lift Trucks Equipped with GFI 4448
Timing Belt 4449
Mazda Engines 4449
GM 2 4L Engine 4449
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 4449
Gasoline Fuel Injector, Mazda Engines 4449
LPG Fuel Injector, GM Engines 4449
Gasoline Fuel Injector, GM Engines 4449
Fuel Injector, Yanmar Engines 4449
Forks 4449
Integral Sideshift Carriage 4449
Bearings, Replace 4449
Transmission Oil and Filter (Dry Brake), Replace 4449
Iron Transmission Housing 4449
Aluminum Transmission Housing 4450
Remove 4450
Clean and Inspect 4454
Install 4454
Transmission Oil Change, Wet Brake Drive Axle 4455
Iron Transmission Housing 4455
Aluminum Transmission Housing 4456
Wet Brake Axle Center Section and Planetary Housing, Oil Change 4459
Brake Fluid (Master Cylinder), Change 4459
Brake Fluid (Dry Brake), Remove 4464
Steer Axle, Wheel Bearing Lubrication 4464
Service Brakes (Dry Brake) 4464
Differential (Dry Brake) 4465
Maintenance Procedures Every 4000 Hours or 2 Years 4465
Hydraulic Oil, Replace 4466
Cooling System 4466
Safety Procedures When Working Near Mast 4467
Hood Latch Check 4470
Lift Chain Adjustments 4471
Jump-Starting the Lift Truck 4473
Jump-Starting Using a Battery Charger 4473
Jump-Starting a Lift Truck Using Another Lift Truck 4473
Welding Repairs 4473
Overhead Guard Changes 4474
Wheel and Tire Replacement 4474
General 4474
Solid Rubber Tire, Change (GC/GLC Series) 4474
Remove and Install Tire on Wheel 4475
Pneumatic Tire With Tube, Repair 4476
Remove Wheels From Lift Truck 4476
Remove Tire From Wheel 4476
Install Wheel in Tire 4479
Install Tire on Two-Piece Wheel 4481
Add Air to Pneumatic Tires With Tube 4482
Install the Wheels 4483
Dual Drive Wheels, Install 4483
Pneumatic Tubeless Tire, Repair 4484
Remove Wheels From Lift Truck 4484
Add Air to Pneumatic Tubeless Tire 4489
Wheels, Install 4489
Solid Rubber Tires on Pneumatic Wheels, Change 4489
Adhesives and Sealants 4493
524223778-8000YRM1151-(10-2016)-US-EN 4497
Lift Truck Lifting Capacity 4501
Counterweight Weights 4501
Tire Sizes 4501
Capacities 4502
Electrical System 4507
Transmission Oil Pressures 4508
Hydraulic System Relief Pressures 4512
Steering System 4513
Stall Speeds (in RPM ±100 rpm) 4514
Mazda FE (Except 2007 Emission Compliant Engines) 4514
Mazda FE (2007 Emission Compliant Engines Only) 4514
Mazda F2 (Except 2007 Emission Compliant Engines) 4514
Mazda F2 (2007 Emission Compliant Engines Only) 4514
GM 2 4L 4515
Yanmar 2 6L 4515
Yanmar 3 3L 4515
Mast Speeds 4515
Tilt Angles 4518
Front End Equipment – Mast Creep 4519
Mast Creep 4519
Engine Specifications 4519
Torque Specifications 4521
Frame 4521
Mast 4521
Steering System, Cushioned Tire Trucks 4521
Steering System, Pneumatic Tire Trucks 4522
Drive Axle (Dry Brake) 4522
Drive Axle (Wet Brake) 4522
Transmission – Iron Housing 4523
Transmission – Aluminum Housing 4523
Engine – Mazda FE and F2 4524
Engine – GM 2 4L 4525
Engine – Yanmar 2 6L and 3 3L Diesel 4526
524223779-8000YRM1152-(03-2020)-US-EN 4531
General Information About Diagrams and Schematics 4535
Symbol Definitions 4535
Diagrams Manual Applications 4536
Diagrams and Schematics 4538
524223779-8000YRM1152-(06-2021)-US-EN 4601
General Information About Diagrams and Schematics 4605
Symbol Definitions 4605
Diagrams Manual Applications 4606
Diagrams and Schematics 4608
524223780-8000YRM1134-(03-2020)-US-EN 4669
Series Code / Model Designation Reference Table 4675
Description 4677
Proc_Cal_001: Service Password Entry 4679
When to Perform 4679
Why Perform 4679
How to Perform 4679
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 4680
When to Perform 4680
Calibration Order 4680
Why Perform 4680
How to Perform 4681
Proc_Cal_003: Save and Exit 4682
When to Perform 4682
Why Perform 4682
How to Perform 4682
Proc_Cal_004: Lift Valve Output Threshold 4683
When to Perform 4683
Calibration Order 4683
Why Perform 4683
How to Perform 4684
Proc_Cal_005: Lower Valve Output Threshold 4686
When to Perform 4686
Calibration Order 4686
Why Perform 4686
How to Perform 4686
Proc_Cal_006: Tilt Back Valve Output Threshold 4689
When to Perform 4689
Calibration Order 4689
Why Perform 4689
How to Perform 4689
Proc_Cal_007: Tilt Forward Valve Output Threshold 4692
When to Perform 4692
Calibration Order 4692
Why Perform 4692
How to Perform 4692
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 4695
When to Perform 4695
Calibration Order 4695
Why Perform 4695
How to Perform 4695
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 4698
When to Perform 4698
Calibration Order 4698
Why Perform 4698
How to Perform 4698
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 4701
When to Perform 4701
Calibration Order 4701
Why Perform 4701
How to Perform 4701
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 4704
When to Perform 4704
Calibration Order 4704
Why Perform 4704
How to Perform 4704
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 4707
When to Perform 4707
Calibration Order 4707
Why Perform 4707
How to Perform 4707
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 4710
When to Perform 4710
Calibration Order 4710
Why Perform 4710
How to Perform 4710
Proc_Cal_014: Load Weight Zero Point 4714
When to Perform 4714
Calibration Order 4714
Why Perform 4714
How to Perform 4714
Proc_Cal_015: Loaded Weight Calibration 4716
When to Perform 4716
Calibration Order 4716
Why Perform 4716
How to Perform 4716
Proc_Cal_016: Transmission Valve Calibration 4719
Applicable System/Option 4719
When to Perform 4719
Calibration Order 4719
Why Perform 4719
How to Perform 4719
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 4721
Applicable System/Option 4721
When to Perform 4721
Calibration Order 4721
Why Perform 4721
How to Perform 4721
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 4723
Applicable System/Option 4723
When to Perform 4723
Calibration Order 4723
Why Perform 4723
How to Perform 4724
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 4725
Required Tools 4725
When to Perform 4725
Calibration Order 4725
Why Perform 4726
How to Perform 4726
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 4727
When to Perform 4727
Why Perform 4727
How to Perform 4727
Proc_Cal_026: Travel Speed Calibration 4729
When to Perform 4729
Calibration Order 4729
Why Perform 4729
How to Perform 4729
524223780-8000YRM1134-(05-2022)-US-EN 4733
Series Code / Model Designation Reference Table 4739
Description 4742
Proc_Cal_001: Service Password Entry 4744
When to Perform 4744
Why Perform 4744
How to Perform 4744
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 4745
When to Perform 4745
Calibration Order 4745
Why Perform 4745
How to Perform 4745
Proc_Cal_003: Save and Exit 4747
When to Perform 4747
Why Perform 4747
How to Perform 4747
Proc_Cal_004: Lift Valve Output Threshold 4748
When to Perform 4748
Calibration Order 4748
Why Perform 4748
How to Perform 4748
Proc_Cal_005: Lower Valve Output Threshold 4751
When to Perform 4751
Calibration Order 4751
Why Perform 4751
How to Perform 4751
Proc_Cal_006: Tilt Back Valve Output Threshold 4754
When to Perform 4754
Calibration Order 4754
Why Perform 4754
How to Perform 4754
Proc_Cal_007: Tilt Forward Valve Output Threshold 4757
When to Perform 4757
Calibration Order 4757
Why Perform 4757
How to Perform 4757
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 4760
When to Perform 4760
Calibration Order 4760
Why Perform 4760
How to Perform 4760
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 4763
When to Perform 4763
Calibration Order 4763
Why Perform 4763
How to Perform 4763
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 4766
When to Perform 4766
Calibration Order 4766
Why Perform 4766
How to Perform 4766
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 4769
When to Perform 4769
Calibration Order 4769
Why Perform 4769
How to Perform 4769
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 4772
When to Perform 4772
Calibration Order 4772
Why Perform 4772
How to Perform 4772
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 4775
When to Perform 4775
Calibration Order 4775
Why Perform 4775
How to Perform 4775
Proc_Cal_014: Load Weight Zero Point 4778
When to Perform 4778
Calibration Order 4778
Why Perform 4778
How to Perform 4778
Proc_Cal_015: Loaded Weight Calibration 4780
When to Perform 4780
Calibration Order 4780
Why Perform 4780
How to Perform 4780
Proc_Cal_016: Transmission Valve Calibration 4783
Applicable System/Option 4783
When to Perform 4783
Calibration Order 4783
Why Perform 4783
How to Perform 4783
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 4785
Applicable System/Option 4785
When to Perform 4785
Calibration Order 4785
Why Perform 4785
How to Perform 4785
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 4788
Applicable System/Option 4788
When to Perform 4788
Calibration Order 4788
Why Perform 4788
How to Perform 4788
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 4791
Required Tools 4791
When to Perform 4791
Calibration Order 4791
Why Perform 4791
How to Perform 4791
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 4793
When to Perform 4793
Why Perform 4793
How to Perform 4793
Proc_Cal_026: Travel Speed Calibration 4795
When to Perform 4795
Calibration Order 4795
Why Perform 4795
How to Perform 4795
524289373-0900YRM1325-(12-2009)-US-EN 4799
toc 4799
Gasoline Fuel System 4799
Safety Precautions Maintenance and Repair 4800
General 4803
Abbreviations 4803
Intake-Air System 4803
Intake-Air System Manifold Vacuum Check 4803
Throttle Body 4804
Remove 4804
Install 4805
Intake Manifold 4805
Remove 4805
Install 4805
Fuel System 4806
Before Repair Procedure 4806
Fuel Line Safety Procedure 4806
After Repair Procedure 4809
Fuel Hose, Install 4809
Fuel Leakage Check 4809
Fuel Line Pressure Check 4810
Fuel Injectors 4811
Remove 4811
Install 4811
Pressure Regulator 4813
Remove 4813
Install 4813
Exhaust System 4814
Counterweight Exhaust System 4814
Remove and Disassemble 4814
Inspect 4814
Assemble and Install 4814
Overhead Exhaust System 4816
Remove and Disassemble 4816
Inspect 4816
Assemble and Install 4816
Exhaust Manifold 4818
Remove 4818
Install 4818
Positive Crankcase Ventilation (PCV) Valve 4820
Remove 4820
Inspect 4820
Install 4820
Oxygen Sensor 4821
Remove 4821
Install 4821
Control System 4823
Engine Control Unit (ECU) 4823
Remove 4823
Install 4824
Fuel Level Sensor 4825
Remove 4825
Install 4825
Technical Data 4826
tables 4799
Table 1 PCV Valve Specifications 4820
Table 2 Gasoline Fuel Systems Technical Data 4826
524289374-0900YRM1326-(04-2018)-US-EN 4829
General 4835
LPG Tank and Bracket Replacement 4835
Remove LPG Tank for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4835
Install LPG Tank for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4837
Remove LPG Tank for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4838
LPG Tank Install for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4840
Remove LPG Bracket for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4841
Install LPG Bracket for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4843
Remove LPG Tank Bracket Alignment Pin, Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4844
Install LPG Tank Bracket Alignment Pin, Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4846
Remove LPG Bracket for Lift Truck Models and GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4847
Install LPG Bracket for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4847
Fuel Filter Unit Repair 4847
Fuel Filter Element 4847
Remove 4847
Clean/Inspect 4848
Install 4848
Fuel Filter Housing 4848
Remove 4848
Disassemble 4851
Assemble 4853
Install 4854
Electronic Throttle Body Repair 4854
Remove 4854
Install 4856
Electronic Pressure Regulator (EPR) Repair 4856
Remove 4857
Disassemble 4861
Assemble 4863
Install 4864
LPG Shutoff Valve Assembly 4864
Remove 4864
Install 4868
Fuel Mixer Repair 4870
Remove 4870
Install 4873
Control System 4873
Engine Control Unit (ECU) 4873
Remove 4873
Install 4875
Low LPG Pressure Switch 4875
Remove 4875
Install 4876
LPG Low Level Sensor 4876
Remove 4877
Install 4880
Exhaust System 4881
Counterweight Exhaust System 4881
Remove and Disassemble 4881
Inspect 4883
Assemble and Install 4883
Overhead Exhaust System 4883
Remove and Disassemble 4884
Inspect 4886
Assemble and Install 4886
Exhaust Manifold 4887
Remove 4887
Install 4888
Positive Crankcase Ventilation (PCV) Valve 4889
Remove 4889
Inspect 4889
Install 4889
Oxygen Sensor 4889
Remove 4889
Install 4891
LPG Fuel Testing 4892
General 4892
Available Fuel Tests 4892
Composition Test (ASTM D-2163) 4892
Ammonia Test (ASTM D-4490) 4892
Basic Nitrogen Test (ASTM UOP269-90) 4892
Residues Test (ASTM D-2158) 4892
Vapor Pressure Test (ASTM D-2598) 4892
Sulfur Compounds Test (ASTM D-5623) 4893
Methanol Test (ASTM D-4864) 4893
Copper Corrosion (ASTM D-1838) 4893
Where To Send LPG Fuel Samples For Testing 4893
524289375-2200YRM1327-(09-2012)-US-EN 4897
General 4901
Ignition System 4901
General 4901
Ignition Timing Adjustment, Gasoline and LPG 4901
Spark Plugs Check 4906
Spark Plug Wires Check 4906
Coil Replacement 4907
Remove 4907
Inspect 4908
Install 4908
Starter Repair 4909
General 4909
Remove 4909
No-Load Test 4910
Magnetic Switch Test 4911
Pull-Out Test 4911
Holding Coil Test 4911
Return Test 4911
Pinion Movement Inspection 4912
Install 4912
Alternator Repair 4912
General 4912
Charging System Inspection 4914
Output Current Check 4914
No-Load Adjusted Voltage Check 4915
Remove 4916
Inspect 4916
Rectifier Check 4916
Install 4917
Engine Sensors and Switches 4918
Oil Pressure Sensor, Gas and LPG Engines 4918
Remove 4918
Install 4918
Air Filter Restriction Switch, Gas and LPG Engines 4918
Remove 4918
Install 4918
Cam Angle Sensor, Gas and LPG Engines 4919
Remove 4919
Install 4920
Voltage Check 4920
Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Engines 4921
Remove 4921
Install 4922
Intake Air Temperature (IAT) Sensor, LPG Engines 4923
Remove 4923
Install 4923
Intake Air Temperature (IAT) Sensor, Gas Engines 4923
Remove 4923
Install 4923
Fuel Temperature Sensor, LPG Engines 4926
Remove 4926
Install 4926
Engine Coolant Temperature (ECT) Sensor 4927
2007 Emissions Compliant Gas Engines 4927
Remove 4927
Install 4927
2007 and 2010 Emissions Compliant LPG Engines 4928
Remove 4928
Install 4928
2010 Emissions Compliant Gas and LPG Engines 4930
Remove 4930
Install 4930
524329117-8000YRM1387-(03-2020)-US-EN 4935
General Information About Diagrams and Schematics 4939
Symbol Definitions 4939
Diagrams Manual Applications 4940
Diagrams and Schematics 4942
524329117-8000YRM1387-(06-2021)-US-EN 5007
General Information About Diagrams and Schematics 5011
Symbol Definitions 5011
Diagrams Manual Applications 5012
Diagrams and Schematics 5014
550001092-8000YRM1409-(03-2020)-US-EN 5077
General Information About Diagrams and Schematics 5081
Symbol Definitions 5081
Diagrams Manual Applications 5082
Diagrams and Schematics 5084
550001092-8000YRM1409-(06-2021)-US-EN 5165
General Information About Diagrams and Schematics 5169
Symbol Definitions 5169
Diagrams Manual Applications 5170
Diagrams and Schematics 5172
550010194-1300YRM1421-(08-2013)-US-EN 5247
toc 5247
Single Speed PowerShift 5247
Safety Precautions Maintenance and Repair 5248
General 5251
Serial Number 5251
Hydraulic Gear Pump 5252
Remove 5252
Install 5252
Charge Pump Repair 5253
Original Charge Pump 5253
Remove 5253
Disassemble 5254
Clean 5254
Inspect 5254
Assemble 5254
Install 5254
New Charge Pump, Manufactured After July, 2013 5255
Remove 5255
Clean 5256
Inspect 5256
Install 5257
Torque Converter Replacement 5259
Remove 5259
Clean and Inspect 5259
Install 5259
Stator Support Assembly Repair 5260
Remove 5260
Disassemble 5265
Clean 5266
Inspect 5266
Assemble 5267
Install 5267
Clutch Packs Repair 5269
Remove 5269
Engine, Torque Converter, and Transmission Assembly 5269
Transmission Components 5270
Disassemble 5272
Transmission 5272
Housings 5272
Forward Clutch Pack 5275
Reverse Clutch Pack 5280
Clean 5286
Inspect 5286
Assemble 5287
Transmission 5287
Reverse Clutch Pack 5287
Forward Clutch Pack 5294
Housings 5300
Install 5302
Transmission Components 5302
Engine, Torque Converter, and Transmission Assembly 5305
Inching Overlap Adjustment 5305
Proportional and Enable Solenoid Valves 5306
Proportional Valves 5306
Remove 5306
Disassemble 5308
Clean and Inspect 5308
Assemble 5308
Install 5308
Enable Solenoid Valve 5308
Remove 5308
Disassemble 5308
Clean and Inspect 5308
Assemble 5309
Install 5309
Foot Directional Control Pedal Repair 5309
Remove and Disassembly 5309
Clean and Inspect 5313
Assemble and Install 5313
550030170-1300YRM1447-(08-2013)-US-EN 5317
toc 5317
Single Speed Powershift 5317
Safety Precautions Maintenance and Repair 5318
General 5321
Serial Number 5321
Hydraulic Gear Pump 5322
Remove 5322
Install 5322
Housing Fittings Replacement 5322
Remove 5322
Disassemble 5323
Assemble 5323
Install 5323
Charge Pump Repair 5323
Lift Trucks Manufactured Before July, 2013 5323
Remove 5323
Disassemble 5325
Clean 5325
Inspect 5325
Assemble 5325
Install 5325
Lift Trucks Manufactured After July, 2013 5327
Remove 5327
Clean 5327
Inspect 5327
Install 5328
Torque Converter Replacement 5331
Remove 5331
Clean and Inspect 5331
Install 5331
Stator Support Assembly Repair 5333
Remove 5333
Disassemble 5338
Clean 5342
Inspect 5342
Assemble 5343
Install 5343
Clutch Packs Repair 5346
Remove 5346
Disassemble 5347
Housings 5347
Clutch Packs 5352
Forward Clutch Pack 5352
Reverse Clutch Pack 5357
Clean 5363
Inspect 5363
Assemble 5364
Clutch Packs 5364
Reverse Clutch Pack 5364
Forward Clutch Pack 5371
Housings 5378
Install 5378
Drive Chains and Sprockets 5384
Remove 5384
Clean 5386
Inspect 5386
Install 5386
Proportional and Enable Solenoid Valves 5387
Proportional Valves 5387
Remove 5387
Disassemble 5387
Clean and Inspect 5387
Assemble 5390
Install 5390
Enable Solenoid Valve 5390
Remove 5390
Disassemble 5391
Clean and Inspect 5391
Assemble 5391
Install 5391
Foot Directional Control Pedal Repair 5393
Remove and Disassemble 5393
Clean and Inspect 5397
Assemble and Install 5397
550043436-1300YRM1529-(11-2018)-US-EN 5403
General 5407
Serial Number 5407
Charge Pump Repair 5407
Lift Trucks Manufactured Before July, 2013 5407
Remove 5407
Inspect 5407
Install 5407
Lift Trucks Manufactured After July, 2013 5408
Remove 5408
Inspect 5408
Install 5408
Torque Converter Replace 5409
Remove 5409
Install 5418
Housings and Chain Drive Repair 5424
Remove 5424
Clean 5435
Inspect 5435
Install 5435
Clutch Packs Repair 5442
Remove and Disassemble 5442
Transmission, Remove and Disassemble 5442
Clean 5461
Inspect 5461
Assemble and Install 5462
Transmission, Assemble and Install 5470
Control Valve Repair 5474
Remove and Disassemble 5474
Clean 5478
Inspect 5478
Assemble and Install 5478
Foot Directional Control Pedal Repair 5479
Remove and Disassemble 5479
Assemble and Install 5483
Direction Control Lever 5484
Remove 5484
Install 5484
550055283-8000YRM1585-(06-2021)-US-EN 5489
General Information About Diagrams and Schematics 5493
Symbol Definitions 5493
Diagrams Manual Applications 5494
Diagrams and Schematics 5496
550055283-8000YRM1585-(07-2020)-US-EN 5585
General Information About Diagrams and Schematics 5589
Symbol Definitions 5589
Diagrams Manual Applications 5590
Diagrams and Schematics 5592
550073240-1900YRM1620-(01-2023)-US-EN 5681
Proper Flushing after Major Hydraulic Repairs 5687
Introduction 5687
The Phases of Wear 5687
Causes of Hydraulic System Failure 5687
Progression of Contaminant Caused Hydraulic System Failure 5688
Hydraulic System Flushing Techniques 5688
Double Oil and Filter Change 5688
Mechanical Cleaning 5689
Cleaning of Components 5689
How to Clean Tubes and Hoses 5689
Filter Caddy 5689
Start-Up Procedure for Cleaned System 5690
Contaminated Oil Coolers 5690
Additional Filter Caddy Functions 5691
How to Handle Different Fluids 5691
Water Removal Filters 5691
Fluid Conditioning and System Flushing Procedures 5692
Operation of the Filter Caddy 5692
Filter Caddy operation 5692
Fluid Conditioning Procedure 5692
Filter Caddy Start-Up 5693
System Flushing Procedure 5693
Component Cleaning Procedure 5694
Reservoir Cleaning Procedure 5694
Cylinder Cleaning Procedure 5694
Hose and Tube Cleaning Procedure 5694
Valve Cleaning Procedure 5695
Front-End Attachment Cleaning Procedure 5696
System Flushing Procedure 5696
Filter Caddy Start-Up 5697
System Start-Up and Flushing 5697
Reservoir Fluid Cleaning Times 5698
Dealing With Different Fluid Types 5699
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5699
Filter Caddy Maintenance 5699
Servicing the Strainer 5699
DC Motor 5699
Hydraulic Oil Sampling Method and Procedure 5700
Hydraulic Oil Sampling Method 5700
Objective 5700
General Guidelines 5700
Synopsis 5701
Hydraulic Oil Analysis Report Guidelines 5702
Sampling Conditions 5702
Equipment 5702
Sampling Procedure 5703
Hydraulic Oil Sampling 5703
Sample Labeling 5703
Results Documentation 5703
550073240-1900YRM1620-(03-2020)-US-EN 5705
Proper Flushing after Major Hydraulic Repairs 5709
Introduction 5709
The Phases of Wear 5709
Causes of Hydraulic System Failure 5709
Progression of Contaminant Caused Hydraulic System Failure 5710
Hydraulic System Flushing Techniques 5710
Double Oil and Filter Change 5710
Mechanical Cleaning 5711
Cleaning of Components 5711
How to Clean Tubes and Hoses 5711
Filter Caddy 5711
Start-Up Procedure for Cleaned System 5712
Contaminated Oil Coolers 5712
Additional Filter Caddy Functions 5712
How to Handle Different Fluids 5712
Water Removal Filters 5713
Fluid Conditioning and System Flushing Procedures 5713
Operation of the Filter Caddy 5713
Filter Caddy operation 5713
Fluid Conditioning Procedure 5714
Filter Caddy Start-Up 5714
System Flushing Procedure 5715
Component Cleaning Procedure 5715
Reservoir Cleaning Procedure 5715
Cylinder Cleaning Procedure 5715
Hose and Tube Cleaning Procedure 5716
Valve Cleaning Procedure 5716
Front-End Attachment Cleaning Procedure 5717
System Flushing Procedure 5717
Filter Caddy Start-Up 5718
System Start-Up and Flushing 5718
Reservoir Fluid Cleaning Times 5719
Dealing With Different Fluid Types 5719
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5719
Filter Caddy Maintenance 5720
Servicing the Strainer 5720
DC Motor 5720
Hydraulic Oil Sampling Method and Procedure 5720
Hydraulic Oil Sampling Method 5720
Objective 5720
General Guidelines 5720
Synopsis 5721
Hydraulic Oil Analysis Report Guidelines 5722
Sampling Conditions 5723
Equipment 5723
Sampling Procedure 5723
Hydraulic Oil Sampling 5723
Sample Labeling 5724
Results Documentation 5724
550093750-2100YRM1668-(02-2018)-US-EN 5727
General 5731
Safety Procedures When Working Near Mast 5732
Main Lift Cylinder Repair 5734
Remove 5734
Disassemble 5736
Clean 5738
Inspect 5738
Assemble 5738
Install 5739
Main Lift Cylinder Leak Check 5739
Free-Lift Cylinder 5740
Remove 5740
Disassemble 5741
Clean 5743
Inspect 5743
Assemble 5743
Install 5743
Tilt Cylinder Repair 5744
Remove 5744
Disassemble 5746
Clean 5748
Inspect 5748
Assemble 5748
Install 5749
Tilt Cylinder Adjustment 5750
Tilt Cylinder Leak Check 5751
Integral Sideshift Cylinder Repair Prior to December 2016 5753
Remove 5753
Disassemble 5754
Clean 5755
Inspect 5755
Assemble 5755
Install 5755
Integral Sideshift Cylinder Repair After December 2016 5756
General 5756
Remove 5756
Disassemble 5758
Clean 5758
Inspect 5758
Assemble 5758
Install 5759
Integral Side-Shift Cylinder Gland Leak Checks 5760
Fork Positioner Cylinder Repair Prior to December 2016 5761
Remove 5761
Disassemble 5761
Clean 5763
Inspect 5764
Assemble 5764
Install 5764
Fork Positioner Cylinder Adjustment 5764
Fork Positioner Cylinder Repair After December 2016 5765
General 5765
Remove 5765
Disassemble 5765
Clean 5768
Inspect 5769
Assemble 5769
Install 5769
Fork Positioner Cylinder Adjustment 5769
Seal Kit Installation 5770
External Installation (Seal and Backup Ring) 5770
Internal Installation (Piston Rod Assembly) 5770
Torque Specifications 5771
Main Lift Cylinders 5771
Free-Lift Cylinder 5771
Tilt Cylinders 5771
Integral Sideshift Cylinder 5771
Fork Positioner Cylinder 5771
550093750-2100YRM1668-(04-2023)-US-EN 5775
General 5781
Safety Procedures When Working Near Mast 5784
Main Lift Cylinder Repair 5786
Remove 5786
Disassemble 5788
Clean 5790
Inspect 5790
Assemble 5790
Install 5791
Main Lift Cylinder Leak Check 5791
Free-Lift Cylinder 5792
Remove 5792
Disassemble 5793
Clean 5795
Inspect 5795
Assemble 5795
Install 5795
Tilt Cylinder Repair 5797
Remove 5797
Disassemble 5799
Clean 5800
Inspect 5801
Assemble 5801
Install 5802
Tilt Cylinder Adjustment 5802
Tilt Cylinder Leak Check 5804
Integral Sideshift Cylinder Repair Prior to December 2016 5806
Remove 5806
Disassemble 5806
Clean 5807
Inspect 5807
Assemble 5807
Install 5808
Integral Sideshift Cylinder Repair After December 2016 5809
General 5809
Remove 5809
Disassemble 5810
Clean 5811
Inspect 5811
Assemble 5811
Install 5811
Integral Side-Shift Cylinder Gland Leak Checks 5812
Fork Positioner Cylinder Repair Prior to December 2016 5813
Remove 5813
Disassemble 5813
Clean 5816
Inspect 5816
Assemble 5817
Install 5817
Fork Positioner Cylinder Adjustment 5817
Fork Positioner Cylinder Repair After December 2016 5819
General 5819
Remove 5819
Disassemble 5819
Clean 5822
Inspect 5822
Assemble 5823
Install 5823
Fork Positioner Cylinder Adjustment 5823
Seal Kit Installation 5825
External Installation (Seal and Backup Ring) 5825
Internal Installation (Piston Rod Assembly) 5825
Torque Specifications 5826
Main Lift Cylinders 5826
Free-Lift Cylinder 5826
Tilt Cylinders 5826
Integral Sideshift Cylinder 5826
Fork Positioner Cylinder 5826
550093755-4000YRM1669-(04-2023)-US-EN 5829
General 5837
Safety Procedures When Working Near Mast 5839
Fork Replacement 5841
Standard Carriage and Integral Sideshift Carriage 5841
Remove 5841
Install 5842
Checks 5842
Fork Positioner Carriage 5844
Remove 5845
Install 5845
Checks 5847
Carriages Repair, Two-Stage LFL Mast 5850
Standard Carriage 5850
Remove 5850
Clean and Inspect 5851
Install 5851
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5851
Remove 5851
Disassemble 5853
Clean and Inspect 5854
Assemble 5855
Install 5855
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 5856
Remove 5856
Disassemble 5859
Clean and Inspect 5859
Assemble 5860
Install 5861
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5861
Remove 5861
Disassemble 5864
Clean and Inspect 5864
Assemble 5865
Install 5866
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5866
Remove 5866
Install 5868
Fork Positioner Hydraulic Hose Adjustment 5870
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5871
Remove 5871
Disassemble and Assemble 5875
Clean and Inspect 5875
Install 5875
Fork Positioner Hydraulic Hose Adjustment 5876
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 5877
Remove 5877
Disassemble and Assemble 5881
Clean and Inspect 5881
Install 5881
Fork Positioner Hydraulic Hose Adjustment 5882
Two-Stage LFL Mast Repair 5884
Mast With Serial Number F507 5884
Remove 5884
Disassemble 5888
Clean and Inspect 5895
Assemble 5897
Install 5898
Header Hoses 5900
Remove 5900
Installation 5900
Adjustment 5904
Mast With Serial Number F562 5905
Remove 5905
Disassemble 5909
Clean and Inspect 5916
Assemble 5918
Install 5919
Header Hose Installation and Adjustment 5920
Remove 5920
Installation 5921
Adjustment 5925
Carriages Repair, Three-Stage FFL Mast 5927
Standard Carriage 5927
Remove 5927
Clean and Inspect 5928
Install 5929
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5929
Remove 5929
Disassemble 5930
Clean and Inspect 5931
Assemble 5932
Install 5932
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5933
Remove 5933
Disassemble 5935
Clean and Inspect 5936
Assemble 5937
Install 5937
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5938
Remove 5938
Disassemble 5940
Clean and Inspect 5941
Assemble 5942
Install 5942
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5943
Remove 5943
Install 5945
Fork Positioner Hydraulic Hose Adjustment 5947
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5948
Remove 5948
Disassemble and Assemble 5950
Clean and Inspect 5950
Install 5950
Fork Positioner Hydraulic Hose Adjustment 5951
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 5952
Remove 5952
Disassemble and Assemble 5955
Clean and Inspect 5955
Install 5955
Fork Positioner Hydraulic Hose Adjustment 5956
Three-Stage FFL Mast Repair 5958
Mast With Serial Number F508 5958
Remove 5958
Disassemble 5961
Clean and Inspect 5971
Assemble 5974
Install 5975
Header Hose Installation and Adjustment 5977
Remove 5977
Installation 5977
Adjustment 5986
Mast With Serial Number F563 5986
Remove 5986
Disassemble 5990
Clean and Inspect 6000
Assemble 6003
Install 6004
Header Hose Installation and Adjustment 6006
Remove 6006
Installation 6006
Adjustment 6014
Mast Adjustments 6016
Load Roller, Adjust 6016
Mast Side Kicking, Adjust 6018
Carriage Adjustments 6019
Lift Chains Adjustment 6021
Hydraulic Quick Disconnect Hoses 6023
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 6023
Lift Trucks Equipped With E-Hydraulic Controls 6023
Lift Trucks Equipped With Manual Hydraulic Controls 6023
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 6024
Lift Trucks Equipped With E-Hydraulic Controls 6024
Lift Trucks Equipped With Manual Hydraulic Controls 6024
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 6024
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 6024
550093755-4000YRM1669-(06-2019)-US-EN 6027
General 6033
Safety Procedures When Working Near Mast 6034
Fork Replacement 6036
Standard Carriage and Integral Sideshift Carriage 6036
Remove 6036
Install 6038
Checks 6038
Fork Positioner Carriage 6040
Remove 6041
Install 6041
Checks 6043
Carriages Repair, Two-Stage LFL Mast 6045
Standard Carriage 6045
Remove 6045
Clean and Inspect 6046
Install 6047
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 6047
Remove 6047
Disassemble 6048
Clean and Inspect 6049
Assemble 6050
Install 6050
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 6051
Remove 6051
Disassemble 6054
Clean and Inspect 6054
Assemble 6055
Install 6055
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 6056
Remove 6056
Disassemble 6059
Clean and Inspect 6059
Assemble 6060
Install 6060
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 6061
Remove 6061
Install 6063
Fork Positioner Hydraulic Hose Adjustment 6065
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 6066
Remove 6066
Disassemble and Assemble 6070
Clean and Inspect 6070
Install 6070
Fork Positioner Hydraulic Hose Adjustment 6071
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 6072
Remove 6072
Disassemble and Assemble 6076
Clean and Inspect 6076
Install 6076
Fork Positioner Hydraulic Hose Adjustment 6077
Two-Stage LFL Mast Repair 6078
Mast With Serial Number F507 6078
Remove 6078
Disassemble 6082
Clean and Inspect 6089
Assemble 6091
Install 6092
Header Hoses 6094
Remove 6094
Installation 6094
Adjustment 6098
Mast With Serial Number F562 6099
Remove 6099
Disassemble 6103
Clean and Inspect 6110
Assemble 6112
Install 6113
Header Hose Installation and Adjustment 6114
Remove 6114
Installation 6115
Adjustment 6119
Carriages Repair, Three-Stage FFL Mast 6120
Standard Carriage 6120
Remove 6120
Clean and Inspect 6122
Install 6122
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 6122
Remove 6122
Disassemble 6124
Clean and Inspect 6125
Assemble 6126
Install 6126
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 6127
Remove 6127
Disassemble 6129
Clean and Inspect 6130
Assemble 6131
Install 6131
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 6132
Remove 6132
Disassemble 6134
Clean and Inspect 6135
Assemble 6136
Install 6136
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 6137
Remove 6137
Install 6139
Fork Positioner Hydraulic Hose Adjustment 6141
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 6142
Remove 6142
Disassemble and Assemble 6144
Clean and Inspect 6144
Install 6144
Fork Positioner Hydraulic Hose Adjustment 6145
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 6146
Remove 6146
Disassemble and Assemble 6149
Clean and Inspect 6149
Install 6149
Fork Positioner Hydraulic Hose Adjustment 6150
Three-Stage FFL Mast Repair 6151
Mast With Serial Number F508 6151
Remove 6151
Disassemble 6155
Clean and Inspect 6165
Assemble 6168
Install 6169
Header Hose Installation and Adjustment 6171
Remove 6171
Installation 6171
Adjustment 6179
Mast With Serial Number F563 6180
Remove 6180
Disassemble 6183
Clean and Inspect 6193
Assemble 6196
Install 6197
Header Hose Installation and Adjustment 6199
Remove 6199
Installation 6199
Adjustment 6207
Mast Adjustments 6208
Load Roller, Adjust 6208
Mast Side Kicking, Adjust 6210
Carriage Adjustments 6210
Lift Chains Adjustment 6212
Hydraulic Quick Disconnect Hoses 6214
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 6214
Lift Trucks Equipped With E-Hydraulic Controls 6214
Lift Trucks Equipped With Manual Hydraulic Controls 6215
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 6215
Lift Trucks Equipped With E-Hydraulic Controls 6215
Lift Trucks Equipped With Manual Hydraulic Controls 6216
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 6216
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 6216

S.V 06/24