Yale Forklift A910 (GLC20VX, GLC25VX, GLC30VX, GLC35VX) Service Manual PDF

Description

Yale Forklift A910 (GLC20VX, GLC25VX, GLC30VX, GLC35VX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A910 (GLC20VX, GLC25VX, GLC30VX, GLC35VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 6794
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A910 (GLC20VX, GLC25VX, GLC30VX, GLC35VX) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-UK-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
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)-UK-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
524223754-0100YRM1120-(12-2012)-US-EN 2169
toc 2169
Frame 2169
Safety Precautions Maintenance and Repair 2170
General 2173
Description 2173
Hood, Seat, and Side Covers Replacement 2174
Remove 2174
Install 2180
Steering Column 2185
Description 2185
Steering Column Repair 2185
Remove 2185
Disassemble 2187
Clean 2187
Inspect 2187
Assemble 2187
Install 2190
LPG Tank and Bracket Assembly 2190
Counterweight Replacement 2191
Remove 2191
Install 2194
Tow Pin, Remove and Install 2195
Overhead Guard Replacement 2195
Remove and Install 2195
LED Tail, Backup, and Brake Lights, Replace 2196
Operator Restraint System Replacement 2197
Description 2197
Automatic Locking Retractor (ALR) 2197
Emergency Locking Retractor (ELR) 2197
Engine Replacement 2199
Remove 2199
Install 2204
Transmission Replacement 2206
Remove Transmission with Iron Housing 2206
Install Transmission with Iron Housing 2208
Remove Transmission with Aluminum Housing 2208
Install Transmission with Aluminum Housing 2213
Throttle Pedal and Cable Adjustment 2216
Mazda Gas/LPG Engines With Basic Power Shift Transmission and El 2216
Mazda Gasoline Engine With Electronic Transmission 2218
Throttle Pedal Stop Adjustment 2219
Yanmar Diesel Engine With Basic Power Shift Transmission 2220
Yanmar Diesel Engine With Electronic Throttle 2220
Exhaust System Repair 2221
Lift Trucks With Counterweight Exhaust System 2221
Mazda Gas and LPG Engines 2221
Remove and Disassemble 2221
Inspect 2221
Assemble and Install 2221
Yanmar Diesel Engine 2223
Remove and Disassemble 2223
Inspect 2223
Assemble and Install 2223
Lift Trucks With Overhead Exhaust System 2225
Yanmar Diesel Engine 2225
Remove and Disassemble 2225
Inspect 2225
Assemble and Install 2226
Mazda Gas and LPG Engines 2228
Remove and Disassemble 2228
Inspect 2228
Assemble and Install 2228
Cooling System 2230
Description 2230
Hydraulic Filter Assembly Repair 2230
Remove 2230
Clean and Inspect 2231
Install 2231
Fuel and Hydraulic Tanks Repair 2232
Inspect 2232
Clean 2232
Steam Method of Cleaning 2232
Chemical Solution Method of Cleaning 2233
Additional Preparations for Repair 2233
Small Leaks, Repair 2233
Large Leaks, Repair 2233
Preparations for Use After Repair 2234
Safety Labels 2234
tables 2169
Table 1 Gas Spring Installation, Lift Truck Models GLP/GDP16VX, 2181
Table 2 Gas Spring Installation, Lift Truck Models GLP/GDP20-35 2183
Table 3 Weight of Counterweights, Lift Truck Models GLC20-35VX 2193
Table 4 Weight of Counterweights, Lift Truck Models GC/GLC030VX 2193
Table 5 Weight of Counterweights, Lift Truck Models GLP/GDP16-1 2193
Table 6 Weight of Counterweights, Lift Truck Models GLP/GDP20-3 2193
524223755-0600YRM1121-(12-2012)-UK-EN 2241
toc 2241
GM Engine Repair 2241
Safety Precautions Maintenance and Repair 2242
General 2247
Engine Serial Number 2247
Engine Removal and Installation 2249
Intake Manifold 2249
Remove 2249
Clean and Inspect 2250
Install 2250
Exhaust Manifold 2251
Remove 2251
Clean and Inspect 2251
Install 2251
Camshaft and Cylinder Head Repair 2252
Rocker Arm Cover 2252
Remove 2252
Install 2252
Camshaft Timing Pulley and/or Front Seal 2252
Remove 2252
Install 2253
Camshaft Carrier and Cylinder Head 2254
Remove 2254
Disassemble 2255
Camshaft Carrier 2255
Cylinder Head 2256
Clean and Inspect 2257
Camshaft Carrier 2257
Cylinder Head 2257
Valve and Valve Seat 2259
Assemble 2260
Cylinder Head 2260
Camshaft Carrier 2260
Install 2260
Timing Belt 2262
Timing Belt Front Cover 2262
Remove 2262
Install 2263
Timing Belt and Timing Belt Tensioner 2263
Remove 2263
Install 2264
Timing Belt Rear Cover 2265
Remove 2265
Install 2265
Lubrication System Repair 2266
Oil Pan 2266
Remove 2266
Install 2266
Oil Pump 2268
Remove 2268
Clean and Inspect 2269
Install 2270
Piston and Piston Rod Assemblies Repair 2270
Piston Rod Bearings, Replace 2270
Piston and Piston Rod Assemblies 2272
Remove 2272
Disassemble 2273
Pistons, Clean and Inspect 2274
Cylinder Bores, Inspect and Repair 2274
Piston Rings, Inspect 2275
Assemble 2276
Install 2276
Crankshaft and Main Bearings 2277
Crankshaft Timing Pulley and/or Front Seal 2277
Remove 2277
Install 2278
Crankshaft Rear Main Oil Seal 2279
Remove 2279
Install 2279
Crankshaft/RPM Sensor 2279
Remove 2279
Install 2280
Crankshaft Reluctor Wheel 2280
Remove and Install 2280
Crankshaft and Main Bearings 2280
Remove 2280
Inspect and Repair 2281
Bearing Selection 2282
Main Bearings and Journal Clearance, Check 2283
Install 2284
Flywheel and Flywheel Housing 2285
Remove 2285
Install 2285
Cooling System Repair 2286
Serpentine Belt 2286
Remove 2286
Inspect 2286
Install 2286
Water Pump 2287
Remove 2287
Inspect 2287
Install 2289
Thermostat 2290
Remove 2290
Check 2290
Install 2291
Thermostat Housing 2292
Remove 2292
Clean and Inspect 2292
Install 2292
Sensors and Switches 2294
Crankshaft Position (CKP) Sensor 2294
Remove 2294
Install 2294
Camshaft Position (CMP) Sensor 2294
Remove for Lift Trucks Built Before January, 2010 2294
Assembly 2294
Sensor Only 2294
Install for Lift Trucks Built Before January, 2010 2295
Assembly 2295
Sensor Only 2295
Remove for Lift Trucks Built After January, 2010 2296
Install for Lift Trucks Built After January, 2010 2296
Oil Pressure Sensor 2296
Remove 2296
Install 2296
Ignition System 2297
Spark Plug Wire Inspection 2297
Spark Plug Wire Replacement 2297
Remove 2297
Install 2298
Spark Plug Replacement 2298
Remove 2298
Install 2299
Spark Plug Inspection 2299
Usage 2299
Inspect 2299
Visual Inspection 2301
Coil Pack 2301
Remove 2301
Install 2301
Alternator Repair 2302
Alternator 2302
Remove 2302
Install 2302
Alternator Fuse, Replace 2302
Starter Repair 2303
Remove 2303
Install 2303
Engine Specifications 2304
Engine Data 2304
Cylinder Bore 2304
Piston 2304
Piston Rings 2305
Wrist Pin 2305
Crankshaft 2305
Piston Rod 2306
Camshaft and Camshaft Carrier 2306
Valve System 2306
Cylinder Head Warpage 2307
Lubrication System 2307
Cooling System 2307
Torque Specifications 2308
Special Tools 2309
524223755-0600YRM1121-(12-2012)-US-EN 2315
toc 2315
GM Engine Repair 2315
Safety Precautions Maintenance and Repair 2316
General 2321
Engine Serial Number 2321
Engine Removal and Installation 2323
Intake Manifold 2323
Remove 2323
Clean and Inspect 2324
Install 2324
Exhaust Manifold 2325
Remove 2325
Clean and Inspect 2325
Install 2325
Camshaft and Cylinder Head Repair 2326
Rocker Arm Cover 2326
Remove 2326
Install 2326
Camshaft Timing Pulley and/or Front Seal 2326
Remove 2326
Install 2327
Camshaft Carrier and Cylinder Head 2328
Remove 2328
Disassemble 2329
Camshaft Carrier 2329
Cylinder Head 2330
Clean and Inspect 2331
Camshaft Carrier 2331
Cylinder Head 2331
Valve and Valve Seat 2333
Assemble 2334
Cylinder Head 2334
Camshaft Carrier 2334
Install 2334
Timing Belt 2336
Timing Belt Front Cover 2336
Remove 2336
Install 2337
Timing Belt and Timing Belt Tensioner 2337
Remove 2337
Install 2338
Timing Belt Rear Cover 2339
Remove 2339
Install 2339
Lubrication System Repair 2340
Oil Pan 2340
Remove 2340
Install 2340
Oil Pump 2342
Remove 2342
Clean and Inspect 2343
Install 2344
Piston and Piston Rod Assemblies Repair 2344
Piston Rod Bearings, Replace 2344
Piston and Piston Rod Assemblies 2346
Remove 2346
Disassemble 2347
Pistons, Clean and Inspect 2348
Cylinder Bores, Inspect and Repair 2348
Piston Rings, Inspect 2349
Assemble 2350
Install 2350
Crankshaft and Main Bearings 2351
Crankshaft Timing Pulley and/or Front Seal 2351
Remove 2351
Install 2352
Crankshaft Rear Main Oil Seal 2353
Remove 2353
Install 2353
Crankshaft/RPM Sensor 2353
Remove 2353
Install 2354
Crankshaft Reluctor Wheel 2354
Remove and Install 2354
Crankshaft and Main Bearings 2354
Remove 2354
Inspect and Repair 2355
Bearing Selection 2356
Main Bearings and Journal Clearance, Check 2357
Install 2358
Flywheel and Flywheel Housing 2359
Remove 2359
Install 2359
Cooling System Repair 2360
Serpentine Belt 2360
Remove 2360
Inspect 2360
Install 2360
Water Pump 2361
Remove 2361
Inspect 2361
Install 2363
Thermostat 2364
Remove 2364
Check 2364
Install 2365
Thermostat Housing 2366
Remove 2366
Clean and Inspect 2366
Install 2366
Sensors and Switches 2368
Crankshaft Position (CKP) Sensor 2368
Remove 2368
Install 2368
Camshaft Position (CMP) Sensor 2368
Remove for Lift Trucks Built Before January, 2010 2368
Assembly 2368
Sensor Only 2368
Install for Lift Trucks Built Before January, 2010 2369
Assembly 2369
Sensor Only 2369
Remove for Lift Trucks Built After January, 2010 2370
Install for Lift Trucks Built After January, 2010 2370
Oil Pressure Sensor 2370
Remove 2370
Install 2370
Ignition System 2371
Spark Plug Wire Inspection 2371
Spark Plug Wire Replacement 2371
Remove 2371
Install 2372
Spark Plug Replacement 2372
Remove 2372
Install 2373
Spark Plug Inspection 2373
Usage 2373
Inspect 2373
Visual Inspection 2375
Coil Pack 2375
Remove 2375
Install 2375
Alternator Repair 2376
Alternator 2376
Remove 2376
Install 2376
Alternator Fuse, Replace 2376
Starter Repair 2377
Remove 2377
Install 2377
Engine Specifications 2378
Engine Data 2378
Cylinder Bore 2378
Piston 2378
Piston Rings 2379
Wrist Pin 2379
Crankshaft 2379
Piston Rod 2380
Camshaft and Camshaft Carrier 2380
Valve System 2380
Cylinder Head Warpage 2381
Lubrication System 2381
Cooling System 2381
Torque Specifications 2382
Special Tools 2383
524223756-0600YRM1122-(03-2020)-US-EN 2389
General 2393
Serial Number 2394
Engine Removal and Installation 2394
Cylinder Head, Camshaft, and Valve Mechanism Repair 2394
Remove 2394
Clean 2397
Inspect and Repair 2397
Cylinder Head 2397
Rocker Shaft Assembly 2397
Camshaft 2398
Valve Guides 2399
Valve Seats 2399
Valves 2400
Valve Springs 2400
Install 2401
Crankshaft and Main Bearings Repair 2405
Remove 2405
Inspect and Repair 2406
Crankshaft 2406
Main Bearings 2406
Install 2407
Pistons and Connecting Rods Repair 2408
Remove and Disassemble 2408
Clean 2408
Inspect and Repair 2408
Pistons 2408
Piston Rings 2408
Connecting Rods and Bearings 2409
Assemble and Install 2409
Cylinder Block Repair 2411
Oil Pump Repair 2412
Remove 2412
Disassemble 2413
Clean 2413
Inspect 2413
Assemble 2414
Install 2414
Cooling System Repair 2416
Thermostat 2416
Replace 2416
Fan Assembly 2416
Remove and Disassemble 2416
Assemble and Install 2417
Water Pump 2417
Remove 2417
Install 2418
Flywheel and Ring Gear Repair 2419
Remove 2419
Install 2419
Valve Adjustment 2419
Compression Pressure Check 2421
Engine Timing Adjustment 2422
Engine Specifications 2422
Engine Data 2422
Engine Speeds 2422
2007, and Later, Emission Compliant Engines 2422
All Engines Except 2007, and Later, Emission Compliant Engines 2423
Thermostat 2423
Cylinder Head 2423
Valve Mechanism 2423
Camshaft 2424
Crankshaft 2424
Connecting Rods 2424
Cylinder Block 2425
Pistons 2425
Oil Pump 2425
Torque Specifications 2426
524223757-0700YRM1123-(06-2016)-UK-EN 2429
General 2433
Cooling System Checks 2433
Exhaust Leaks Into Cooling System 2433
Water Flow Restrictions in Radiator 2433
Radiator Hoses 2433
Water Pump 2434
Flushing the Cooling System 2434
Cooling System, Clean 2434
Radiator Replacement 2435
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) 2436
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 2451
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2454
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) 2457
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) 2464
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 2469
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2471
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) 2474
Fan Assembly Replacement 2486
Fan Removal 2486
Inspect 2501
Fan Installation 2501
524223757-0700YRM1123-(06-2021)-US-EN 2507
General 2511
Cooling System Checks 2511
Exhaust Leaks Into Cooling System 2511
Water Flow Restrictions in Radiator 2511
Radiator Hoses 2511
Water Pump 2511
Flushing the Cooling System 2513
Cooling System, Clean 2513
Radiator Replacement 2515
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) 2515
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) 2530
Radiator, Remove for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2533
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) 2536
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) 2542
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) 2546
Radiator, Install for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2547
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) 2550
Fan Assembly Replacement 2561
Fan Removal 2561
Inspect 2575
Fan Installation 2576
524223758-0900YRM1124-(04-2018)-US-EN 2581
General 2585
Hoses Replacement 2585
LPG Tank and Bracket Replacement 2585
Remove LPG Tank 2585
Install LPG Tank 2587
Remove LPG Bracket 2588
Install LPG Bracket 2590
Remove LPG Tank Bracket Alignment Pin 2590
Install LPG Tank Bracket Alignment Pin 2592
Fuel Filter Unit Repair 2592
Fuel Filter Element 2592
Remove 2592
Clean/Inspect 2593
Install 2593
Fuel Filter Housing 2593
Remove 2593
Disassemble 2594
Assemble 2594
Install 2595
Electronic Throttle Body Repair 2595
Electronic Throttle Body 2595
Remove 2595
Install 2596
Electronic Throttle Body Adapter Plate 2596
Remove 2596
Install 2596
Fuel Injector Repair 2596
Fuel Rail 2597
Remove for Lift Trucks Built Before January, 2010 2597
Install for Lift Trucks Built Before January, 2010 2598
Remove for Lift Trucks Built After January, 2010 2598
Install for Lift Trucks Built After January, 2010 2599
Fuel Injector for Lift Trucks Built Before January, 2010 2600
Remove 2600
Clean 2600
Install 2600
Fuel Injector Adapters for Lift Trucks Built Before January, 2010 2601
Remove 2601
Install 2603
Fuel Injectors and Adapters for Lift Trucks Built After January, 2010 2603
Remove 2603
Clean 2603
Install 2604
LPG Regulator Repair 2604
LPG Regulator 2604
Remove 2604
Install 2605
LPG Regulator Fuel Filter 2605
Remove 2605
Install 2606
Lock-Off Solenoid and Cartridge 2606
Remove 2606
Install 2607
Control System 2607
Electronic Control Unit (ECU) 2607
Remove 2607
Install 2609
Fuel Pump Relay 2609
Remove 2609
Install 2610
Injector Driver Module 2610
Remove 2610
Install 2611
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 2611
Remove 2611
Install 2611
Engine Coolant Temperature (ECT) Sensor 2612
Remove 2612
Install 2612
Oxygen Sensor 2612
Remove 2612
Install 2613
Low LPG Pressure Switch 2613
Remove 2613
Install 2614
Exhaust System Repair 2615
Remove and Disassemble 2615
Inspect 2616
Assemble and Install 2616
LPG Fuel Testing 2617
General 2617
Available Fuel Tests 2617
Composition Test (ASTM D-2163) 2617
Ammonia Test (ASTM D-4490) 2617
Basic Nitrogen Test (ASTM UOP269-90) 2617
Residues Test (ASTM D-2158) 2617
Vapor Pressure Test (ASTM D-2598) 2618
Sulfur Compounds Test (ASTM D-5623) 2618
Methanol Test (ASTM D-4864) 2618
Copper Corrosion (ASTM D-1838) 2618
Where To Send LPG Fuel Samples For Testing 2618
524223759-0900YRM1125-(05-2005)-US-EN 2621
toc 2621
LPG Fuel System 2621
Safety Precautions Maintenance and Repair 2622
General 2625
Hoses Replacement 2625
LPG Tank Replacement 2625
Remove 2625
Install 2627
Fuel Filter 2628
Remove 2628
Clean and Inspect 2628
Install 2629
Relief Valve Replacement 2630
Remove and Install 2630
Carburetor Repair 2630
Remove 2630
Disassemble 2630
Clean 2632
Assemble 2632
Install 2632
Fuel Injector Repair 2633
Remove 2633
Clean and Inspect 2633
Install 2633
Governor Repair 2633
Remove 2633
Install 2633
Regulator Repair 2634
Remove 2634
Install 2634
Control System 2635
Engine Control Unit (ECU) 2635
Remove 2635
Install 2636
Engine Coolant Temperature (ECT) Sensor 2636
Remove 2636
Install 2636
Camshaft Position (CMP) Sensor 2636
Voltage Check 2636
Intake Air Temperature (IAT) Sensor 2637
Remove 2637
Install 2637
Manifold Absolute Pressure (MAP) Sensor 2638
Remove 2638
Install 2638
Oxygen Sensor 2638
Remove 2638
Install 2638
Throttle Position (TP) Sensor 2639
Remove 2639
Install 2639
524223759-0900YRM1125-(10-2005)-UK-EN 2643
toc 2643
LPG Fuel System 2643
Safety Precautions Maintenance and Repair 2644
General 2647
Hoses Replacement 2647
LPG Tank Replacement 2647
Remove 2647
Install 2649
Fuel Filter 2650
Remove 2650
Clean and Inspect 2650
Install 2651
Relief Valve Replacement 2652
Remove and Install 2652
Carburetor Repair 2652
Remove 2652
Disassemble 2652
Clean 2654
Assemble 2654
Install 2654
Fuel Injector Repair 2655
Remove 2655
Clean and Inspect 2655
Install 2655
Governor Repair 2655
Remove 2655
Install 2655
Regulator Repair 2656
Remove 2656
Install 2656
Control System 2657
Engine Control Unit (ECU) 2657
Remove 2657
Install 2658
Engine Coolant Temperature (ECT) Sensor 2658
Remove 2658
Install 2658
Camshaft Position (CMP) Sensor 2658
Voltage Check 2658
Intake Air Temperature (IAT) Sensor 2659
Remove 2659
Install 2659
Manifold Absolute Pressure (MAP) Sensor 2660
Remove 2660
Install 2660
Oxygen Sensor 2660
Remove 2660
Install 2660
Throttle Position (TP) Sensor 2661
Remove 2661
Install 2661
524223760-0900YRM1126-(02-2010)-US-EN 2665
toc 2665
Gasoline Fuel System 2665
Safety Precautions Maintenance and Repair 2666
General 2669
Electronic Throttle Body Repair 2669
Electronic Throttle Body 2669
Remove 2669
Install 2669
Fuel System Repair 2670
Before Repair Procedure 2670
After Repair Procedure 2670
Fuel Leakage Check for Lift Trucks Built Before January, 2010 2670
Fuel Leakage Check for Lift Trucks Built After January, 2010 2671
Fuel Line Pressure Check 2672
Fuel Injectors 2673
Remove 2673
Install 2675
Pressure Regulator 2676
Remove 2676
Install 2676
Control System 2676
Electronic Control Unit (ECU) 2676
Remove 2676
Install 2678
Power Latch Relay 2678
Remove 2678
Install 2678
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) 2679
Remove 2679
Install 2679
Engine Coolant Temperature (ECT) Sensor 2679
Remove 2679
Install 2680
Oxygen Sensor 2680
Remove 2680
Install 2680
Exhaust System Repair 2681
Remove and Disassemble 2681
Inspect 2681
Assemble and Install 2681
524223761-0900YRM1127-(05-2005)-US-EN 2685
toc 2685
Gasoline Fuel System 2685
Safety Precautions Maintenance and Repair 2686
General 2689
Abbreviations 2689
Engine Tune-up 2689
Engine Tune-Up Preparation 2689
Idle Speed Adjustment 2689
Idle-Up Speed Check 2689
Intake-Air System 2691
Intake-Air System Manifold Vacuum Check 2691
Throttle Body 2692
Remove 2692
Install 2692
Electronic Governor 2692
Remove 2692
Install 2692
Intake-Air Control (IAC) Valve 2692
Remove 2692
Install 2692
Intake Manifold 2694
Remove 2694
Install 2694
Fuel System 2695
Before Repair Procedure 2695
Fuel Line Safety Procedure 2695
After Repair Procedure 2695
Fuel Hose, Install 2695
Fuel Leakage Check 2696
Fuel Line Pressure Check 2696
Fuel Injector 2697
Remove 2697
Install 2698
Pressure Regulator 2698
Remove 2698
Install 2699
Exhaust System 2699
Exhaust System, Inspect 2699
Three-Way Catalytic (TWC) Converter 2699
Remove and Install 2699
Exhaust Manifold 2699
Remove 2699
Install 2699
Positive Crankcase Ventilation (PCV) Valve 2701
Remove 2701
Inspect 2701
Install 2701
Control System 2701
Engine Control Unit (ECU) 2701
Remove 2701
Install 2703
Intake Air Temperature (IAT) Sensor 2704
Remove 2704
Install 2704
Mass Air Flow (MAF) Sensor 2704
Remove 2704
Install 2704
Throttle Position (TP) Sensor 2705
TP Sensor, Adjust 2705
Remove 2706
Install 2706
Engine Coolant Temperature (ECT) Sensor 2706
Remove 2706
Install 2706
Camshaft Position (CMP) Sensor 2707
Voltage Check 2707
Oxygen Sensor 2708
Remove 2708
Install 2708
Manifold Absolute Pressure (MAP)/Boost Sensor 2708
Remove 2708
Install 2708
Technical Data 2709
tables 2685
Table 1 PCV Valve Specifications 2701
Table 2 Closed Throttle Position Specifications 2706
Table 3 Gasoline Fuel Systems Technical Data 2709
524223762-1300YRM1129-(11-2018)-US-EN 2713
General 2717
Serial Number 2717
Charge Pump Repair 2717
Remove 2717
Inspect 2718
Install 2718
Torque Converter Replace 2718
Remove 2718
Install 2726
Front Cover Housing and Chain Drive Repair 2732
Remove 2732
Clean 2741
Inspect 2741
Install 2741
Clutch Packs Repair 2750
Remove and Disassemble 2750
Transmission, Remove and Disassemble 2750
Clean 2769
Inspect 2769
Assemble and Install 2770
Transmission, Assemble and Install 2778
Control Valve Repair 2784
Remove and Disassemble 2784
Clean 2788
Inspect 2788
Assemble and Install 2788
Foot Directional Control Pedal Repair 2789
Remove and Disassemble 2789
Assemble and Install 2793
Direction Control Lever 2794
Remove 2794
Install 2794
524223763-1400YRM1132-(11-2008)-UK-EN 2799
toc 2799
Drive Axle and Differential Assembly Repair 2799
Safety Precautions Maintenance and Repair 2800
General 2803
Drive Axle Repair 2803
Remove and Disassemble 2803
Clean and Inspect 2803
Assemble and Install 2805
Differential Repair 2807
Remove 2807
Differential Assembly From Center Section 2807
Drive Pinion, Pinion Gear, and Bearings From Center Section 2811
Disassemble 2815
Differential Assembly 2815
Drop Box Housing 2818
Center Section 2819
Clean and Inspect 2821
Assemble 2821
Center Section 2821
Drop Box Housing 2824
Differential Assembly 2825
Install 2829
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 2829
Drive Pinion, Pinion Gear, and Bearings Into Center Section 2831
Differential Assembly Into Center Section 2834
Ring Gear Backlash, Adjust 2840
Ring Gear, Runout Check 2841
Gear Set, Tooth Contact Pattern Check 2841
Torque Specifications 2844
tables 2799
Table 1 Pinion Variation Numbers Examples 2830
Table 2 Ring and Pinion Tooth Contact Adjustment 2841
Table 3 Correct Tooth Contact 2842
Table 4 Incorrect Tooth Contact 2843
524223763-1400YRM1132-(11-2008)-US-EN 2847
toc 2847
Drive Axle and Differential Assembly Repair 2847
Safety Precautions Maintenance and Repair 2848
General 2851
Drive Axle Repair 2851
Remove and Disassemble 2851
Clean and Inspect 2851
Assemble and Install 2853
Differential Repair 2855
Remove 2855
Differential Assembly From Center Section 2855
Drive Pinion, Pinion Gear, and Bearings From Center Section 2859
Disassemble 2863
Differential Assembly 2863
Drop Box Housing 2866
Center Section 2867
Clean and Inspect 2869
Assemble 2869
Center Section 2869
Drop Box Housing 2872
Differential Assembly 2873
Install 2877
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 2877
Drive Pinion, Pinion Gear, and Bearings Into Center Section 2879
Differential Assembly Into Center Section 2882
Ring Gear Backlash, Adjust 2888
Ring Gear, Runout Check 2889
Gear Set, Tooth Contact Pattern Check 2889
Torque Specifications 2892
tables 2847
Table 1 Pinion Variation Numbers Examples 2878
Table 2 Ring and Pinion Tooth Contact Adjustment 2889
Table 3 Correct Tooth Contact 2890
Table 4 Incorrect Tooth Contact 2891
524223764-1600YRM1133-(07-2013)-UK-EN 2895
toc 2895
Steering Axle 2895
Safety Precautions Maintenance and Repair 2896
General 2899
Steering Axle Assembly Repair 2901
Remove 2901
Disassemble 2902
Clean 2910
Inspect 2910
Assemble 2910
Install 2916
Spindles, Bearings, and Tie Rods Repair 2918
Spindles and Bearings 2918
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2918
Remove 2918
Disassemble 2920
Clean 2921
Inspect 2921
Assemble 2921
Install 2922
Spindles and Bearings 2925
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2925
Remove and Disassemble 2925
Assemble and Install 2926
Tie Rods 2926
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2926
Remove 2926
Install 2927
Tie Rods 2928
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2928
Remove 2928
Install 2934
Steering Cylinder Repair 2934
Remove and Disassemble 2934
Clean and Inspect 2935
Assemble and Install 2935
Torque Specifications 2936
524223764-1600YRM1133-(07-2013)-US-EN 2941
toc 2941
Steering Axle 2941
Safety Precautions Maintenance and Repair 2942
General 2945
Steering Axle Assembly Repair 2947
Remove 2947
Disassemble 2948
Clean 2956
Inspect 2956
Assemble 2956
Install 2962
Spindles, Bearings, and Tie Rods Repair 2964
Spindles and Bearings 2964
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2964
Remove 2964
Disassemble 2966
Clean 2967
Inspect 2967
Assemble 2967
Install 2968
Spindles and Bearings 2971
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2971
Remove and Disassemble 2971
Assemble and Install 2972
Tie Rods 2972
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2972
Remove 2972
Install 2973
Tie Rods 2974
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2974
Remove 2974
Install 2980
Steering Cylinder Repair 2980
Remove and Disassemble 2980
Clean and Inspect 2981
Assemble and Install 2981
Torque Specifications 2982
524223765-1800YRM1135-(09-2018)-US-EN 2987
General 2991
Dry Brake System 2991
Wet Brake System 2991
Service Brakes Repair (Dry Brake) 2991
Remove and Disassemble 2992
Clean 3000
Inspect 3000
Assemble and Install 3001
Adjust 3008
Inching Overlap Adjustment 3008
Parking Brake Repair 3009
Remove and Disassemble 3009
Assemble and Install 3012
Adjust 3012
Master Cylinder Repair 3013
Remove (Dry Brake) 3013
Disassemble (Dry Brake) 3014
Clean and Inspect (Dry Brake) 3016
Assemble (Dry Brake) 3016
Bench Bleed Master Cylinder (Dry Brake) 3016
Install and Adjust (Dry Brake) 3016
Remove (Wet Brake) 3017
Disassemble (Wet Brake) 3019
Clean and Inspect (Wet Brake) 3020
Assemble (Wet Brake) 3021
Install and Adjust (Wet Brake) 3021
Service Brakes Adjustment (Dry Brake) 3022
Brake System Air Removal 3022
Using Pressure Bleed System 3022
Using Brake Pedal Pressure 3023
Brake Pedal Adjustment 3023
Free Pedal Adjustment 3024
Torque Specifications 3026
524223766-1900YRM1136-(01-2022)-US-EN 3029
General 3033
Hydraulic Gear Pump Assembly 3034
Variable Displacement Pump Assembly 3035
Single Gear Pump Assembly Repair 3036
Remove 3036
Disassemble 3042
Clean 3044
Inspect 3044
Assemble 3044
Install 3044
Tandem Gear Pump Assembly 3049
Remove 3049
Disassemble 3050
Clean 3053
Inspect 3053
Assemble 3053
Install 3054
Gear Pump Specifications 3055
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 3061
Remove 3061
Disassemble 3071
Clean 3074
Inspect 3075
Assemble 3075
Install 3075
63 0 cc/rev – Variable Displacement Pump Repair 3080
Remove 3080
Disassemble 3083
Clean 3085
Inspect 3085
Assemble 3085
Install 3085
Variable Displacement Pump Checks and Adjustments (Single Pump) 3089
Margin Pressure Check 3089
Flow Compensator Adjustment 3090
Pressure Compensator Adjustment 3090
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 3092
Variable Displacement Pump Specifications 3095
Torque Specifications 3097
Hydraulic Gear Pump 3097
Variable Displacement Pump 3098
Special Tools 3099
524223766-1900YRM1136-(11-2017)-UK-EN 3101
General 3105
Hydraulic Gear Pump Assembly 3106
Variable Displacement Pump Assembly 3107
Single Gear Pump Assembly Repair 3107
Remove 3107
Disassemble 3114
Clean 3114
Inspect 3116
Assemble 3116
Install 3116
Tandem Gear Pump Assembly 3120
Remove 3121
Disassemble 3123
Clean 3125
Inspect 3125
Assemble 3125
Install 3126
Gear Pump Specifications 3126
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 3132
Remove 3132
Disassemble 3142
Clean 3145
Inspect 3145
Assemble 3145
Install 3146
63 0 cc/rev – Variable Displacement Pump Repair 3149
Remove 3149
Disassemble 3152
Clean 3152
Inspect 3152
Assemble 3154
Install 3154
Variable Displacement Pump Checks and Adjustments (Single Pump) 3156
Margin Pressure Check 3156
Flow Compensator Adjustment 3157
Pressure Compensator Adjustment 3157
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 3158
Variable Displacement Pump Specifications 3161
Torque Specifications 3162
Hydraulic Gear Pump 3163
Variable Displacement Pump 3164
Special Tools 3164
524223767-2000YRM1137-(01-2017)-UK-EN 3169
General 3175
Electro-Hydraulic Main Control Valve 3176
Description 3176
Remove 3184
Electro-Hydraulic Control Valve Sections 3189
General 3189
Outlet Control Valve Section 3189
Remove 3189
Disassemble 3190
Clean 3192
Inspect 3192
Assemble 3192
Install 3193
Auxiliary Control Valve Sections 3193
Remove 3193
Disassemble 3200
Clean 3201
Inspect 3202
Assemble 3202
Install 3204
Tilt Control Valve Section 3205
Remove 3205
Disassemble 3205
Clean 3211
Inspect 3211
Assemble 3211
Install 3212
Lift/Lower Control Valve Section 3213
Remove 3213
Disassemble 3213
Clean 3222
Inspect 3222
Assemble 3222
Install 3223
Mid-Inlet Section 3223
Remove 3223
Clean 3224
Inspect 3224
Install 3224
Install 3224
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 3229
Lift Pilot Pin 3229
Lower Pilot Pin 3233
Abnormal/Erroneous EHPV Adjustment 3235
Manual Main Control Valve 3236
Description 3236
Remove 3240
OPS Solenoid Assembly 3248
General 3248
Remove 3249
Clean and Inspect 3252
Install 3252
Manual Control Valve Sections 3253
General 3253
Outlet Control Valve Section 3253
Remove 3253
Disassemble 3253
Clean 3256
Inspect 3256
Assemble 3256
Install 3257
Auxiliary Control Valve Sections 3257
Remove 3257
Disassemble 3257
Clean 3260
Inspect 3260
Assemble 3260
Install 3261
Lift/Tilt Control Valve Section 3261
Remove 3261
Disassemble 3261
Clean 3268
Inspect 3268
Assemble 3269
Install 3270
Mid-Inlet Section 3271
Remove 3271
Clean 3271
Inspect 3271
Install 3271
Install 3272
Pressure Relief Valve Check and Adjustment 3278
Primary Relief Valve 3279
Secondary Relief Valve 3283
Steering Control Unit Repair 3290
Steering Control Unit, Remove 3290
Steering Control Unit, Disassemble 3294
Steering Control Unit, Clean 3296
Steering Control Unit, Inspect 3296
Steering Control Unit, Assemble 3296
Relief Valve, Disassemble 3297
Relief Valve, Clean 3297
Relief Valve, Inspect 3298
Relief Valve, Assemble 3298
Steering Control Unit, Install 3298
524223767-2000YRM1137-(06-2021)-US-EN 3303
General 3307
Electro-Hydraulic Main Control Valve 3308
Description 3308
Remove 3316
Electro-Hydraulic Control Valve Sections 3321
General 3321
Outlet Control Valve Section 3321
Remove 3321
Disassemble 3321
Clean 3324
Inspect 3324
Assemble 3325
Install 3325
Auxiliary Control Valve Sections 3325
Remove 3326
Disassemble 3331
Clean 3333
Inspect 3333
Assemble 3333
Install 3335
Tilt Control Valve Section 3336
Remove 3336
Disassemble 3337
Clean 3341
Inspect 3341
Assemble 3342
Install 3343
Lift/Lower Control Valve Section 3343
Remove 3343
Disassemble 3343
Clean 3349
Inspect 3349
Assemble 3349
Install 3350
Mid-Inlet Section 3350
Remove 3350
Clean 3351
Inspect 3351
Install 3351
Install 3351
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 3356
Lift Pilot Pin 3356
Lower Pilot Pin 3359
Abnormal/Erroneous EHPV Adjustment 3361
Manual Main Control Valve 3362
Description 3362
Remove 3366
OPS Solenoid Assembly 3374
General 3374
Remove 3375
Clean and Inspect 3377
Install 3377
Manual Control Valve Sections 3378
General 3378
Outlet Control Valve Section 3378
Remove 3378
Disassemble 3378
Clean 3381
Inspect 3381
Assemble 3381
Install 3381
Auxiliary Control Valve Sections 3382
Remove 3382
Disassemble 3382
Clean 3385
Inspect 3385
Assemble 3385
Install 3385
Lift/Tilt Control Valve Section 3386
Remove 3386
Disassemble 3386
Clean 3392
Inspect 3392
Assemble 3392
Install 3394
Mid-Inlet Section 3394
Remove 3394
Clean 3395
Inspect 3395
Install 3395
Install 3395
Pressure Relief Valve Check and Adjustment 3403
Primary Relief Valve 3403
Secondary Relief Valve 3406
Steering Control Unit Repair 3411
Steering Control Unit, Remove 3411
Steering Control Unit, Disassemble 3415
Steering Control Unit, Clean 3417
Steering Control Unit, Inspect 3417
Steering Control Unit, Assemble 3417
Relief Valve, Disassemble 3418
Relief Valve, Clean 3418
Relief Valve, Inspect 3419
Relief Valve, Assemble 3419
Steering Control Unit, Install 3419
524223768-2100YRM1139-(02-2014)-US-EN 3423
524223769-2200YRM1128-(01-2023)-US-EN 3471
Series Code / Model Designation Reference Table 3479
General 3481
Deutsch Crimping Tool 3482
How to Strip a Wire for Use With Deutsch Crimping Tool 3482
How to Crimp With the Deutsch Crimping Tool 3483
Calibration Test for the Deutsch Crimping Tool 3485
Deutsch Connectors 3487
DT, DTM, and DTP Series Connectors 3487
HD Series Connectors 3530
Metri-Pack Connectors 3552
Remove and Install 3552
Micro-Pack Connectors 3555
Weather-Pack Connectors 3556
AMPSEAL Crimping Tools 3558
AMP Hand Crimping Tool With Certi-Crimp 3558
Description 3558
Stripping Wire for Use with AMP Hand Crimping Tool 3559
Insulation Crimp Adjustment 3560
Maintenance and Inspection for AMP Hand Crimping Tool 3560
AMP Hand Crimping Tool 3560
Crimp Height Inspection 3560
How to use AMP Hand Crimping Tool 3561
AMP Pro-Crimper II Tool 3561
Description 3561
Remove and Install Die Set and Locator Assembly 3562
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3562
Contact Support Adjustment 3563
Crimp Height Adjustment 3564
Maintenance and Inspection Procedures 3564
PRO-CRIMPER II Tool 3564
Crimp Height Inspection 3564
How to Use AMP PRO-CRIMPER II Tool 3565
AMPSEAL Connector Assemblies 3566
Description for Plug Connector Assembly 3566
Seal Plug 3567
Contact Crimping 3567
Description for Plug Connector and Header Assembly 3572
Voltage Reading 3575
Seal Plug 3575
Contact Crimping 3575
AMP Superseal 1 5 Crimping Tools 3582
Mini Mic Receptacle and Tab Contacts 3582
Description 3582
Crimping Conditions and Measurements 3582
Insertion of Rubber Seal on Cable 3584
AMP Hand Application Tool 3589
Description 3589
Maintenance and Inspection 3589
Crimp Height Inspection 3589
Crimp Height Adjustment 3590
How to Use AMP Hand Application Tool 3590
AMP Pro-Crimper II Tool 3591
Description 3591
Remove and Install Die Set and Locator Assembly 3591
Adjustments 3592
Contact Support 3592
Crimp Height 3593
Inspections and Maintenance 3594
Crimp Height Inspection 3594
Visual Inspection 3594
Maintenance 3595
How to Use Pro-Crimper II Tool 3595
AMP Superseal 1 5 Connector Assemblies 3596
Description 3596
Repair and Maintenance 3603
Panel Mount Option 3603
AMP Fastin-Faston Hand Tools 3604
Description – AMP Double Action Hand Tool 3604
Maintenance and Inspection Procedures 3604
Daily Maintenance 3604
Periodic Tool Inspection 3605
Lubrication 3605
Visual Inspection 3605
Crimp Height Inspection 3605
Certi-Crimp Ratchet Inspection 3606
How to Use AMP Double Action Hand Tool 3607
Description – AMP Extraction Tool 3608
Maintenance and Inspection 3609
How to Use AMP Extraction Tool 3609
AMP Fastin-Faston Receptacles and Housings 3611
Description 3611
Wire Repair 3619
Wire Splicing Requirements 3619
Deutsch Jiffy Splice 3620
Twisted/Shielded Cable and Leads Repair 3626
Special Tools 3628
524223769-2200YRM1128-(07-2020)-UK-EN 3637
Series Code / Model Designation Reference Table 3643
General 3646
Deutsch Crimping Tool 3646
How to Strip a Wire for Use With Deutsch Crimping Tool 3646
How to Crimp With the Deutsch Crimping Tool 3647
Calibration Test for the Deutsch Crimping Tool 3649
Deutsch Connectors 3651
DT, DTM, and DTP Series Connectors 3651
HD Series Connectors 3693
Metri-Pack Connectors 3716
Remove and Install 3716
Micro-Pack Connectors 3718
Weather-Pack Connectors 3719
AMPSEAL Crimping Tools 3721
AMP Hand Crimping Tool With Certi-Crimp 3721
Description 3721
Stripping Wire for Use with AMP Hand Crimping Tool 3721
Insulation Crimp Adjustment 3722
Maintenance and Inspection for AMP Hand Crimping Tool 3722
AMP Hand Crimping Tool 3722
Crimp Height Inspection 3722
How to use AMP Hand Crimping Tool 3723
AMP Pro-Crimper II Tool 3723
Description 3723
Remove and Install Die Set and Locator Assembly 3724
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3725
Contact Support Adjustment 3725
Crimp Height Adjustment 3726
Maintenance and Inspection Procedures 3726
PRO-CRIMPER II Tool 3726
Crimp Height Inspection 3726
How to Use AMP PRO-CRIMPER II Tool 3727
AMPSEAL Connector Assemblies 3728
Description for Plug Connector Assembly 3728
Seal Plug 3729
Contact Crimping 3729
Description for Plug Connector and Header Assembly 3734
Voltage Reading 3736
Seal Plug 3736
Contact Crimping 3736
AMP Superseal 1 5 Crimping Tools 3743
Mini Mic Receptacle and Tab Contacts 3743
Description 3743
Crimping Conditions and Measurements 3743
Insertion of Rubber Seal on Cable 3745
AMP Hand Application Tool 3750
Description 3750
Maintenance and Inspection 3750
Crimp Height Inspection 3750
Crimp Height Adjustment 3751
How to Use AMP Hand Application Tool 3751
AMP Pro-Crimper II Tool 3752
Description 3752
Remove and Install Die Set and Locator Assembly 3753
Adjustments 3753
Contact Support 3753
Crimp Height 3754
Inspections and Maintenance 3755
Crimp Height Inspection 3755
Visual Inspection 3755
Maintenance 3756
How to Use Pro-Crimper II Tool 3756
AMP Superseal 1 5 Connector Assemblies 3757
Description 3757
Repair and Maintenance 3764
Panel Mount Option 3764
AMP Fastin-Faston Hand Tools 3765
Description – AMP Double Action Hand Tool 3765
Maintenance and Inspection Procedures 3765
Daily Maintenance 3765
Periodic Tool Inspection 3766
Lubrication 3766
Visual Inspection 3766
Crimp Height Inspection 3766
Certi-Crimp Ratchet Inspection 3767
How to Use AMP Double Action Hand Tool 3768
Description – AMP Extraction Tool 3769
Maintenance and Inspection 3769
How to Use AMP Extraction Tool 3770
AMP Fastin-Faston Receptacles and Housings 3771
Description 3771
Wire Repair 3778
Wire Splicing Requirements 3778
Deutsch Jiffy Splice 3779
Twisted/Shielded Cable and Leads Repair 3784
Special Tools 3787
524223770-2200YRM1130-(03-2020)-UK-EN 3795
General 3799
Description 3799
Dash Display Menu Access 3799
Menu Navigation 3800
Standard Display 3800
Main Menu 3800
Passwords Menu 3801
Password Administration 3801
Add Password 3801
Delete Password 3802
Edit Password 3802
Other Password Functions 3803
Operator Passwords – Enable/Disable 3803
Password Time-Out Delay 3803
Passwords – Number Wrong to Disable 3804
Lockout Reset Password 3804
View Password Log 3805
View Versions 3806
VSM Versions 3806
Dash Display Versions 3807
Engine Controller Version 3808
Transmission (Xmsn) Controller Version 3809
Truck Serial Number 3810
Diagnostics 3811
View Fault Log 3811
Set Travel and Braking 3812
Speed Limit 3812
Acceleration Rate 3813
Auto-Deceleration Rate 3813
Set Power Reversal Rate 3814
Set Inching/Brake Overlap 3815
Setup Display Menu 3816
Set Operator Language 3816
Set Units 3817
Set Time Format (12/24 Hour) 3817
Set Daylight Saving Time 3817
Set Time 3820
Set Date Format 3821
Set Date 3821
Setup Hydraulics 3822
Return to Set Tilt Delay/On/Off 3822
Setup General Items 3823
Light Shutdown Time-Out 3823
Impact Sensor – Enable/Disable 3824
Impact Sensor – Soft Impact Settings 3825
Impact Sensor – Hard Impact Settings 3826
Adjust Impact Sensor Settings 3826
Initial Adjustment of Soft and Hard Impact Settings 3828
Readjustment of Soft and Hard Impact Settings 3828
Impact Sensor – Impact Alarm/Shutdown Reset 3829
Impact Sensor – Alarm Time Duration and Deactivation 3830
Impact Sensor – View Impact Event Log 3831
Engine Mode Indicator 3832
Generation 1 (ECO-eLo ONLY) 3832
Generation 2 3833
Operator Checklist 3834
Operator Checklist Off-On Mode 3834
Edit Operator Checklist 3834
Set Operator Checklist Expiration 3835
View Checklist Log 3835
Clear Operator Checklist Log 3836
Clear Operator Checklist Fault 3836
Calibrations 3837
Set Tilt Stop Point 3837
Calibrate Loaded Weight 3837
524223770-2200YRM1130-(05-2021)-US-EN 3839
General 3843
Description 3843
Dash Display Menu Access 3843
Menu Navigation 3844
Standard Display 3844
Main Menu 3844
Passwords Menu 3845
Password Administration 3845
Add Password 3845
Delete Password 3845
Edit Password 3846
Other Password Functions 3847
Operator Passwords – Enable/Disable 3847
Password Time-Out Delay 3847
Passwords – Number Wrong to Disable 3847
Lockout Reset Password 3848
View Password Log 3848
View Versions 3849
VSM Versions 3849
Dash Display Versions 3850
Engine Controller Version 3851
Transmission (Xmsn) Controller Version 3852
Truck Serial Number 3853
Diagnostics 3854
View Fault Log 3854
Set Travel and Braking 3855
Speed Limit 3855
Acceleration Rate 3856
Auto-Deceleration Rate 3856
Set Power Reversal Rate 3857
Set Inching/Brake Overlap 3858
Setup Display Menu 3859
Set Operator Language 3859
Set Units 3860
Set Time Format (12/24 Hour) 3860
Set Daylight Saving Time 3861
Set Time 3864
Set Date Format 3864
Set Date 3865
Setup Hydraulics 3866
Return to Set Tilt Delay/On/Off 3866
Setup General Items 3867
Light Shutdown Time-Out 3867
Impact Sensor – Enable/Disable 3868
Impact Sensor – Soft Impact Settings 3869
Impact Sensor – Hard Impact Settings 3869
Adjust Impact Sensor Settings 3870
Initial Adjustment of Soft and Hard Impact Settings 3872
Readjustment of Soft and Hard Impact Settings 3872
Impact Sensor – Impact Alarm/Shutdown Reset 3873
Impact Sensor – Alarm Time Duration and Deactivation 3874
Impact Sensor – View Impact Event Log 3875
Engine Mode Indicator 3875
Generation 1 (ECO-eLo ONLY) 3875
Generation 2 3876
Operator Checklist 3877
Operator Checklist Off-On Mode 3877
Edit Operator Checklist 3877
Set Operator Checklist Expiration 3877
View Checklist Log 3878
Clear Operator Checklist Log 3879
Clear Operator Checklist Fault 3879
Calibrations 3880
Set Tilt Stop Point 3880
Calibrate Loaded Weight 3880
524223771-2200YRM1131-(03-2020)-UK-EN 3883
Series Code / Model Designation Reference Table 3889
General 3891
Description 3891
Dash Display Menu Access 3891
Menu Navigation 3892
Main Menu 3892
Passwords 3893
Adding Passwords 3893
Hourmeters 3895
View Versions 3896
VSM Versions 3896
Dash Display Versions 3897
Engine Controller Version 3898
Transmission (Xmsn) Controller Version 3899
Truck Serial Number 3900
Truck Configuration 3901
Diagnostics 3902
Clear Fault Log 3902
View Fault Log 3903
No-Run Data Display 3904
Engine Accelerator and Throttle Data Display 3904
Engine Speeds and Governor Data Display 3905
Engine Fuel and Emissions Data Display 3906
Engine General Data Display 3908
XMSN/Brake Data Display 3909
Hydraulic Data Display 3912
General Truck Data Display 3914
Set Travel and Braking 3915
Speed Limit 3915
Acceleration Rate 3916
Auto-Deceleration Rate 3917
Set Power Reversal Rate 3917
Set Inching/Brake Overlap 3918
Setup Hydraulics 3918
Lift Maximum Speed 3919
Lower Maximum Speed 3919
Tilt Maximum Speed 3920
Auxiliary Function One, Direction A, Maximum Speed 3922
Auxiliary Function One, Direction B, Maximum Speed 3924
Auxiliary Function Two, Direction A, Maximum Speed 3924
Auxiliary Function Two, Direction B, Maximum Speed 3925
Auxiliary Function Three, Direction A, Maximum Speed 3926
Auxiliary Function Three, Direction B, Maximum Speed 3926
Lift/Lower Ramp Rate 3927
Hydraulic Auxiliary Ramp Rate 3927
Return to Set Tilt Delay/On/Off 3928
Hydraulic Input Device 3929
Auxiliary Solenoid 3929
Dual Function 3930
Setup Display 3931
Set Service Language 3931
Setup General Items 3931
Motion Alarm Activation Type 3932
Light Shutdown Time-Out 3933
Restore Default Settings 3933
Restore Engine Controller Default Calibration 3934
Impact Sensor – Enable/Disable 3934
Impact Sensor – Soft Impact Settings 3935
Impact Sensor – Hard Impact Settings 3936
Adjust Impact Sensor Settings 3937
Initial Adjustment of Soft and Hard Impact Settings 3939
Readjustment of Soft and Hard Impact Settings 3939
Impact Sensor – Impact Alarm/Shutdown Reset 3940
Impact Sensor – Alarm Time Duration and Deactivation 3941
Impact Sensor – View Impact Event Log 3942
Engine Mode Indicator 3942
Generation 1 (ECO-eLo ONLY) 3942
Generation 2 3943
Diesel Particulate Filter (DPF) Display 3944
General Description 3944
Passive Regeneration Only 3944
Regeneration Level 0 3944
Auto/Active Regeneration Inhibited 3945
Auto/Active Regeneration 3945
Regeneration Level 1 3945
Parked Regeneration Request 3946
Regeneration Level 2 3946
Warning Level 3946
Regeneration Level 3 3946
Service Level 3947
Regeneration Level 4 3947
Display, Diesel Particulate Filter (DPF), Revised 3947
Operator Interface 3947
Refer to Operator Manual 3947
CAN Communication Lost 3948
Passive Regeneration Only 3948
Regeneration Level 0 3948
Auto/Active Regeneration Inhibited 3948
Auto/Active Regeneration 3949
Regeneration Level 1 3949
Idle-up Auto/Active Regeneration 3949
Parked Regeneration Request 3949
Regeneration Level 2 3949
Warning Level 3951
Regeneration Level 3 3951
Service Level 3951
Regeneration Level 4 3951
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3951
Display, Diesel Particulate Filter (DPF), Stage V Engine 3951
Operator Interface 3952
Refer to Operator Manual 3952
CAN Communication Lost 3952
Passive Regeneration Only 3952
Regeneration Level 0 3952
Auto/Active Regeneration Inhibited 3953
Auto/Active Regeneration 3953
Regeneration Level 1 3953
Idle-up Auto/Active Regeneration 3954
Parked Regeneration Request 3954
Regeneration Level 2 3954
Warning Level 3955
Regeneration Level 3 3955
Service Level 3956
Regeneration Level 4 3956
Stage V Content 3956
Emissions System Malfunction 3956
Ash Load 3956
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3957
Operator Interface 3957
Refer to Operator Manual 3957
CAN Communication Lost 3958
Passive Regeneration Only 3958
Regeneration Level 0 3958
Auto/Active Regeneration Inhibited 3958
Auto/Active Regeneration 3959
Regeneration Level 1 3959
Idle-up Auto/Active Regeneration 3959
Parked Regeneration Request 3959
Regeneration Level 2 3959
Warning Level 3961
Regeneration Level 3 3961
Service Level 3961
Regeneration Level 4 3961
Calibrations 3962
Calibrate Transmission Valve 3964
Set Tilt Stop Point 3964
Calibrate Loaded Weight 3964
Calibrate Travel Speed Sensor 3965
Calibrate Mazda LP and Gas Accelerator Pedal 3965
524223771-2200YRM1131-(05-2021)-US-EN 3967
Series Code / Model Designation Reference Table 3973
General 3975
Description 3975
Dash Display Menu Access 3975
Menu Navigation 3976
Main Menu 3977
Passwords 3977
Adding Passwords 3977
Hourmeters 3979
View Versions 3980
VSM Versions 3980
Dash Display Versions 3981
Engine Controller Version 3982
Transmission (Xmsn) Controller Version 3983
Truck Serial Number 3984
Truck Configuration 3985
Diagnostics 3986
Clear Fault Log 3986
View Fault Log 3987
No-Run Data Display 3988
Engine Accelerator and Throttle Data Display 3989
Engine Speeds and Governor Data Display 3991
Engine Fuel and Emissions Data Display 3992
Engine General Data Display 3994
XMSN/Brake Data Display 3995
Hydraulic Data Display 3997
General Truck Data Display 4000
Set Travel and Braking 4002
Speed Limit 4002
Acceleration Rate 4003
Auto-Deceleration Rate 4003
Set Power Reversal Rate 4004
Set Inching/Brake Overlap 4004
Setup Hydraulics 4005
Lift Maximum Speed 4005
Lower Maximum Speed 4006
Tilt Maximum Speed 4006
Auxiliary Function One, Direction A, Maximum Speed 4008
Auxiliary Function One, Direction B, Maximum Speed 4011
Auxiliary Function Two, Direction A, Maximum Speed 4011
Auxiliary Function Two, Direction B, Maximum Speed 4012
Auxiliary Function Three, Direction A, Maximum Speed 4013
Auxiliary Function Three, Direction B, Maximum Speed 4013
Lift/Lower Ramp Rate 4014
Hydraulic Auxiliary Ramp Rate 4014
Return to Set Tilt Delay/On/Off 4015
Hydraulic Input Device 4016
Auxiliary Solenoid 4016
Dual Function 4017
Setup Display 4018
Set Service Language 4018
Setup General Items 4018
Motion Alarm Activation Type 4019
Light Shutdown Time-Out 4020
Restore Default Settings 4020
Restore Engine Controller Default Calibration 4021
Impact Sensor – Enable/Disable 4021
Impact Sensor – Soft Impact Settings 4022
Impact Sensor – Hard Impact Settings 4022
Adjust Impact Sensor Settings 4023
Initial Adjustment of Soft and Hard Impact Settings 4025
Readjustment of Soft and Hard Impact Settings 4025
Impact Sensor – Impact Alarm/Shutdown Reset 4026
Impact Sensor – Alarm Time Duration and Deactivation 4027
Impact Sensor – View Impact Event Log 4028
Engine Mode Indicator 4028
Generation 1 (ECO-eLo ONLY) 4028
Generation 2 4029
Diesel Particulate Filter (DPF) Display 4030
General Description 4030
Passive Regeneration Only 4030
Regeneration Level 0 4030
Auto/Active Regeneration Inhibited 4031
Auto/Active Regeneration 4031
Regeneration Level 1 4031
Parked Regeneration Request 4032
Regeneration Level 2 4032
Warning Level 4033
Regeneration Level 3 4033
Service Level 4033
Regeneration Level 4 4033
Display, Diesel Particulate Filter (DPF), Revised 4033
Operator Interface 4034
Refer to Operator Manual 4034
CAN Communication Lost 4034
Passive Regeneration Only 4034
Regeneration Level 0 4034
Auto/Active Regeneration Inhibited 4035
Auto/Active Regeneration 4035
Regeneration Level 1 4035
Idle-up Auto/Active Regeneration 4035
Parked Regeneration Request 4036
Regeneration Level 2 4036
Warning Level 4037
Regeneration Level 3 4037
Service Level 4037
Regeneration Level 4 4037
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 4038
Display, Diesel Particulate Filter (DPF), Stage V Engine 4038
Operator Interface 4038
Refer to Operator Manual 4038
CAN Communication Lost 4039
Passive Regeneration Only 4039
Regeneration Level 0 4039
Auto/Active Regeneration Inhibited 4039
Auto/Active Regeneration 4040
Regeneration Level 1 4040
Idle-up Auto/Active Regeneration 4040
Parked Regeneration Request 4040
Regeneration Level 2 4040
Warning Level 4042
Regeneration Level 3 4042
Service Level 4042
Regeneration Level 4 4042
Stage V Content 4042
Emissions System Malfunction 4042
Ash Load 4043
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 4044
Operator Interface 4044
Refer to Operator Manual 4044
CAN Communication Lost 4045
Passive Regeneration Only 4045
Regeneration Level 0 4045
Auto/Active Regeneration Inhibited 4045
Auto/Active Regeneration 4046
Regeneration Level 1 4046
Idle-up Auto/Active Regeneration 4046
Parked Regeneration Request 4046
Regeneration Level 2 4046
Warning Level 4048
Regeneration Level 3 4048
Service Level 4048
Regeneration Level 4 4048
Calibrations 4049
Calibrate Transmission Valve 4051
Set Tilt Stop Point 4051
Calibrate Loaded Weight 4052
Calibrate Travel Speed Sensor 4052
Calibrate Mazda LP and Gas Accelerator Pedal 4053
524223772-2200YRM1142-(01-2020)-UK-EN 4055
General 4065
Display Switch Cluster 4068
Remove 4068
Install 4071
Direction Control and Turn Signal Levers 4071
Remove 4071
Install 4073
Key Switch 4073
Remove 4073
Install 4074
Display Switch Cluster Panel Bezel and Overlay 4074
Remove 4074
Install 4074
Steering Column Repair 4074
Remove 4074
Disassemble 4077
Assemble 4077
Install 4077
Sensors and Switches 4078
General 4078
Dash and Kick Panel, Remove and Install 4078
Remove 4078
Install 4079
Accelerator Pedal Position Sensor 4080
Remove 4080
Install 4083
Brake Fluid Level Switch 4084
Remove 4084
Install 4086
Service Brake Pedal Position Sensor 4087
Remove 4087
Install 4090
Parking Brake Sensor 4091
Remove 4091
Install 4092
Service Brake Pressure Sensor 4093
Remove 4093
Install 4095
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4096
Remove 4096
Install 4096
Sensor Microswitch (Foot Directional Control Pedal) 4097
Remove 4097
Install 4100
Low Coolant Level Sensor 4101
Remove 4101
Install 4104
Fuel Level Sensor, Gas and Diesel Engines Only 4105
Remove 4105
Install 4106
Armrest Switch 4106
Remove 4106
Install 4108
Seat Sensor (Operator Presence System) 4108
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) 4108
Remove 4108
Install 4109
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4109
Remove 4109
Install 4110
Full Suspension Seats; All Lift Truck Models 4110
Remove 4110
Install 4110
Hood Shut Off Switch 4110
Remove 4110
Install 4113
Remote Key Switch 4114
Remove 4114
Install 4114
Hydraulic Filter Pressure Switch 4115
Remove 4115
Install 4117
Transmission Speed Sensor 4117
Remove 4117
Install 4120
Transmission Pressure Sensors 4121
Remove 4121
Install 4123
Transmission Temperature Sensor 4124
Remove 4124
Install 4126
Engine Speed Sensor 4128
Remove 4128
Install 4128
Intermediate Speed Sensor 4129
Remove 4129
Install 4129
Return to Set Tilt (Tilt Angle) Sensor 4129
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) 4129
Remove 4129
Install 4130
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) 4131
Remove 4131
Install 4132
Rear Horn Button Switch 4132
Remove 4132
Install 4133
Impact Sensor 4134
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) 4134
Remove 4134
Install 4137
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) 4137
Remove 4137
Install 4138
Load Weight Sensor 4139
Remove 4139
Install 4140
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 4141
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 4141
Crankshaft Position (CKP) Sensor 4141
Camshaft Position (CMP) Sensor 4141
Oil Pressure Sensor 4141
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 4141
Engine Coolant Temperature (ECT) Sensor 4142
Air Flow Restriction Switch 4142
Remove for GM 2 4L Gas and LPG Trucks 4142
Install for GM 2 4L Gas and LPG Trucks 4142
Oxygen Sensor 4143
Remove 4143
Install 4146
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 4147
Crankshaft Position (CKP) Sensor 4147
Camshaft Position (CMP) Sensor 4147
Oil Pressure Sensor 4147
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 4147
Engine Coolant Temperature (ECT) Sensor 4147
Air Flow Restriction Switch 4147
Oxygen Sensor 4147
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 4147
Low LPG Pressure Switch 4147
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 4148
Air Filter Restriction Switch 4148
Remove 4148
Install 4148
Oil Pressure Sensor 4148
Remove 4148
Install 4148
Engine Speed Sensor 4148
Remove 4148
Install 4148
Engine Coolant Temperature (ECT) Sensor 4148
Remove 4148
Install 4148
Throttle Position Sensor (TPS) 4151
Remove 4151
Install 4152
Fuel/Water Separator Sensor 4152
Remove 4152
Install 4152
Glow Plug Relay 4153
Remove 4153
Install 4155
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 4155
Air Filter Restriction Switch 4155
Remove 4155
Install 4155
Engine Oil Pressure Sensor 4160
Remove 4160
Install 4160
Engine Speed Sensor 4160
Remove 4160
Install 4161
Engine Coolant Temperature (ECT) Sensor 4161
Remove 4161
Install 4162
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 4163
Remove 4163
Install 4163
Fuel/Water Separator Sensor 4164
Remove 4164
Install 4164
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 4165
Intake Air Temperature Sensor 4165
Remove 4165
Install 4166
Intake Air Pressure Sensor 4166
Remove 4166
Install 4166
Air Inlet Heater 4166
Remove 4166
Install 4167
Engine Oil Pressure Sensor 4167
Remove 4167
Install 4167
Engine Coolant Temperature (ECT) Sensor 4167
Remove 4167
Install 4167
Crankshaft Position Sensor 4168
Remove 4168
Install 4168
Adjust Shim Procedure 4169
Camshaft Position Sensor 4170
Remove 4170
Install 4170
Air Flow Restriction Sensor 4171
Remove 4171
Install 4171
Fuel/Water Separator 4171
Remove 4171
Install 4172
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 4172
Intake Air Temperature Sensor 4176
Remove 4176
Install 4177
Boost Sensor 4177
Remove 4177
Install 4178
Throttle Valve Assembly and Air Intake Heater 4178
Remove 4178
Install 4178
Engine Coolant Temperature (ECT) Sensor 4179
Remove 4179
Install 4179
Engine Oil Pressure Sensor 4179
Remove 4179
Install 4180
Crankshaft Position Sensor 4180
Remove 4180
Install 4180
Adjust Shim Procedure 4181
Camshaft Position Sensor 4182
Remove 4182
Install 4183
Differential Pressure Sensor 4183
Remove 4183
Install 4183
Mass Air Flow Sensor 4184
Remove 4184
Install 4185
Fuel/Water Separator 4185
Remove 4185
Install 4186
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 4186
Engine Coolant Temperature (ECT) Sensor 4187
Remove 4187
Install 4187
Throttle Position Sensor 4188
Engine Oil Pressure Sensor 4188
Remove 4188
Install 4188
Engine Speed Sensor 4188
Remove 4188
Install 4188
Fuel Shut Off Solenoid 4188
Remove 4188
Install 4188
Vehicle System Manager (VSM) 4189
General 4189
VSM Replacement 4189
Remove 4189
Install 4191
Programming a New VSM and/or Display Switch Cluster 4191
General 4191
PC Service Tool Software 4192
Data Transferring 4192
New VSM 4192
New (Blank) Display Switch Cluster 4192
Used (Non-Blank) Display Switch Cluster 4192
Power Distribution Module (PDM) and Component Parts 4194
Remove 4194
PDM as a Unit 4194
Install 4198
PDM as a Unit 4198
Remove and Install 4199
PDM Component Parts 4199
Transmission Control Unit 4199
Remove 4199
Install 4203
Battery 4205
Remove 4205
Install 4205
Lights 4206
Work Lights (Front and Rear) 4206
Remove 4206
Install 4206
Strobe Light 4207
Remove 4207
Install 4207
LED Tail, Backup, and Brake Lights 4208
Remove 4208
Install 4209
Front Marker/Turn Signal Lights 4210
Replacing Whole Front Marker/Turn Signal Light Assembly 4210
Remove 4210
Install 4210
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 4211
Remove 4211
Install 4211
Diesel Particulate Filter (DPF) Display 4211
Remove 4211
Clean and Inspect 4212
Install 4212
Electronic-Hydraulic Controls – Generation 1 4213
E-Hydraulic Controls – Test 4213
Mini-Levers 4213
Full Stroke Test 4213
Function Returns to Neutral Test 4213
Push Button Switch 4213
General 4214
Mini-Lever Replacement 4214
Remove 4214
Clean and Inspect 4215
Install 4215
Push Button Switch Replacement 4216
Remove 4216
Install 4218
Mini-Lever Module (MLM) 4218
Remove 4218
Install 4218
Joystick 4219
Remove and Disassemble 4219
Inspect 4219
Assemble and Install 4219
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 4220
General 4220
Mini-levers, Remove and Install 4220
Armrest Assembly 4221
Remove 4221
Install 4224
Horn Button 4224
Remove 4224
Install 4224
Direction Control Switch 4225
Remove 4225
Install 4225
push (override) buttons and Toggle Switch 4225
Remove 4226
Install 4227
Joystick 4228
Remove and Disassemble 4228
Inspect 4228
Assemble and Install 4228
Joystick Armrest Slider Assembly 4229
Remove 4229
Install 4230
Electronic-Hydraulic Controls, After January, 2020 4230
E-Hydraulic Controls – TEST 4230
Mini-Levers 4230
Full Stroke Test 4230
Function Returns to Neutral Test 4230
Push (Override) Button 4231
General 4231
Mini-levers, Remove and Install 4231
Armrest Assembly 4232
Remove 4232
Install 4235
Horn Button 4235
Remove 4235
Install 4235
Direction Control Switch 4235
Remove 4235
Install 4236
Push (Override) buttons and Toggle Switch 4236
Remove 4237
Install 4239
Special Tools 4240
524223772-2200YRM1142-(08-2021)-US-EN 4243
General 4253
Display Switch Cluster 4257
Remove 4257
Install 4259
Direction Control and Turn Signal Levers 4259
Remove 4259
Install 4260
Key Switch 4261
Remove 4261
Install 4262
Display Switch Cluster Panel Bezel and Overlay 4262
Remove 4262
Install 4262
Steering Column Repair 4263
Remove 4263
Disassemble 4266
Assemble 4266
Install 4266
Sensors and Switches 4267
General 4267
Dash and Kick Panel, Remove and Install 4267
Remove 4267
Install 4268
Accelerator Pedal Position Sensor 4268
Remove 4268
Install 4272
Brake Fluid Level Switch 4273
Remove 4273
Install 4274
Service Brake Pedal Position Sensor 4276
Remove 4276
Install 4278
Parking Brake Sensor 4279
Remove 4279
Install 4281
Service Brake Pressure Sensor 4281
Remove 4281
Install 4283
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4285
Remove 4285
Install 4285
Sensor Microswitch (Foot Directional Control Pedal) 4285
Remove 4285
Install 4288
Low Coolant Level Sensor 4289
Remove 4289
Install 4292
Fuel Level Sensor, Gas and Diesel Engines Only 4293
Remove 4293
Install 4294
Armrest Switch 4294
Remove 4294
Install 4296
Seat Sensor (Operator Presence System) 4296
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) 4296
Remove 4296
Install 4297
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4297
Remove 4297
Install 4297
Full Suspension Seats; All Lift Truck Models 4298
Remove 4298
Install 4298
Hood Shut Off Switch 4299
Remove 4299
Install 4301
Remote Key Switch 4302
Remove 4302
Install 4302
Hydraulic Filter Pressure Switch 4303
Remove 4303
Install 4305
Transmission Speed Sensor 4305
Remove 4305
Install 4308
Transmission Pressure Sensors 4309
Remove 4309
Install 4311
Transmission Temperature Sensor 4312
Remove 4312
Install 4314
Engine Speed Sensor 4316
Remove 4316
Install 4317
Intermediate Speed Sensor 4317
Remove 4317
Install 4317
Return to Set Tilt (Tilt Angle) Sensor 4318
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) 4318
Remove 4318
Install 4318
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) 4318
Remove 4319
Install 4320
Rear Horn Button Switch 4321
Remove 4321
Install 4321
Impact Sensor 4322
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) 4322
Remove 4322
Install 4324
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) 4324
Remove 4324
Install 4325
Load Weight Sensor 4325
Remove 4325
Install 4327
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 4328
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 4328
Crankshaft Position (CKP) Sensor 4328
Camshaft Position (CMP) Sensor 4328
Oil Pressure Sensor 4328
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 4328
Engine Coolant Temperature (ECT) Sensor 4329
Air Flow Restriction Switch 4329
Remove for GM 2 4L Gas and LPG Trucks 4329
Install for GM 2 4L Gas and LPG Trucks 4329
Oxygen Sensor 4330
Remove 4330
Install 4333
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 4334
Crankshaft Position (CKP) Sensor 4334
Camshaft Position (CMP) Sensor 4334
Oil Pressure Sensor 4334
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 4334
Engine Coolant Temperature (ECT) Sensor 4334
Air Flow Restriction Switch 4334
Oxygen Sensor 4334
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 4334
Low LPG Pressure Switch 4334
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 4335
Air Filter Restriction Switch 4335
Remove 4335
Install 4335
Oil Pressure Sensor 4335
Remove 4335
Install 4335
Engine Speed Sensor 4335
Remove 4335
Install 4335
Engine Coolant Temperature (ECT) Sensor 4335
Remove 4335
Install 4335
Throttle Position Sensor (TPS) 4338
Remove 4338
Install 4339
Fuel/Water Separator Sensor 4339
Remove 4339
Install 4339
Glow Plug Relay 4340
Remove 4340
Install 4342
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 4342
Air Filter Restriction Switch 4342
Remove 4342
Install 4343
Engine Oil Pressure Sensor 4347
Remove 4347
Install 4347
Engine Speed Sensor 4347
Remove 4347
Install 4348
Engine Coolant Temperature (ECT) Sensor 4348
Remove 4348
Install 4349
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 4350
Remove 4350
Install 4350
Fuel/Water Separator Sensor 4351
Remove 4351
Install 4351
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 4352
Intake Air Temperature Sensor 4352
Remove 4352
Install 4353
Intake Air Pressure Sensor 4353
Remove 4353
Install 4353
Air Inlet Heater 4353
Remove 4353
Install 4354
Engine Oil Pressure Sensor 4354
Remove 4354
Install 4354
Engine Coolant Temperature (ECT) Sensor 4354
Remove 4354
Install 4354
Crankshaft Position Sensor 4355
Remove 4355
Install 4355
Adjust Shim Procedure 4356
Camshaft Position Sensor 4357
Remove 4357
Install 4357
Air Flow Restriction Sensor 4357
Remove 4357
Install 4358
Fuel/Water Separator 4358
Remove 4358
Install 4359
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 4359
Intake Air Temperature Sensor 4363
Remove 4363
Install 4364
Boost Sensor 4364
Remove 4364
Install 4365
Throttle Valve Assembly and Air Intake Heater 4365
Remove 4365
Install 4365
Engine Coolant Temperature (ECT) Sensor 4366
Remove 4366
Install 4366
Engine Oil Pressure Sensor 4367
Remove 4367
Install 4367
Crankshaft Position Sensor 4367
Remove 4367
Install 4367
Adjust Shim Procedure 4368
Camshaft Position Sensor 4370
Remove 4370
Install 4370
Differential Pressure Sensor 4370
Remove 4370
Install 4371
Mass Air Flow Sensor 4371
Remove 4371
Install 4372
Fuel/Water Separator 4373
Remove 4373
Install 4374
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 4375
Engine Coolant Temperature (ECT) Sensor 4376
Remove 4376
Install 4376
Throttle Position Sensor 4376
Engine Oil Pressure Sensor 4376
Remove 4376
Install 4376
Engine Speed Sensor 4376
Remove 4376
Install 4376
Fuel Shut Off Solenoid 4377
Remove 4377
Install 4377
Vehicle System Manager (VSM) 4378
General 4378
VSM Replacement 4378
Remove 4378
Install 4380
Programming a New VSM and/or Display Switch Cluster 4380
General 4380
PC Service Tool Software 4381
Data Transferring 4381
New VSM 4381
New (Blank) Display Switch Cluster 4381
Used (Non-Blank) Display Switch Cluster 4381
Power Distribution Module (PDM) and Component Parts 4384
Remove 4384
PDM as a Unit 4384
Install 4387
PDM as a Unit 4387
Remove and Install 4388
PDM Component Parts 4388
Transmission Control Unit (TCU) 4389
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) 4389
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) 4389
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 4390
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 4390
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 4390
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 4391
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 4392
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 4394
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 4394
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 4394
Battery 4395
Remove 4395
Install 4395
Lights 4396
Work Lights (Front and Rear) 4396
Remove 4396
Install 4396
Strobe Light 4397
Remove 4397
Install 4397
LED Tail, Backup, and Brake Lights 4398
Remove 4398
Install 4399
Front Marker/Turn Signal Lights 4400
Replacing Whole Front Marker/Turn Signal Light Assembly 4400
Remove 4400
Install 4400
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 4401
Remove 4401
Install 4401
Diesel Particulate Filter (DPF) Display 4402
Remove 4402
Clean and Inspect 4403
Install 4403
Electronic-Hydraulic Controls – Generation 1 4404
E-Hydraulic Controls – Test 4404
Mini-Levers 4404
Full Stroke Test 4404
Function Returns to Neutral Test 4404
Push Button Switch 4404
General 4405
Mini-Lever Replacement 4405
Remove 4405
Clean and Inspect 4406
Install 4406
Push Button Switch Replacement 4407
Remove 4407
Install 4409
Mini-Lever Module (MLM) 4409
Remove 4409
Install 4409
Joystick 4410
Remove and Disassemble 4410
Inspect 4410
Assemble and Install 4410
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 4411
General 4411
Mini-levers, Remove and Install 4411
Armrest Assembly 4412
Remove 4412
Install 4415
Horn Button 4415
Remove 4415
Install 4415
Direction Control Switch 4416
Remove 4416
Install 4416
push (override) buttons and Toggle Switch 4416
Remove 4417
Install 4418
Joystick 4419
Remove and Disassemble 4419
Inspect 4419
Assemble and Install 4419
Joystick Armrest Slider Assembly 4420
Remove 4420
Install 4421
Electronic-Hydraulic Controls, After January, 2020 4422
E-Hydraulic Controls – TEST 4422
Mini-Levers 4422
Full Stroke Test 4422
Function Returns to Neutral Test 4422
Push (Override) Button 4422
General 4423
Mini-levers, Remove and Install 4423
Armrest Assembly 4424
Remove 4424
Install 4427
Horn Button 4427
Remove 4427
Install 4427
Direction Control Switch 4427
Remove 4427
Install 4428
Push (Override) buttons and Toggle Switch 4428
Remove 4429
Install 4431
Special Tools 4432
524223773-2200YRM1143-(05-2005)-US-EN 4435
toc 4435
Electrical System 4435
Safety Precautions Maintenance and Repair 4436
Ignition System 4439
General 4439
Ignition Timing Adjustment, Gasoline and LPG 4439
Spark Plugs Check 4439
Spark Plug Wires Check 4439
Distributor Repair 4442
Remove 4442
Disassemble 4443
Inspect 4443
Assemble 4444
Install 4444
Igniter 4445
Remove 4445
Test 4445
Install 4445
Camshaft Position (CMP) Sensor 4446
Voltage Check 4446
Ignition Coil Check 4447
Primary Coil Winding 4447
Secondary Coil Winding 4447
Starter Repair 4448
General 4448
Remove 4448
No-Load Test 4449
Magnetic Switch Test 4449
Pull-Out Test 4449
Holding Coil Test 4450
Return Test 4450
Pinion Movement Inspection 4450
Install 4450
Alternator Repair 4451
General 4451
Charging System Inspection 4451
Output Current Check 4452
No-Load Adjusted Voltage Check 4452
Remove 4453
Inspect 4453
Rectifier Check 4453
Install 4454
tables 4435
Table 1 Spark Plug Wire 4439
Table 2 Starter Specifications 4448
Table 3 Problem Diagnosis Chart 4449
Table 4 Specifications 4452
Table 5 Rectifier Check Table 4453
524223773-2200YRM1143-(10-2005)-UK-EN 4457
toc 4457
Electrical System 4457
Safety Precautions Maintenance and Repair 4458
Ignition System 4461
General 4461
Ignition Timing Adjustment, Gasoline and LPG 4461
Spark Plugs Check 4461
Spark Plug Wires Check 4461
Distributor Repair 4464
Remove 4464
Disassemble 4465
Inspect 4465
Assemble 4466
Install 4466
Igniter 4467
Remove 4467
Test 4467
Install 4467
Camshaft Position (CMP) Sensor 4468
Voltage Check 4468
Ignition Coil Check 4469
Primary Coil Winding 4469
Secondary Coil Winding 4469
Starter Repair 4470
General 4470
Remove 4470
No-Load Test 4471
Magnetic Switch Test 4471
Pull-Out Test 4471
Holding Coil Test 4472
Return Test 4472
Pinion Movement Inspection 4472
Install 4472
Alternator Repair 4473
General 4473
Charging System Inspection 4473
Output Current Check 4474
No-Load Adjusted Voltage Check 4474
Remove 4475
Inspect 4475
Rectifier Check 4475
Install 4476
tables 4457
Table 1 Spark Plug Wire 4461
Table 2 Starter Specifications 4470
Table 3 Problem Diagnosis Chart 4471
Table 4 Specifications 4474
Table 5 Rectifier Check Table 4475
524223776-4000YRM1148-(09-2015)-US-EN 4479
General 4483
Safety Procedures When Working Near Mast 4484
Fork Replacement 4486
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4486
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4488
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4489
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4489
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4490
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4491
Carriages Repair 4492
Standard Carriage 4492
Remove 4492
Repair 4493
Install 4493
Standard Carriage, Remove 4494
Hang-On Sideshift Carriage, Remove 4495
Standard Carriage and Hang-On Sideshift Carriage, Repair 4496
Standard Carriage, Install 4497
Hang-On Sideshift Carriage, Install 4497
Integral Sideshift Carriage 4498
Remove 4498
Clean and Inspect 4501
Repair 4502
Install 4502
Fork Positioner 4503
Remove 4503
Clean and Inspect 4508
Disassemble and Assemble 4508
Install 4508
Fork Positioner Hydraulic Hose Adjustment 4509
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4511
Connecting Attachment Hydraulic Quick Disconnect Hoses 4511
Mast Repair 4512
Mast, Remove 4512
Two-Stage LFL and Two-Stage FFL Masts 4515
Disassemble 4515
Clean and Inspect 4525
Three-Stage FFL Mast 4526
Disassemble 4526
Clean and Inspect 4534
Two-Stage LFL and Two-Stage FFL Mast 4536
Assemble 4536
Three-Stage FFL Mast 4539
Assemble 4539
Four-Stage FFL Mast – Manufactured Before July, 2009 4541
Disassemble 4541
Clean and Inspect 4546
Assemble 4548
Four-Stage FFL Mast – Manufactured After July, 2009 4549
Disassemble 4549
Clean and Inspect 4556
Assemble 4559
Mast, Install 4560
Header Hose Arrangement 4563
Two-Stage LFL 4563
Two-Stage FFL 4571
Three-Stage FFL 4586
Standard 4586
Optional Equipment Lift Truck GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4603
Four-Stage FFL Mast – Manufactured Before July, 2009 4611
Four-Stage FFL Mast – Manufactured After July, 2009 4620
Adjustment 4627
Lift Chains Adjustment 4627
Carriage Adjustments 4630
Mast Adjustments 4630
Load Roller Adjustment 4630
Mast Side Kicking Adjustment 4633
524223777-8000YRM1150-(12-2017)-US-EN 4637
General 4643
Serial Number Data 4643
How to Move Disabled Lift Truck 4643
How to Tow Lift Truck 4643
How to Put Lift Truck on Blocks 4644
How to Raise Drive Tires 4644
How to Raise Steering Tires 4645
How to Clean a Lift Truck 4646
Maintenance Schedule 4646
Maintenance Procedures Every 8 Hours or Daily 4671
How to Make Checks With Engine Stopped 4672
Tires and Wheels 4672
Safety Labels 4673
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4673
Operator Restraint System 4674
Automatic Locking Retractor (ALR) 4674
Emergency Locking Retractor (ELR) 4674
Adjust Seat – Full Suspension 4674
Adjust Seat – Internal Suspension 4676
Hood and Seat Latches 4677
Engine Compartment 4677
Paper Application 4677
Fuel, Oil, and Coolant Leaks, Check 4678
Hydraulic Hoses 4678
Coolant Hoses 4678
Steering Column Gas Cylinder 4678
Transmission 4678
Hydraulic System Oil 4678
Engine Oil 4679
Air Filter 4685
Forks 4685
Remove 4685
Inspect 4687
Install 4688
Adjust 4688
How to Make Checks With Engine Running 4689
Indicator Lights, Horn, Fuses, and Relays 4689
Service Brakes 4692
Brake Fluid Level 4692
Operation, Check 4692
Parking Brake 4692
Engine Oil Pressure 4693
Cooling System 4693
Steering System 4694
Control Levers and Pedals 4694
Lift System, Operate 4694
First Service After First 100 Hours of Operation 4695
Mazda and GM Engine Oil and Oil Filter 4695
Yanmar Engine Oil and Oil Filter 4696
Maintenance Procedures Every 250 Hours or 6 Months 4696
Mazda and GM Engine Oil and Oil Filter 4696
Drive Belt 4697
Mazda 2 0L and 2 2L Engines 4697
Fan and Alternator Drive Belt 4697
GM 2 4L Engine 4697
Fan and Alternator Drive Belt 4697
Drain Tar From LPG Regulator (Except 2007 Mazda Emission Compliant Engines) 4698
Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engines Only) 4699
Maintenance Procedures Every 500 Hours or 6 Months 4699
Hydraulic System Oil 4700
Hydraulic Tank Breather 4700
Inspect 4700
Battery 4701
Yanmar Engine Oil and Oil Filter 4701
Drive Belt 4702
Yanmar Diesel Engine 4702
Fan and Alternator Drive Belt 4702
Timing Belt, Checks and Inspection 4703
PCV Valve 4705
Clean Debris From Radiator Core 4705
Transmission Oil Level 4705
Wet Brake Planetary Housing Oil Level Check 4707
Forks 4708
Mast Lubrication 4708
Header Hose Checks 4712
Lift Chain Lubrication 4712
Tilt Cylinder Lubrication 4713
Master Brake Cylinder Rod End Pin Lubrication 4714
Manual Hydraulic Levers Lubrication 4714
Brake Fluid 4715
Tie Rod Lubrication (GP/GLP/GDP040-070VX) 4716
Differential and Drive Axle Oil (Dry Brake) 4716
Maintenance Procedures Every 1000 Hours or 6 Months 4716
Valve Clearance, Check and Adjust 4716
Ignition System 4717
GM 2 4L Engine 4717
Mazda Engines 2 0L and 2 2LFE and F2 4717
LPG Fuel Filter Element Replace, GM 2 4L Engine 4717
Remove 4717
Install 4717
LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 4718
LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines Only 4718
Remove 4718
Clean/Inspect 4719
Install 4719
Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant Engines Only 4719
Remove and Replace 4719
Fuel Filter Replacement, Yanmar Engine 4720
Priming the Fuel System (Yanmar) 4722
Lift Chains Wear Check 4722
Lift Chain Lubrication 4723
Integral Sideshift Carriage, Check Bearings 4723
Integral Sideshift Carriage, Check Lower Mounting Hooks 4724
Steering Axle 4724
Control Levers and Pedals 4724
Maintenance Procedures Every 2000 Hours or Annually 4724
Hydraulic System 4725
Hydraulic Filter, Replace 4725
Hydraulic Tank Breather, Replace 4726
Air Filter 4727
PCV Valve 4728
Oxygen Sensor 4729
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 4731
Remove and Replace 4731
LPG Regulator Fuel Filter, GM Engines 4731
Remove 4731
Install 4732
Gasoline Fuel Filter 4732
Remove and Replace for Lift Trucks Equipped with GFI 4732
Timing Belt 4733
Mazda Engines 4733
GM 2 4L Engine 4733
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 4733
Gasoline Fuel Injector, Mazda Engines 4733
LPG Fuel Injector, GM Engines 4733
Gasoline Fuel Injector, GM Engines 4733
Fuel Injector, Yanmar Engines 4733
Forks 4733
Integral Sideshift Carriage 4733
Bearings, Replace 4733
Transmission Oil and Filter (Dry Brake), Replace 4733
Iron Transmission Housing 4733
Aluminum Transmission Housing 4734
Remove 4734
Clean and Inspect 4738
Install 4738
Transmission Oil Change, Wet Brake Drive Axle 4739
Iron Transmission Housing 4739
Aluminum Transmission Housing 4740
Wet Brake Axle Center Section and Planetary Housing, Oil Change 4743
Brake Fluid (Master Cylinder), Change 4743
Brake Fluid (Dry Brake), Remove 4748
Steer Axle, Wheel Bearing Lubrication 4748
Service Brakes (Dry Brake) 4748
Differential (Dry Brake) 4749
Maintenance Procedures Every 4000 Hours or 2 Years 4749
Hydraulic Oil, Replace 4750
Cooling System 4750
Safety Procedures When Working Near Mast 4751
Hood Latch Check 4754
Lift Chain Adjustments 4755
Jump-Starting the Lift Truck 4757
Jump-Starting Using a Battery Charger 4757
Jump-Starting a Lift Truck Using Another Lift Truck 4757
Welding Repairs 4757
Overhead Guard Changes 4758
Wheel and Tire Replacement 4758
General 4758
Solid Rubber Tire, Change (GC/GLC Series) 4758
Remove and Install Tire on Wheel 4759
Pneumatic Tire With Tube, Repair 4760
Remove Wheels From Lift Truck 4760
Remove Tire From Wheel 4760
Install Wheel in Tire 4763
Install Tire on Two-Piece Wheel 4765
Add Air to Pneumatic Tires With Tube 4766
Install the Wheels 4767
Dual Drive Wheels, Install 4767
Pneumatic Tubeless Tire, Repair 4768
Remove Wheels From Lift Truck 4768
Add Air to Pneumatic Tubeless Tire 4773
Wheels, Install 4773
Solid Rubber Tires on Pneumatic Wheels, Change 4773
Adhesives and Sealants 4777
524223778-8000YRM1151-(10-2016)-US-EN 4781
Lift Truck Lifting Capacity 4785
Counterweight Weights 4785
Tire Sizes 4785
Capacities 4786
Electrical System 4791
Transmission Oil Pressures 4792
Hydraulic System Relief Pressures 4796
Steering System 4797
Stall Speeds (in RPM ±100 rpm) 4798
Mazda FE (Except 2007 Emission Compliant Engines) 4798
Mazda FE (2007 Emission Compliant Engines Only) 4798
Mazda F2 (Except 2007 Emission Compliant Engines) 4798
Mazda F2 (2007 Emission Compliant Engines Only) 4798
GM 2 4L 4799
Yanmar 2 6L 4799
Yanmar 3 3L 4799
Mast Speeds 4799
Tilt Angles 4802
Front End Equipment – Mast Creep 4803
Mast Creep 4803
Engine Specifications 4803
Torque Specifications 4805
Frame 4805
Mast 4805
Steering System, Cushioned Tire Trucks 4805
Steering System, Pneumatic Tire Trucks 4806
Drive Axle (Dry Brake) 4806
Drive Axle (Wet Brake) 4806
Transmission – Iron Housing 4807
Transmission – Aluminum Housing 4807
Engine – Mazda FE and F2 4808
Engine – GM 2 4L 4809
Engine – Yanmar 2 6L and 3 3L Diesel 4810
524223779-8000YRM1152-(03-2020)-UK-EN 4815
General Information About Diagrams and Schematics 4819
Symbol Definitions 4819
Diagrams Manual Applications 4820
Diagrams and Schematics 4822
524223779-8000YRM1152-(06-2021)-US-EN 4885
General Information About Diagrams and Schematics 4889
Symbol Definitions 4889
Diagrams Manual Applications 4890
Diagrams and Schematics 4892
524223780-8000YRM1134-(03-2020)-UK-EN 4953
Series Code / Model Designation Reference Table 4959
Description 4961
Proc_Cal_001: Service Password Entry 4963
When to Perform 4963
Why Perform 4963
How to Perform 4963
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 4964
When to Perform 4964
Calibration Order 4964
Why Perform 4964
How to Perform 4965
Proc_Cal_003: Save and Exit 4966
When to Perform 4966
Why Perform 4966
How to Perform 4966
Proc_Cal_004: Lift Valve Output Threshold 4967
When to Perform 4967
Calibration Order 4967
Why Perform 4967
How to Perform 4968
Proc_Cal_005: Lower Valve Output Threshold 4970
When to Perform 4970
Calibration Order 4970
Why Perform 4970
How to Perform 4970
Proc_Cal_006: Tilt Back Valve Output Threshold 4973
When to Perform 4973
Calibration Order 4973
Why Perform 4973
How to Perform 4973
Proc_Cal_007: Tilt Forward Valve Output Threshold 4976
When to Perform 4976
Calibration Order 4976
Why Perform 4976
How to Perform 4976
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 4979
When to Perform 4979
Calibration Order 4979
Why Perform 4979
How to Perform 4979
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 4982
When to Perform 4982
Calibration Order 4982
Why Perform 4982
How to Perform 4982
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 4985
When to Perform 4985
Calibration Order 4985
Why Perform 4985
How to Perform 4985
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 4988
When to Perform 4988
Calibration Order 4988
Why Perform 4988
How to Perform 4988
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 4991
When to Perform 4991
Calibration Order 4991
Why Perform 4991
How to Perform 4991
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 4994
When to Perform 4994
Calibration Order 4994
Why Perform 4994
How to Perform 4994
Proc_Cal_014: Load Weight Zero Point 4998
When to Perform 4998
Calibration Order 4998
Why Perform 4998
How to Perform 4998
Proc_Cal_015: Loaded Weight Calibration 5000
When to Perform 5000
Calibration Order 5000
Why Perform 5000
How to Perform 5000
Proc_Cal_016: Transmission Valve Calibration 5003
Applicable System/Option 5003
When to Perform 5003
Calibration Order 5003
Why Perform 5003
How to Perform 5003
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 5005
Applicable System/Option 5005
When to Perform 5005
Calibration Order 5005
Why Perform 5005
How to Perform 5005
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 5007
Applicable System/Option 5007
When to Perform 5007
Calibration Order 5007
Why Perform 5007
How to Perform 5008
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 5009
Required Tools 5009
When to Perform 5009
Calibration Order 5009
Why Perform 5010
How to Perform 5010
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 5011
When to Perform 5011
Why Perform 5011
How to Perform 5011
Proc_Cal_026: Travel Speed Calibration 5013
When to Perform 5013
Calibration Order 5013
Why Perform 5013
How to Perform 5013
524223780-8000YRM1134-(05-2022)-US-EN 5017
Series Code / Model Designation Reference Table 5023
Description 5026
Proc_Cal_001: Service Password Entry 5028
When to Perform 5028
Why Perform 5028
How to Perform 5028
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 5029
When to Perform 5029
Calibration Order 5029
Why Perform 5029
How to Perform 5029
Proc_Cal_003: Save and Exit 5031
When to Perform 5031
Why Perform 5031
How to Perform 5031
Proc_Cal_004: Lift Valve Output Threshold 5032
When to Perform 5032
Calibration Order 5032
Why Perform 5032
How to Perform 5032
Proc_Cal_005: Lower Valve Output Threshold 5035
When to Perform 5035
Calibration Order 5035
Why Perform 5035
How to Perform 5035
Proc_Cal_006: Tilt Back Valve Output Threshold 5038
When to Perform 5038
Calibration Order 5038
Why Perform 5038
How to Perform 5038
Proc_Cal_007: Tilt Forward Valve Output Threshold 5041
When to Perform 5041
Calibration Order 5041
Why Perform 5041
How to Perform 5041
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 5044
When to Perform 5044
Calibration Order 5044
Why Perform 5044
How to Perform 5044
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 5047
When to Perform 5047
Calibration Order 5047
Why Perform 5047
How to Perform 5047
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 5050
When to Perform 5050
Calibration Order 5050
Why Perform 5050
How to Perform 5050
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 5053
When to Perform 5053
Calibration Order 5053
Why Perform 5053
How to Perform 5053
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 5056
When to Perform 5056
Calibration Order 5056
Why Perform 5056
How to Perform 5056
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 5059
When to Perform 5059
Calibration Order 5059
Why Perform 5059
How to Perform 5059
Proc_Cal_014: Load Weight Zero Point 5062
When to Perform 5062
Calibration Order 5062
Why Perform 5062
How to Perform 5062
Proc_Cal_015: Loaded Weight Calibration 5064
When to Perform 5064
Calibration Order 5064
Why Perform 5064
How to Perform 5064
Proc_Cal_016: Transmission Valve Calibration 5067
Applicable System/Option 5067
When to Perform 5067
Calibration Order 5067
Why Perform 5067
How to Perform 5067
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 5069
Applicable System/Option 5069
When to Perform 5069
Calibration Order 5069
Why Perform 5069
How to Perform 5069
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 5072
Applicable System/Option 5072
When to Perform 5072
Calibration Order 5072
Why Perform 5072
How to Perform 5072
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 5075
Required Tools 5075
When to Perform 5075
Calibration Order 5075
Why Perform 5075
How to Perform 5075
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 5077
When to Perform 5077
Why Perform 5077
How to Perform 5077
Proc_Cal_026: Travel Speed Calibration 5079
When to Perform 5079
Calibration Order 5079
Why Perform 5079
How to Perform 5079
524242683-8000YRM1150-(12-2017)-UK-EN 5083
General 5089
Serial Number Data 5089
How to Move Disabled Lift Truck 5089
How to Tow Lift Truck 5089
How to Put Lift Truck on Blocks 5090
How to Raise Drive Tires 5090
How to Raise Steering Tires 5091
How to Clean a Lift Truck 5092
Maintenance Schedule 5092
Maintenance Procedures Every 8 Hours or Daily 5110
How to Make Checks With Engine Stopped 5110
Tires and Wheels 5110
Safety Labels 5111
Mast, Carriage, Lift Chains, Header Hoses, Attachment 5111
Operator Restraint System 5112
Emergency Locking Retractor (ELR) 5112
Adjust Seat – Full Suspension 5113
Hood and Seat Latches 5116
Engine Compartment 5116
Paper Application 5116
Fuel, Oil, and Coolant Leaks, Check 5117
Hydraulic Hoses 5117
Coolant Hoses 5117
Steering Column Gas Cylinder 5117
Transmission 5117
Hydraulic System Oil 5117
Engine Oil 5118
Air Filter 5120
Forks 5120
Remove 5120
Inspect 5120
Install 5120
Adjust 5121
How to Make Checks With Engine Running 5122
Indicator Lights, Horn, Fuses, and Relays 5122
Service Brakes 5124
Brake Fluid Level 5124
Operation, Check 5125
Parking Brake 5125
Engine Oil Pressure 5125
Cooling System 5126
Steering System 5127
Control Levers and Pedals 5127
Lift System, Operate 5127
First Service After First 100 Hours of Operation 5127
Mazda and GM Engine Oil and Oil Filter 5128
Yanmar Engine Oil and Oil Filter 5129
Maintenance Procedures Every 500 Hours or 1 Year 5129
Hydraulic System Oil 5129
Hydraulic Tank Breather 5130
Inspect 5130
Battery 5130
Engine Oil and Oil Filter, Mazda and Yanmar Engines 5131
Engine Oil and Oil Filter, GM 2 4L Engine 5132
Drive Belt 5132
Mazda Engines FE and F2 5132
Fan and Alternator Drive Belt 5132
Yanmar Diesel Engine 5133
Fan and Alternator Drive Belt 5133
GM 2 4L Engine 5134
Fan and Alternator Drive Belt 5134
Timing Belt, Checks and Inspection 5135
PCV Valve 5137
Clean Debris From Radiator Core 5137
Transmission Oil Level 5137
Wet Brake Planetary Housing Oil Level Check 5139
Forks 5140
Mast Lubrication 5140
Header Hose Checks 5144
Lift Chain Lubrication 5144
Tilt Cylinder Lubrication 5145
Master Brake Cylinder Rod End Pin Lubrication 5146
Manual Hydraulic Levers Lubrication 5146
Brake Fluid 5147
Drain Tar From LPG Regulator 5148
Tie Rod Lubrication 5149
Lift Truck Models GLP/GDP20-35VX 5149
Differential and Drive Axle Oil (Dry Brake) 5149
Maintenance Procedures Every 1000 Hours or 1 Year 5149
Valve Clearance, Check and Adjust 5150
Ignition System 5150
GM 2 4L Engine 5150
Mazda Engines FE and F2 5150
LPG Fuel Filter Element Replace, GM 2 4L Engine 5150
Remove 5150
Install 5150
LPG Vapor Fuel Filter Replace, Mazda Engines 5151
Fuel Filter Replacement, Yanmar Engine 5152
Priming the Fuel System (Yanmar) 5154
Lift Chains Wear Check 5154
Lift Chain Lubrication 5155
Integral Sideshift Carriage, Check Bearings 5155
Integral Sideshift Carriage, Check Lower Mounting Hooks 5156
Steering Axle 5156
Control Levers and Pedals 5156
Maintenance Procedures Every 2000 Hours or Annually 5156
Hydraulic System 5157
Hydraulic Filter, Replace 5157
Hydraulic Tank Breather, Replace 5158
Air Filter 5159
PCV Valve 5160
Oxygen Sensor 5161
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 5161
Remove and Replace 5161
LPG Regulator Fuel Filter, GM Engines 5161
Remove 5161
Install 5162
Timing Belt 5163
Mazda Engines 5163
GM 2 4L Engine 5163
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 5163
LPG Fuel Injector, GM Engines 5163
Fuel Injector, Yanmar Engines 5163
Forks 5163
Integral Sideshift Carriage 5163
Bearings, Replace 5163
Transmission Oil and Filter (Dry Brake), Replace 5163
Iron Transmission Housing 5163
Aluminum Transmission Housing 5165
Remove 5165
Clean and Inspect 5168
Install 5168
Transmission Oil Change, Wet Brake Drive Axle 5169
Iron Transmission Housing 5169
Aluminum Transmission Housing 5171
Wet Brake Axle Center Section and Planetary Housing, Oil Change 5174
Brake Fluid (Master Cylinder), Change 5178
Brake Fluid (Dry Brake), Remove 5179
Steer Axle, Wheel Bearing Lubrication 5179
Service Brakes (Dry Brake) 5179
Differential (Dry Brake) 5180
Maintenance Procedures Every 4000 Hours or 2 Years 5180
Hydraulic Oil, Replace 5181
Cooling System 5181
Safety Procedures When Working Near Mast 5182
Hood Latch Check 5185
Lift Chain Adjustments 5186
Jump-Starting the Lift Truck 5188
Jump-Starting Using a Battery Charger 5188
Jump-Starting a Lift Truck Using Another Lift Truck 5188
Welding Repairs 5188
Overhead Guard Changes 5189
Wheel and Tire Replacement 5189
General 5190
Solid Rubber Tire, Change (GC/GLC Series) 5190
Remove and Install Tire on Wheel 5190
Pneumatic Tire With Tube, Repair 5191
Remove Wheels From Lift Truck 5191
Remove Tire From Wheel 5192
Install Wheel in Tire 5194
Install Tire on Two-Piece Wheel 5196
Add Air to Pneumatic Tires With Tube 5197
Install the Wheels 5198
Dual Drive Wheels, Install 5198
Pneumatic Tubeless Tire, Repair 5199
Remove Wheels From Lift Truck 5199
Add Air to Pneumatic Tubeless Tire 5204
Wheels, Install 5204
Solid Rubber Tires on Pneumatic Wheels, Change 5204
Snap-On-Tire, Change 5208
Easy Mounting Style Solid Rubber Tires on Pneumatic Wheels, Change 5211
Adhesives and Sealants 5215
524289373-0900YRM1325-(12-2009)-US-EN 5219
toc 5219
Gasoline Fuel System 5219
Safety Precautions Maintenance and Repair 5220
General 5223
Abbreviations 5223
Intake-Air System 5223
Intake-Air System Manifold Vacuum Check 5223
Throttle Body 5224
Remove 5224
Install 5225
Intake Manifold 5225
Remove 5225
Install 5225
Fuel System 5226
Before Repair Procedure 5226
Fuel Line Safety Procedure 5226
After Repair Procedure 5229
Fuel Hose, Install 5229
Fuel Leakage Check 5229
Fuel Line Pressure Check 5230
Fuel Injectors 5231
Remove 5231
Install 5231
Pressure Regulator 5233
Remove 5233
Install 5233
Exhaust System 5234
Counterweight Exhaust System 5234
Remove and Disassemble 5234
Inspect 5234
Assemble and Install 5234
Overhead Exhaust System 5236
Remove and Disassemble 5236
Inspect 5236
Assemble and Install 5236
Exhaust Manifold 5238
Remove 5238
Install 5238
Positive Crankcase Ventilation (PCV) Valve 5240
Remove 5240
Inspect 5240
Install 5240
Oxygen Sensor 5241
Remove 5241
Install 5241
Control System 5243
Engine Control Unit (ECU) 5243
Remove 5243
Install 5244
Fuel Level Sensor 5245
Remove 5245
Install 5245
Technical Data 5246
tables 5219
Table 1 PCV Valve Specifications 5240
Table 2 Gasoline Fuel Systems Technical Data 5246
524289374-0900YRM1326-(04-2018)-US-EN 5249
General 5255
LPG Tank and Bracket Replacement 5255
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) 5255
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) 5257
Remove LPG Tank for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 5258
LPG Tank Install for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 5260
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) 5261
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) 5263
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) 5264
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) 5266
Remove LPG Bracket for Lift Truck Models and GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 5267
Install LPG Bracket for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 5267
Fuel Filter Unit Repair 5267
Fuel Filter Element 5267
Remove 5267
Clean/Inspect 5268
Install 5268
Fuel Filter Housing 5268
Remove 5268
Disassemble 5271
Assemble 5273
Install 5274
Electronic Throttle Body Repair 5274
Remove 5274
Install 5276
Electronic Pressure Regulator (EPR) Repair 5276
Remove 5277
Disassemble 5281
Assemble 5283
Install 5284
LPG Shutoff Valve Assembly 5284
Remove 5284
Install 5288
Fuel Mixer Repair 5290
Remove 5290
Install 5293
Control System 5293
Engine Control Unit (ECU) 5293
Remove 5293
Install 5295
Low LPG Pressure Switch 5295
Remove 5295
Install 5296
LPG Low Level Sensor 5296
Remove 5297
Install 5300
Exhaust System 5301
Counterweight Exhaust System 5301
Remove and Disassemble 5301
Inspect 5303
Assemble and Install 5303
Overhead Exhaust System 5303
Remove and Disassemble 5304
Inspect 5306
Assemble and Install 5306
Exhaust Manifold 5307
Remove 5307
Install 5308
Positive Crankcase Ventilation (PCV) Valve 5309
Remove 5309
Inspect 5309
Install 5309
Oxygen Sensor 5309
Remove 5309
Install 5311
LPG Fuel Testing 5312
General 5312
Available Fuel Tests 5312
Composition Test (ASTM D-2163) 5312
Ammonia Test (ASTM D-4490) 5312
Basic Nitrogen Test (ASTM UOP269-90) 5312
Residues Test (ASTM D-2158) 5312
Vapor Pressure Test (ASTM D-2598) 5312
Sulfur Compounds Test (ASTM D-5623) 5313
Methanol Test (ASTM D-4864) 5313
Copper Corrosion (ASTM D-1838) 5313
Where To Send LPG Fuel Samples For Testing 5313
524289375-2200YRM1327-(09-2012)-US-EN 5317
General 5321
Ignition System 5321
General 5321
Ignition Timing Adjustment, Gasoline and LPG 5321
Spark Plugs Check 5326
Spark Plug Wires Check 5326
Coil Replacement 5327
Remove 5327
Inspect 5328
Install 5328
Starter Repair 5329
General 5329
Remove 5329
No-Load Test 5330
Magnetic Switch Test 5331
Pull-Out Test 5331
Holding Coil Test 5331
Return Test 5331
Pinion Movement Inspection 5332
Install 5332
Alternator Repair 5332
General 5332
Charging System Inspection 5334
Output Current Check 5334
No-Load Adjusted Voltage Check 5335
Remove 5336
Inspect 5336
Rectifier Check 5336
Install 5337
Engine Sensors and Switches 5338
Oil Pressure Sensor, Gas and LPG Engines 5338
Remove 5338
Install 5338
Air Filter Restriction Switch, Gas and LPG Engines 5338
Remove 5338
Install 5338
Cam Angle Sensor, Gas and LPG Engines 5339
Remove 5339
Install 5340
Voltage Check 5340
Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Engines 5341
Remove 5341
Install 5342
Intake Air Temperature (IAT) Sensor, LPG Engines 5343
Remove 5343
Install 5343
Intake Air Temperature (IAT) Sensor, Gas Engines 5343
Remove 5343
Install 5343
Fuel Temperature Sensor, LPG Engines 5346
Remove 5346
Install 5346
Engine Coolant Temperature (ECT) Sensor 5347
2007 Emissions Compliant Gas Engines 5347
Remove 5347
Install 5347
2007 and 2010 Emissions Compliant LPG Engines 5348
Remove 5348
Install 5348
2010 Emissions Compliant Gas and LPG Engines 5350
Remove 5350
Install 5350
524329117-8000YRM1387-(03-2020)-UK-EN 5355
General Information About Diagrams and Schematics 5359
Symbol Definitions 5359
Diagrams Manual Applications 5360
Diagrams and Schematics 5362
524329117-8000YRM1387-(06-2021)-US-EN 5427
General Information About Diagrams and Schematics 5431
Symbol Definitions 5431
Diagrams Manual Applications 5432
Diagrams and Schematics 5434
550001092-8000YRM1409-(03-2020)-UK-EN 5497
General Information About Diagrams and Schematics 5501
Symbol Definitions 5501
Diagrams Manual Applications 5502
Diagrams and Schematics 5504
550001092-8000YRM1409-(06-2021)-US-EN 5585
General Information About Diagrams and Schematics 5589
Symbol Definitions 5589
Diagrams Manual Applications 5590
Diagrams and Schematics 5592
550010194-1300YRM1421-(08-2013)-UK-EN 5667
toc 5667
Single Speed PowerShift 5667
Safety Precautions Maintenance and Repair 5668
General 5671
Serial Number 5671
Hydraulic Gear Pump 5672
Remove 5672
Install 5672
Charge Pump Repair 5673
Original Charge Pump 5673
Remove 5673
Disassemble 5674
Clean 5674
Inspect 5674
Assemble 5674
Install 5674
New Charge Pump, Manufactured After July, 2013 5675
Remove 5675
Clean 5676
Inspect 5676
Install 5677
Torque Converter Replacement 5679
Remove 5679
Clean and Inspect 5679
Install 5679
Stator Support Assembly Repair 5680
Remove 5680
Disassemble 5685
Clean 5686
Inspect 5686
Assemble 5687
Install 5687
Clutch Packs Repair 5689
Remove 5689
Engine, Torque Converter, and Transmission Assembly 5689
Transmission Components 5690
Disassemble 5692
Transmission 5692
Housings 5692
Forward Clutch Pack 5695
Reverse Clutch Pack 5700
Clean 5706
Inspect 5706
Assemble 5707
Transmission 5707
Reverse Clutch Pack 5707
Forward Clutch Pack 5714
Housings 5720
Install 5722
Transmission Components 5722
Engine, Torque Converter, and Transmission Assembly 5725
Inching Overlap Adjustment 5725
Proportional and Enable Solenoid Valves 5726
Proportional Valves 5726
Remove 5726
Disassemble 5728
Clean and Inspect 5728
Assemble 5728
Install 5728
Enable Solenoid Valve 5728
Remove 5728
Disassemble 5728
Clean and Inspect 5728
Assemble 5729
Install 5729
Foot Directional Control Pedal Repair 5729
Remove and Disassembly 5729
Clean and Inspect 5733
Assemble and Install 5733
550010194-1300YRM1421-(08-2013)-US-EN 5737
toc 5737
Single Speed PowerShift 5737
Safety Precautions Maintenance and Repair 5738
General 5741
Serial Number 5741
Hydraulic Gear Pump 5742
Remove 5742
Install 5742
Charge Pump Repair 5743
Original Charge Pump 5743
Remove 5743
Disassemble 5744
Clean 5744
Inspect 5744
Assemble 5744
Install 5744
New Charge Pump, Manufactured After July, 2013 5745
Remove 5745
Clean 5746
Inspect 5746
Install 5747
Torque Converter Replacement 5749
Remove 5749
Clean and Inspect 5749
Install 5749
Stator Support Assembly Repair 5750
Remove 5750
Disassemble 5755
Clean 5756
Inspect 5756
Assemble 5757
Install 5757
Clutch Packs Repair 5759
Remove 5759
Engine, Torque Converter, and Transmission Assembly 5759
Transmission Components 5760
Disassemble 5762
Transmission 5762
Housings 5762
Forward Clutch Pack 5765
Reverse Clutch Pack 5770
Clean 5776
Inspect 5776
Assemble 5777
Transmission 5777
Reverse Clutch Pack 5777
Forward Clutch Pack 5784
Housings 5790
Install 5792
Transmission Components 5792
Engine, Torque Converter, and Transmission Assembly 5795
Inching Overlap Adjustment 5795
Proportional and Enable Solenoid Valves 5796
Proportional Valves 5796
Remove 5796
Disassemble 5798
Clean and Inspect 5798
Assemble 5798
Install 5798
Enable Solenoid Valve 5798
Remove 5798
Disassemble 5798
Clean and Inspect 5798
Assemble 5799
Install 5799
Foot Directional Control Pedal Repair 5799
Remove and Disassembly 5799
Clean and Inspect 5803
Assemble and Install 5803
550030170-1300YRM1447-(08-2013)-UK-EN 5807
toc 5807
Single Speed Powershift 5807
Safety Precautions Maintenance and Repair 5808
General 5811
Serial Number 5811
Hydraulic Gear Pump 5812
Remove 5812
Install 5812
Housing Fittings Replacement 5812
Remove 5812
Disassemble 5813
Assemble 5813
Install 5813
Charge Pump Repair 5813
Lift Trucks Manufactured Before July, 2013 5813
Remove 5813
Disassemble 5815
Clean 5815
Inspect 5815
Assemble 5815
Install 5815
Lift Trucks Manufactured After July, 2013 5817
Remove 5817
Clean 5817
Inspect 5817
Install 5818
Torque Converter Replacement 5821
Remove 5821
Clean and Inspect 5821
Install 5821
Stator Support Assembly Repair 5823
Remove 5823
Disassemble 5828
Clean 5832
Inspect 5832
Assemble 5833
Install 5833
Clutch Packs Repair 5836
Remove 5836
Disassemble 5837
Housings 5837
Clutch Packs 5842
Forward Clutch Pack 5842
Reverse Clutch Pack 5847
Clean 5853
Inspect 5853
Assemble 5854
Clutch Packs 5854
Reverse Clutch Pack 5854
Forward Clutch Pack 5861
Housings 5868
Install 5868
Drive Chains and Sprockets 5874
Remove 5874
Clean 5876
Inspect 5876
Install 5876
Proportional and Enable Solenoid Valves 5877
Proportional Valves 5877
Remove 5877
Disassemble 5877
Clean and Inspect 5877
Assemble 5880
Install 5880
Enable Solenoid Valve 5880
Remove 5880
Disassemble 5881
Clean and Inspect 5881
Assemble 5881
Install 5881
Foot Directional Control Pedal Repair 5883
Remove and Disassemble 5883
Clean and Inspect 5887
Assemble and Install 5887
550030170-1300YRM1447-(08-2013)-US-EN 5893
toc 5893
Single Speed Powershift 5893
Safety Precautions Maintenance and Repair 5894
General 5897
Serial Number 5897
Hydraulic Gear Pump 5898
Remove 5898
Install 5898
Housing Fittings Replacement 5898
Remove 5898
Disassemble 5899
Assemble 5899
Install 5899
Charge Pump Repair 5899
Lift Trucks Manufactured Before July, 2013 5899
Remove 5899
Disassemble 5901
Clean 5901
Inspect 5901
Assemble 5901
Install 5901
Lift Trucks Manufactured After July, 2013 5903
Remove 5903
Clean 5903
Inspect 5903
Install 5904
Torque Converter Replacement 5907
Remove 5907
Clean and Inspect 5907
Install 5907
Stator Support Assembly Repair 5909
Remove 5909
Disassemble 5914
Clean 5918
Inspect 5918
Assemble 5919
Install 5919
Clutch Packs Repair 5922
Remove 5922
Disassemble 5923
Housings 5923
Clutch Packs 5928
Forward Clutch Pack 5928
Reverse Clutch Pack 5933
Clean 5939
Inspect 5939
Assemble 5940
Clutch Packs 5940
Reverse Clutch Pack 5940
Forward Clutch Pack 5947
Housings 5954
Install 5954
Drive Chains and Sprockets 5960
Remove 5960
Clean 5962
Inspect 5962
Install 5962
Proportional and Enable Solenoid Valves 5963
Proportional Valves 5963
Remove 5963
Disassemble 5963
Clean and Inspect 5963
Assemble 5966
Install 5966
Enable Solenoid Valve 5966
Remove 5966
Disassemble 5967
Clean and Inspect 5967
Assemble 5967
Install 5967
Foot Directional Control Pedal Repair 5969
Remove and Disassemble 5969
Clean and Inspect 5973
Assemble and Install 5973
550043436-1300YRM1529-(11-2018)-US-EN 5979
General 5983
Serial Number 5983
Charge Pump Repair 5983
Lift Trucks Manufactured Before July, 2013 5983
Remove 5983
Inspect 5983
Install 5983
Lift Trucks Manufactured After July, 2013 5984
Remove 5984
Inspect 5984
Install 5984
Torque Converter Replace 5985
Remove 5985
Install 5994
Housings and Chain Drive Repair 6000
Remove 6000
Clean 6011
Inspect 6011
Install 6011
Clutch Packs Repair 6018
Remove and Disassemble 6018
Transmission, Remove and Disassemble 6018
Clean 6037
Inspect 6037
Assemble and Install 6038
Transmission, Assemble and Install 6046
Control Valve Repair 6050
Remove and Disassemble 6050
Clean 6054
Inspect 6054
Assemble and Install 6054
Foot Directional Control Pedal Repair 6055
Remove and Disassemble 6055
Assemble and Install 6059
Direction Control Lever 6060
Remove 6060
Install 6060
550055283-8000YRM1585-(06-2021)-US-EN 6065
General Information About Diagrams and Schematics 6069
Symbol Definitions 6069
Diagrams Manual Applications 6070
Diagrams and Schematics 6072
550055283-8000YRM1585-(07-2020)-UK-EN 6161
General Information About Diagrams and Schematics 6165
Symbol Definitions 6165
Diagrams Manual Applications 6166
Diagrams and Schematics 6168
550073240-1900YRM1620-(01-2023)-US-EN 6257
Proper Flushing after Major Hydraulic Repairs 6263
Introduction 6263
The Phases of Wear 6263
Causes of Hydraulic System Failure 6263
Progression of Contaminant Caused Hydraulic System Failure 6264
Hydraulic System Flushing Techniques 6264
Double Oil and Filter Change 6264
Mechanical Cleaning 6265
Cleaning of Components 6265
How to Clean Tubes and Hoses 6265
Filter Caddy 6265
Start-Up Procedure for Cleaned System 6266
Contaminated Oil Coolers 6266
Additional Filter Caddy Functions 6267
How to Handle Different Fluids 6267
Water Removal Filters 6267
Fluid Conditioning and System Flushing Procedures 6268
Operation of the Filter Caddy 6268
Filter Caddy operation 6268
Fluid Conditioning Procedure 6268
Filter Caddy Start-Up 6269
System Flushing Procedure 6269
Component Cleaning Procedure 6270
Reservoir Cleaning Procedure 6270
Cylinder Cleaning Procedure 6270
Hose and Tube Cleaning Procedure 6270
Valve Cleaning Procedure 6271
Front-End Attachment Cleaning Procedure 6272
System Flushing Procedure 6272
Filter Caddy Start-Up 6273
System Start-Up and Flushing 6273
Reservoir Fluid Cleaning Times 6274
Dealing With Different Fluid Types 6275
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 6275
Filter Caddy Maintenance 6275
Servicing the Strainer 6275
DC Motor 6275
Hydraulic Oil Sampling Method and Procedure 6276
Hydraulic Oil Sampling Method 6276
Objective 6276
General Guidelines 6276
Synopsis 6277
Hydraulic Oil Analysis Report Guidelines 6278
Sampling Conditions 6278
Equipment 6278
Sampling Procedure 6279
Hydraulic Oil Sampling 6279
Sample Labeling 6279
Results Documentation 6279
550073240-1900YRM1620-(03-2020)-UK-EN 6281
Proper Flushing after Major Hydraulic Repairs 6285
Introduction 6285
The Phases of Wear 6285
Causes of Hydraulic System Failure 6285
Progression of Contaminant Caused Hydraulic System Failure 6286
Hydraulic System Flushing Techniques 6286
Double Oil and Filter Change 6286
Mechanical Cleaning 6287
Cleaning of Components 6287
How to Clean Tubes and Hoses 6287
Filter Caddy 6287
Start-Up Procedure for Cleaned System 6288
Contaminated Oil Coolers 6288
Additional Filter Caddy Functions 6288
How to Handle Different Fluids 6288
Water Removal Filters 6289
Fluid Conditioning and System Flushing Procedures 6289
Operation of the Filter Caddy 6289
Filter Caddy operation 6289
Fluid Conditioning Procedure 6290
Filter Caddy Start-Up 6290
System Flushing Procedure 6291
Component Cleaning Procedure 6291
Reservoir Cleaning Procedure 6291
Cylinder Cleaning Procedure 6291
Hose and Tube Cleaning Procedure 6292
Valve Cleaning Procedure 6292
Front-End Attachment Cleaning Procedure 6293
System Flushing Procedure 6293
Filter Caddy Start-Up 6294
System Start-Up and Flushing 6294
Reservoir Fluid Cleaning Times 6295
Dealing With Different Fluid Types 6295
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 6295
Filter Caddy Maintenance 6296
Servicing the Strainer 6296
DC Motor 6296
Hydraulic Oil Sampling Method and Procedure 6296
Hydraulic Oil Sampling Method 6296
Objective 6296
General Guidelines 6296
Synopsis 6297
Hydraulic Oil Analysis Report Guidelines 6298
Sampling Conditions 6299
Equipment 6299
Sampling Procedure 6299
Hydraulic Oil Sampling 6299
Sample Labeling 6300
Results Documentation 6300
550093750-2100YRM1668-(02-2018)-UK-EN 6303
General 6307
Safety Procedures When Working Near Mast 6308
Main Lift Cylinder Repair 6310
Remove 6310
Disassemble 6312
Clean 6314
Inspect 6314
Assemble 6314
Install 6315
Main Lift Cylinder Leak Check 6315
Free-Lift Cylinder 6316
Remove 6316
Disassemble 6317
Clean 6319
Inspect 6319
Assemble 6319
Install 6319
Tilt Cylinder Repair 6320
Remove 6320
Disassemble 6322
Clean 6324
Inspect 6324
Assemble 6324
Install 6325
Tilt Cylinder Adjustment 6326
Tilt Cylinder Leak Check 6327
Integral Sideshift Cylinder Repair Prior to December 2016 6329
Remove 6329
Disassemble 6330
Clean 6331
Inspect 6331
Assemble 6331
Install 6331
Integral Sideshift Cylinder Repair After December 2016 6332
General 6332
Remove 6332
Disassemble 6334
Clean 6334
Inspect 6334
Assemble 6334
Install 6335
Integral Side-Shift Cylinder Gland Leak Checks 6336
Fork Positioner Cylinder Repair Prior to December 2016 6337
Remove 6337
Disassemble 6337
Clean 6339
Inspect 6340
Assemble 6340
Install 6340
Fork Positioner Cylinder Adjustment 6340
Fork Positioner Cylinder Repair After December 2016 6341
General 6341
Remove 6341
Disassemble 6341
Clean 6344
Inspect 6345
Assemble 6345
Install 6345
Fork Positioner Cylinder Adjustment 6345
Seal Kit Installation 6346
External Installation (Seal and Backup Ring) 6346
Internal Installation (Piston Rod Assembly) 6346
Torque Specifications 6347
Main Lift Cylinders 6347
Free-Lift Cylinder 6347
Tilt Cylinders 6347
Integral Sideshift Cylinder 6347
Fork Positioner Cylinder 6347
550093750-2100YRM1668-(04-2023)-US-EN 6351
General 6357
Safety Procedures When Working Near Mast 6360
Main Lift Cylinder Repair 6362
Remove 6362
Disassemble 6364
Clean 6366
Inspect 6366
Assemble 6366
Install 6367
Main Lift Cylinder Leak Check 6367
Free-Lift Cylinder 6368
Remove 6368
Disassemble 6369
Clean 6371
Inspect 6371
Assemble 6371
Install 6371
Tilt Cylinder Repair 6373
Remove 6373
Disassemble 6375
Clean 6376
Inspect 6377
Assemble 6377
Install 6378
Tilt Cylinder Adjustment 6378
Tilt Cylinder Leak Check 6380
Integral Sideshift Cylinder Repair Prior to December 2016 6382
Remove 6382
Disassemble 6382
Clean 6383
Inspect 6383
Assemble 6383
Install 6384
Integral Sideshift Cylinder Repair After December 2016 6385
General 6385
Remove 6385
Disassemble 6386
Clean 6387
Inspect 6387
Assemble 6387
Install 6387
Integral Side-Shift Cylinder Gland Leak Checks 6388
Fork Positioner Cylinder Repair Prior to December 2016 6389
Remove 6389
Disassemble 6389
Clean 6392
Inspect 6392
Assemble 6393
Install 6393
Fork Positioner Cylinder Adjustment 6393
Fork Positioner Cylinder Repair After December 2016 6395
General 6395
Remove 6395
Disassemble 6395
Clean 6398
Inspect 6398
Assemble 6399
Install 6399
Fork Positioner Cylinder Adjustment 6399
Seal Kit Installation 6401
External Installation (Seal and Backup Ring) 6401
Internal Installation (Piston Rod Assembly) 6401
Torque Specifications 6402
Main Lift Cylinders 6402
Free-Lift Cylinder 6402
Tilt Cylinders 6402
Integral Sideshift Cylinder 6402
Fork Positioner Cylinder 6402
550093755-4000YRM1669-(04-2023)-US-EN 6405
General 6413
Safety Procedures When Working Near Mast 6415
Fork Replacement 6417
Standard Carriage and Integral Sideshift Carriage 6417
Remove 6417
Install 6418
Checks 6418
Fork Positioner Carriage 6420
Remove 6421
Install 6421
Checks 6423
Carriages Repair, Two-Stage LFL Mast 6426
Standard Carriage 6426
Remove 6426
Clean and Inspect 6427
Install 6427
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 6427
Remove 6427
Disassemble 6429
Clean and Inspect 6430
Assemble 6431
Install 6431
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 6432
Remove 6432
Disassemble 6435
Clean and Inspect 6435
Assemble 6436
Install 6437
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 6437
Remove 6437
Disassemble 6440
Clean and Inspect 6440
Assemble 6441
Install 6442
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 6442
Remove 6442
Install 6444
Fork Positioner Hydraulic Hose Adjustment 6446
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 6447
Remove 6447
Disassemble and Assemble 6451
Clean and Inspect 6451
Install 6451
Fork Positioner Hydraulic Hose Adjustment 6452
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 6453
Remove 6453
Disassemble and Assemble 6457
Clean and Inspect 6457
Install 6457
Fork Positioner Hydraulic Hose Adjustment 6458
Two-Stage LFL Mast Repair 6460
Mast With Serial Number F507 6460
Remove 6460
Disassemble 6464
Clean and Inspect 6471
Assemble 6473
Install 6474
Header Hoses 6476
Remove 6476
Installation 6476
Adjustment 6480
Mast With Serial Number F562 6481
Remove 6481
Disassemble 6485
Clean and Inspect 6492
Assemble 6494
Install 6495
Header Hose Installation and Adjustment 6496
Remove 6496
Installation 6497
Adjustment 6501
Carriages Repair, Three-Stage FFL Mast 6503
Standard Carriage 6503
Remove 6503
Clean and Inspect 6504
Install 6505
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 6505
Remove 6505
Disassemble 6506
Clean and Inspect 6507
Assemble 6508
Install 6508
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 6509
Remove 6509
Disassemble 6511
Clean and Inspect 6512
Assemble 6513
Install 6513
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 6514
Remove 6514
Disassemble 6516
Clean and Inspect 6517
Assemble 6518
Install 6518
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 6519
Remove 6519
Install 6521
Fork Positioner Hydraulic Hose Adjustment 6523
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 6524
Remove 6524
Disassemble and Assemble 6526
Clean and Inspect 6526
Install 6526
Fork Positioner Hydraulic Hose Adjustment 6527
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 6528
Remove 6528
Disassemble and Assemble 6531
Clean and Inspect 6531
Install 6531
Fork Positioner Hydraulic Hose Adjustment 6532
Three-Stage FFL Mast Repair 6534
Mast With Serial Number F508 6534
Remove 6534
Disassemble 6537
Clean and Inspect 6547
Assemble 6550
Install 6551
Header Hose Installation and Adjustment 6553
Remove 6553
Installation 6553
Adjustment 6562
Mast With Serial Number F563 6562
Remove 6562
Disassemble 6566
Clean and Inspect 6576
Assemble 6579
Install 6580
Header Hose Installation and Adjustment 6582
Remove 6582
Installation 6582
Adjustment 6590
Mast Adjustments 6592
Load Roller, Adjust 6592
Mast Side Kicking, Adjust 6594
Carriage Adjustments 6595
Lift Chains Adjustment 6597
Hydraulic Quick Disconnect Hoses 6599
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) 6599
Lift Trucks Equipped With E-Hydraulic Controls 6599
Lift Trucks Equipped With Manual Hydraulic Controls 6599
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) 6600
Lift Trucks Equipped With E-Hydraulic Controls 6600
Lift Trucks Equipped With Manual Hydraulic Controls 6600
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 6600
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 6600
550093755-4000YRM1669-(06-2019)-UK-EN 6603
General 6609
Safety Procedures When Working Near Mast 6610
Fork Replacement 6612
Standard Carriage and Integral Sideshift Carriage 6612
Remove 6612
Install 6614
Checks 6614
Fork Positioner Carriage 6616
Remove 6617
Install 6617
Checks 6619
Carriages Repair, Two-Stage LFL Mast 6621
Standard Carriage 6621
Remove 6621
Clean and Inspect 6622
Install 6623
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 6623
Remove 6623
Disassemble 6624
Clean and Inspect 6625
Assemble 6626
Install 6626
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 6627
Remove 6627
Disassemble 6630
Clean and Inspect 6630
Assemble 6631
Install 6631
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 6632
Remove 6632
Disassemble 6635
Clean and Inspect 6635
Assemble 6636
Install 6636
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 6637
Remove 6637
Install 6639
Fork Positioner Hydraulic Hose Adjustment 6641
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 6642
Remove 6642
Disassemble and Assemble 6646
Clean and Inspect 6646
Install 6646
Fork Positioner Hydraulic Hose Adjustment 6647
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 6648
Remove 6648
Disassemble and Assemble 6652
Clean and Inspect 6652
Install 6652
Fork Positioner Hydraulic Hose Adjustment 6653
Two-Stage LFL Mast Repair 6654
Mast With Serial Number F507 6654
Remove 6654
Disassemble 6658
Clean and Inspect 6665
Assemble 6667
Install 6668
Header Hoses 6670
Remove 6670
Installation 6670
Adjustment 6674
Mast With Serial Number F562 6675
Remove 6675
Disassemble 6679
Clean and Inspect 6686
Assemble 6688
Install 6689
Header Hose Installation and Adjustment 6690
Remove 6690
Installation 6691
Adjustment 6695
Carriages Repair, Three-Stage FFL Mast 6696
Standard Carriage 6696
Remove 6696
Clean and Inspect 6698
Install 6698
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 6698
Remove 6698
Disassemble 6700
Clean and Inspect 6701
Assemble 6702
Install 6702
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 6703
Remove 6703
Disassemble 6705
Clean and Inspect 6706
Assemble 6707
Install 6707
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 6708
Remove 6708
Disassemble 6710
Clean and Inspect 6711
Assemble 6712
Install 6712
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 6713
Remove 6713
Install 6715
Fork Positioner Hydraulic Hose Adjustment 6717
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 6718
Remove 6718
Disassemble and Assemble 6720
Clean and Inspect 6720
Install 6720
Fork Positioner Hydraulic Hose Adjustment 6721
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 6722
Remove 6722
Disassemble and Assemble 6725
Clean and Inspect 6725
Install 6725
Fork Positioner Hydraulic Hose Adjustment 6726
Three-Stage FFL Mast Repair 6727
Mast With Serial Number F508 6727
Remove 6727
Disassemble 6731
Clean and Inspect 6741
Assemble 6744
Install 6745
Header Hose Installation and Adjustment 6747
Remove 6747
Installation 6747
Adjustment 6755
Mast With Serial Number F563 6756
Remove 6756
Disassemble 6759
Clean and Inspect 6769
Assemble 6772
Install 6773
Header Hose Installation and Adjustment 6775
Remove 6775
Installation 6775
Adjustment 6783
Mast Adjustments 6784
Load Roller, Adjust 6784
Mast Side Kicking, Adjust 6786
Carriage Adjustments 6786
Lift Chains Adjustment 6788
Hydraulic Quick Disconnect Hoses 6790
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) 6790
Lift Trucks Equipped With E-Hydraulic Controls 6790
Lift Trucks Equipped With Manual Hydraulic Controls 6791
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) 6791
Lift Trucks Equipped With E-Hydraulic Controls 6791
Lift Trucks Equipped With Manual Hydraulic Controls 6792
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 6792
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 6792

S.V 06/24