Yale Forklift C809 (GC_GLC 030-040 VX_SVX) Service Manual – PDF DOWNLOAD

Description

Yale Forklift C809 (GC_GLC 030-040 VX_SVX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift C809 (GC_GLC 030-040 VX_SVX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5754
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift C809 (GC_GLC 030-040 VX_SVX) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524221866-9000YRM1112-(10-2020)-US-EN 43
SECTION 9010 Operational Diagnostic Procedures 59
Group 05 – Operational Checkout 61
SECTION 9020 Engine 79
Group 10 – Principles of Operation 89
Group 30 – Observed Symptoms 287
Group 40 – Tests and Adjustments 389
SECTION 9030 Electrical System 421
Group 03 – General Maintenance and Diagnostic Data 445
Group 10 – Principles of Operation 539
Group 20 – Diagnostic Trouble Codes 563
Group 30 – Observed Symptoms 1535
SECTION 9040 Drive Train 1591
Group 10 – Principles of Operation 1595
Group 30 – Observed Symptoms 1651
Group 40 – Tests and Adjustments 1701
SECTION 9050 Hydraulic Systems 1711
Group 10 – Principles of Operation 1715
Group 30 – Observed Symptoms 1773
Group 33 – Observed Symptoms-Gear Pump 1775
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1863
Group 40 – Tests and Adjustments 1907
Group 43 – Tests and Adjustments-Gear Pump 1909
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1933
SECTION 9060 Operators Station 1951
Group 10 – Principles of Operation 1953
SECTION 9070 Front End (Mast) and Chassis 1989
Group 10 – Principles of Operation 1991
Group 30 – Observed Symptoms 2013
SECTION 9080 Supplementary Data 2071
Group 50 – Abbreviations and Acronyms 2073
Group 60 – Special Tools List 2081
Group 70 – Fault Mode Indicator Reference 2091
Group 80 – Supplier Specification Data 2093
524223754-0100YRM1120-(12-2012)-US-EN 2097
toc 2097
Frame 2097
Safety Precautions Maintenance and Repair 2098
General 2101
Description 2101
Hood, Seat, and Side Covers Replacement 2102
Remove 2102
Install 2108
Steering Column 2113
Description 2113
Steering Column Repair 2113
Remove 2113
Disassemble 2115
Clean 2115
Inspect 2115
Assemble 2115
Install 2118
LPG Tank and Bracket Assembly 2118
Counterweight Replacement 2119
Remove 2119
Install 2122
Tow Pin, Remove and Install 2123
Overhead Guard Replacement 2123
Remove and Install 2123
LED Tail, Backup, and Brake Lights, Replace 2124
Operator Restraint System Replacement 2125
Description 2125
Automatic Locking Retractor (ALR) 2125
Emergency Locking Retractor (ELR) 2125
Engine Replacement 2127
Remove 2127
Install 2132
Transmission Replacement 2134
Remove Transmission with Iron Housing 2134
Install Transmission with Iron Housing 2136
Remove Transmission with Aluminum Housing 2136
Install Transmission with Aluminum Housing 2141
Throttle Pedal and Cable Adjustment 2144
Mazda Gas/LPG Engines With Basic Power Shift Transmission and El 2144
Mazda Gasoline Engine With Electronic Transmission 2146
Throttle Pedal Stop Adjustment 2147
Yanmar Diesel Engine With Basic Power Shift Transmission 2148
Yanmar Diesel Engine With Electronic Throttle 2148
Exhaust System Repair 2149
Lift Trucks With Counterweight Exhaust System 2149
Mazda Gas and LPG Engines 2149
Remove and Disassemble 2149
Inspect 2149
Assemble and Install 2149
Yanmar Diesel Engine 2151
Remove and Disassemble 2151
Inspect 2151
Assemble and Install 2151
Lift Trucks With Overhead Exhaust System 2153
Yanmar Diesel Engine 2153
Remove and Disassemble 2153
Inspect 2153
Assemble and Install 2154
Mazda Gas and LPG Engines 2156
Remove and Disassemble 2156
Inspect 2156
Assemble and Install 2156
Cooling System 2158
Description 2158
Hydraulic Filter Assembly Repair 2158
Remove 2158
Clean and Inspect 2159
Install 2159
Fuel and Hydraulic Tanks Repair 2160
Inspect 2160
Clean 2160
Steam Method of Cleaning 2160
Chemical Solution Method of Cleaning 2161
Additional Preparations for Repair 2161
Small Leaks, Repair 2161
Large Leaks, Repair 2161
Preparations for Use After Repair 2162
Safety Labels 2162
tables 2097
Table 1 Gas Spring Installation, Lift Truck Models GLP/GDP16VX, 2109
Table 2 Gas Spring Installation, Lift Truck Models GLP/GDP20-35 2111
Table 3 Weight of Counterweights, Lift Truck Models GLC20-35VX 2121
Table 4 Weight of Counterweights, Lift Truck Models GC/GLC030VX 2121
Table 5 Weight of Counterweights, Lift Truck Models GLP/GDP16-1 2121
Table 6 Weight of Counterweights, Lift Truck Models GLP/GDP20-3 2121
524223756-0600YRM1122-(03-2020)-US-EN 2169
General 2173
Serial Number 2174
Engine Removal and Installation 2174
Cylinder Head, Camshaft, and Valve Mechanism Repair 2174
Remove 2174
Clean 2177
Inspect and Repair 2177
Cylinder Head 2177
Rocker Shaft Assembly 2177
Camshaft 2178
Valve Guides 2179
Valve Seats 2179
Valves 2180
Valve Springs 2180
Install 2181
Crankshaft and Main Bearings Repair 2185
Remove 2185
Inspect and Repair 2186
Crankshaft 2186
Main Bearings 2186
Install 2187
Pistons and Connecting Rods Repair 2188
Remove and Disassemble 2188
Clean 2188
Inspect and Repair 2188
Pistons 2188
Piston Rings 2188
Connecting Rods and Bearings 2189
Assemble and Install 2189
Cylinder Block Repair 2191
Oil Pump Repair 2192
Remove 2192
Disassemble 2193
Clean 2193
Inspect 2193
Assemble 2194
Install 2194
Cooling System Repair 2196
Thermostat 2196
Replace 2196
Fan Assembly 2196
Remove and Disassemble 2196
Assemble and Install 2197
Water Pump 2197
Remove 2197
Install 2198
Flywheel and Ring Gear Repair 2199
Remove 2199
Install 2199
Valve Adjustment 2199
Compression Pressure Check 2201
Engine Timing Adjustment 2202
Engine Specifications 2202
Engine Data 2202
Engine Speeds 2202
2007, and Later, Emission Compliant Engines 2202
All Engines Except 2007, and Later, Emission Compliant Engines 2203
Thermostat 2203
Cylinder Head 2203
Valve Mechanism 2203
Camshaft 2204
Crankshaft 2204
Connecting Rods 2204
Cylinder Block 2205
Pistons 2205
Oil Pump 2205
Torque Specifications 2206
524223757-0700YRM1123-(06-2016)-US-EN 2209
General 2213
Cooling System Checks 2213
Exhaust Leaks Into Cooling System 2213
Water Flow Restrictions in Radiator 2213
Radiator Hoses 2213
Water Pump 2214
Flushing the Cooling System 2214
Cooling System, Clean 2214
Radiator Replacement 2215
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) 2216
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 2231
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2234
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) 2237
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) 2244
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 2249
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2251
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) 2254
Fan Assembly Replacement 2266
Fan Removal 2266
Inspect 2281
Fan Installation 2281
524223757-0700YRM1123-(06-2021)-US-EN 2287
General 2291
Cooling System Checks 2291
Exhaust Leaks Into Cooling System 2291
Water Flow Restrictions in Radiator 2291
Radiator Hoses 2291
Water Pump 2291
Flushing the Cooling System 2293
Cooling System, Clean 2293
Radiator Replacement 2295
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) 2295
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) 2310
Radiator, Remove for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2313
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) 2316
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) 2322
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) 2326
Radiator, Install for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2327
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) 2330
Fan Assembly Replacement 2341
Fan Removal 2341
Inspect 2355
Fan Installation 2356
524223759-0900YRM1125-(05-2005)-US-EN 2361
toc 2361
LPG Fuel System 2361
Safety Precautions Maintenance and Repair 2362
General 2365
Hoses Replacement 2365
LPG Tank Replacement 2365
Remove 2365
Install 2367
Fuel Filter 2368
Remove 2368
Clean and Inspect 2368
Install 2369
Relief Valve Replacement 2370
Remove and Install 2370
Carburetor Repair 2370
Remove 2370
Disassemble 2370
Clean 2372
Assemble 2372
Install 2372
Fuel Injector Repair 2373
Remove 2373
Clean and Inspect 2373
Install 2373
Governor Repair 2373
Remove 2373
Install 2373
Regulator Repair 2374
Remove 2374
Install 2374
Control System 2375
Engine Control Unit (ECU) 2375
Remove 2375
Install 2376
Engine Coolant Temperature (ECT) Sensor 2376
Remove 2376
Install 2376
Camshaft Position (CMP) Sensor 2376
Voltage Check 2376
Intake Air Temperature (IAT) Sensor 2377
Remove 2377
Install 2377
Manifold Absolute Pressure (MAP) Sensor 2378
Remove 2378
Install 2378
Oxygen Sensor 2378
Remove 2378
Install 2378
Throttle Position (TP) Sensor 2379
Remove 2379
Install 2379
524223761-0900YRM1127-(05-2005)-US-EN 2383
toc 2383
Gasoline Fuel System 2383
Safety Precautions Maintenance and Repair 2384
General 2387
Abbreviations 2387
Engine Tune-up 2387
Engine Tune-Up Preparation 2387
Idle Speed Adjustment 2387
Idle-Up Speed Check 2387
Intake-Air System 2389
Intake-Air System Manifold Vacuum Check 2389
Throttle Body 2390
Remove 2390
Install 2390
Electronic Governor 2390
Remove 2390
Install 2390
Intake-Air Control (IAC) Valve 2390
Remove 2390
Install 2390
Intake Manifold 2392
Remove 2392
Install 2392
Fuel System 2393
Before Repair Procedure 2393
Fuel Line Safety Procedure 2393
After Repair Procedure 2393
Fuel Hose, Install 2393
Fuel Leakage Check 2394
Fuel Line Pressure Check 2394
Fuel Injector 2395
Remove 2395
Install 2396
Pressure Regulator 2396
Remove 2396
Install 2397
Exhaust System 2397
Exhaust System, Inspect 2397
Three-Way Catalytic (TWC) Converter 2397
Remove and Install 2397
Exhaust Manifold 2397
Remove 2397
Install 2397
Positive Crankcase Ventilation (PCV) Valve 2399
Remove 2399
Inspect 2399
Install 2399
Control System 2399
Engine Control Unit (ECU) 2399
Remove 2399
Install 2401
Intake Air Temperature (IAT) Sensor 2402
Remove 2402
Install 2402
Mass Air Flow (MAF) Sensor 2402
Remove 2402
Install 2402
Throttle Position (TP) Sensor 2403
TP Sensor, Adjust 2403
Remove 2404
Install 2404
Engine Coolant Temperature (ECT) Sensor 2404
Remove 2404
Install 2404
Camshaft Position (CMP) Sensor 2405
Voltage Check 2405
Oxygen Sensor 2406
Remove 2406
Install 2406
Manifold Absolute Pressure (MAP)/Boost Sensor 2406
Remove 2406
Install 2406
Technical Data 2407
tables 2383
Table 1 PCV Valve Specifications 2399
Table 2 Closed Throttle Position Specifications 2404
Table 3 Gasoline Fuel Systems Technical Data 2407
524223762-1300YRM1129-(11-2018)-US-EN 2411
General 2415
Serial Number 2415
Charge Pump Repair 2415
Remove 2415
Inspect 2416
Install 2416
Torque Converter Replace 2416
Remove 2416
Install 2424
Front Cover Housing and Chain Drive Repair 2430
Remove 2430
Clean 2439
Inspect 2439
Install 2439
Clutch Packs Repair 2448
Remove and Disassemble 2448
Transmission, Remove and Disassemble 2448
Clean 2467
Inspect 2467
Assemble and Install 2468
Transmission, Assemble and Install 2476
Control Valve Repair 2482
Remove and Disassemble 2482
Clean 2486
Inspect 2486
Assemble and Install 2486
Foot Directional Control Pedal Repair 2487
Remove and Disassemble 2487
Assemble and Install 2491
Direction Control Lever 2492
Remove 2492
Install 2492
524223764-1600YRM1133-(07-2013)-US-EN 2497
toc 2497
Steering Axle 2497
Safety Precautions Maintenance and Repair 2498
General 2501
Steering Axle Assembly Repair 2503
Remove 2503
Disassemble 2504
Clean 2512
Inspect 2512
Assemble 2512
Install 2518
Spindles, Bearings, and Tie Rods Repair 2520
Spindles and Bearings 2520
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2520
Remove 2520
Disassemble 2522
Clean 2523
Inspect 2523
Assemble 2523
Install 2524
Spindles and Bearings 2527
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2527
Remove and Disassemble 2527
Assemble and Install 2528
Tie Rods 2528
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2528
Remove 2528
Install 2529
Tie Rods 2530
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2530
Remove 2530
Install 2536
Steering Cylinder Repair 2536
Remove and Disassemble 2536
Clean and Inspect 2537
Assemble and Install 2537
Torque Specifications 2538
524223765-1800YRM1135-(09-2018)-US-EN 2543
General 2547
Dry Brake System 2547
Wet Brake System 2547
Service Brakes Repair (Dry Brake) 2547
Remove and Disassemble 2548
Clean 2556
Inspect 2556
Assemble and Install 2557
Adjust 2564
Inching Overlap Adjustment 2564
Parking Brake Repair 2565
Remove and Disassemble 2565
Assemble and Install 2568
Adjust 2568
Master Cylinder Repair 2569
Remove (Dry Brake) 2569
Disassemble (Dry Brake) 2570
Clean and Inspect (Dry Brake) 2572
Assemble (Dry Brake) 2572
Bench Bleed Master Cylinder (Dry Brake) 2572
Install and Adjust (Dry Brake) 2572
Remove (Wet Brake) 2573
Disassemble (Wet Brake) 2575
Clean and Inspect (Wet Brake) 2576
Assemble (Wet Brake) 2577
Install and Adjust (Wet Brake) 2577
Service Brakes Adjustment (Dry Brake) 2578
Brake System Air Removal 2578
Using Pressure Bleed System 2578
Using Brake Pedal Pressure 2579
Brake Pedal Adjustment 2579
Free Pedal Adjustment 2580
Torque Specifications 2582
524223766-1900YRM1136-(01-2022)-US-EN 2585
General 2589
Hydraulic Gear Pump Assembly 2590
Variable Displacement Pump Assembly 2591
Single Gear Pump Assembly Repair 2592
Remove 2592
Disassemble 2598
Clean 2600
Inspect 2600
Assemble 2600
Install 2600
Tandem Gear Pump Assembly 2605
Remove 2605
Disassemble 2606
Clean 2609
Inspect 2609
Assemble 2609
Install 2610
Gear Pump Specifications 2611
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2617
Remove 2617
Disassemble 2627
Clean 2630
Inspect 2631
Assemble 2631
Install 2631
63 0 cc/rev – Variable Displacement Pump Repair 2636
Remove 2636
Disassemble 2639
Clean 2641
Inspect 2641
Assemble 2641
Install 2641
Variable Displacement Pump Checks and Adjustments (Single Pump) 2645
Margin Pressure Check 2645
Flow Compensator Adjustment 2646
Pressure Compensator Adjustment 2646
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2648
Variable Displacement Pump Specifications 2651
Torque Specifications 2653
Hydraulic Gear Pump 2653
Variable Displacement Pump 2654
Special Tools 2655
524223766-1900YRM1136-(11-2017)-US-EN 2657
General 2661
Hydraulic Gear Pump Assembly 2662
Variable Displacement Pump Assembly 2663
Single Gear Pump Assembly Repair 2663
Remove 2663
Disassemble 2670
Clean 2670
Inspect 2672
Assemble 2672
Install 2672
Tandem Gear Pump Assembly 2676
Remove 2677
Disassemble 2679
Clean 2681
Inspect 2681
Assemble 2681
Install 2682
Gear Pump Specifications 2682
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2688
Remove 2688
Disassemble 2698
Clean 2701
Inspect 2701
Assemble 2701
Install 2702
63 0 cc/rev – Variable Displacement Pump Repair 2705
Remove 2705
Disassemble 2708
Clean 2708
Inspect 2708
Assemble 2710
Install 2710
Variable Displacement Pump Checks and Adjustments (Single Pump) 2712
Margin Pressure Check 2712
Flow Compensator Adjustment 2713
Pressure Compensator Adjustment 2713
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2714
Variable Displacement Pump Specifications 2717
Torque Specifications 2718
Hydraulic Gear Pump 2719
Variable Displacement Pump 2720
Special Tools 2720
524223767-2000YRM1137-(01-2017)-US-EN 2725
General 2731
Electro-Hydraulic Main Control Valve 2732
Description 2732
Remove 2740
Electro-Hydraulic Control Valve Sections 2745
General 2745
Outlet Control Valve Section 2745
Remove 2745
Disassemble 2746
Clean 2748
Inspect 2748
Assemble 2748
Install 2749
Auxiliary Control Valve Sections 2749
Remove 2749
Disassemble 2756
Clean 2757
Inspect 2758
Assemble 2758
Install 2760
Tilt Control Valve Section 2761
Remove 2761
Disassemble 2761
Clean 2767
Inspect 2767
Assemble 2767
Install 2768
Lift/Lower Control Valve Section 2769
Remove 2769
Disassemble 2769
Clean 2778
Inspect 2778
Assemble 2778
Install 2779
Mid-Inlet Section 2779
Remove 2779
Clean 2780
Inspect 2780
Install 2780
Install 2780
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2785
Lift Pilot Pin 2785
Lower Pilot Pin 2789
Abnormal/Erroneous EHPV Adjustment 2791
Manual Main Control Valve 2792
Description 2792
Remove 2796
OPS Solenoid Assembly 2804
General 2804
Remove 2805
Clean and Inspect 2808
Install 2808
Manual Control Valve Sections 2809
General 2809
Outlet Control Valve Section 2809
Remove 2809
Disassemble 2809
Clean 2812
Inspect 2812
Assemble 2812
Install 2813
Auxiliary Control Valve Sections 2813
Remove 2813
Disassemble 2813
Clean 2816
Inspect 2816
Assemble 2816
Install 2817
Lift/Tilt Control Valve Section 2817
Remove 2817
Disassemble 2817
Clean 2824
Inspect 2824
Assemble 2825
Install 2826
Mid-Inlet Section 2827
Remove 2827
Clean 2827
Inspect 2827
Install 2827
Install 2828
Pressure Relief Valve Check and Adjustment 2834
Primary Relief Valve 2835
Secondary Relief Valve 2839
Steering Control Unit Repair 2846
Steering Control Unit, Remove 2846
Steering Control Unit, Disassemble 2850
Steering Control Unit, Clean 2852
Steering Control Unit, Inspect 2852
Steering Control Unit, Assemble 2852
Relief Valve, Disassemble 2853
Relief Valve, Clean 2853
Relief Valve, Inspect 2854
Relief Valve, Assemble 2854
Steering Control Unit, Install 2854
524223767-2000YRM1137-(06-2021)-US-EN 2859
General 2863
Electro-Hydraulic Main Control Valve 2864
Description 2864
Remove 2872
Electro-Hydraulic Control Valve Sections 2877
General 2877
Outlet Control Valve Section 2877
Remove 2877
Disassemble 2877
Clean 2880
Inspect 2880
Assemble 2881
Install 2881
Auxiliary Control Valve Sections 2881
Remove 2882
Disassemble 2887
Clean 2889
Inspect 2889
Assemble 2889
Install 2891
Tilt Control Valve Section 2892
Remove 2892
Disassemble 2893
Clean 2897
Inspect 2897
Assemble 2898
Install 2899
Lift/Lower Control Valve Section 2899
Remove 2899
Disassemble 2899
Clean 2905
Inspect 2905
Assemble 2905
Install 2906
Mid-Inlet Section 2906
Remove 2906
Clean 2907
Inspect 2907
Install 2907
Install 2907
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2912
Lift Pilot Pin 2912
Lower Pilot Pin 2915
Abnormal/Erroneous EHPV Adjustment 2917
Manual Main Control Valve 2918
Description 2918
Remove 2922
OPS Solenoid Assembly 2930
General 2930
Remove 2931
Clean and Inspect 2933
Install 2933
Manual Control Valve Sections 2934
General 2934
Outlet Control Valve Section 2934
Remove 2934
Disassemble 2934
Clean 2937
Inspect 2937
Assemble 2937
Install 2937
Auxiliary Control Valve Sections 2938
Remove 2938
Disassemble 2938
Clean 2941
Inspect 2941
Assemble 2941
Install 2941
Lift/Tilt Control Valve Section 2942
Remove 2942
Disassemble 2942
Clean 2948
Inspect 2948
Assemble 2948
Install 2950
Mid-Inlet Section 2950
Remove 2950
Clean 2951
Inspect 2951
Install 2951
Install 2951
Pressure Relief Valve Check and Adjustment 2959
Primary Relief Valve 2959
Secondary Relief Valve 2962
Steering Control Unit Repair 2967
Steering Control Unit, Remove 2967
Steering Control Unit, Disassemble 2971
Steering Control Unit, Clean 2973
Steering Control Unit, Inspect 2973
Steering Control Unit, Assemble 2973
Relief Valve, Disassemble 2974
Relief Valve, Clean 2974
Relief Valve, Inspect 2975
Relief Valve, Assemble 2975
Steering Control Unit, Install 2975
524223768-2100YRM1139-(02-2014)-US-EN 2979
524223769-2200YRM1128-(01-2023)-US-EN 3027
Series Code / Model Designation Reference Table 3035
General 3037
Deutsch Crimping Tool 3038
How to Strip a Wire for Use With Deutsch Crimping Tool 3038
How to Crimp With the Deutsch Crimping Tool 3039
Calibration Test for the Deutsch Crimping Tool 3041
Deutsch Connectors 3043
DT, DTM, and DTP Series Connectors 3043
HD Series Connectors 3086
Metri-Pack Connectors 3108
Remove and Install 3108
Micro-Pack Connectors 3111
Weather-Pack Connectors 3112
AMPSEAL Crimping Tools 3114
AMP Hand Crimping Tool With Certi-Crimp 3114
Description 3114
Stripping Wire for Use with AMP Hand Crimping Tool 3115
Insulation Crimp Adjustment 3116
Maintenance and Inspection for AMP Hand Crimping Tool 3116
AMP Hand Crimping Tool 3116
Crimp Height Inspection 3116
How to use AMP Hand Crimping Tool 3117
AMP Pro-Crimper II Tool 3117
Description 3117
Remove and Install Die Set and Locator Assembly 3118
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3118
Contact Support Adjustment 3119
Crimp Height Adjustment 3120
Maintenance and Inspection Procedures 3120
PRO-CRIMPER II Tool 3120
Crimp Height Inspection 3120
How to Use AMP PRO-CRIMPER II Tool 3121
AMPSEAL Connector Assemblies 3122
Description for Plug Connector Assembly 3122
Seal Plug 3123
Contact Crimping 3123
Description for Plug Connector and Header Assembly 3128
Voltage Reading 3131
Seal Plug 3131
Contact Crimping 3131
AMP Superseal 1 5 Crimping Tools 3138
Mini Mic Receptacle and Tab Contacts 3138
Description 3138
Crimping Conditions and Measurements 3138
Insertion of Rubber Seal on Cable 3140
AMP Hand Application Tool 3145
Description 3145
Maintenance and Inspection 3145
Crimp Height Inspection 3145
Crimp Height Adjustment 3146
How to Use AMP Hand Application Tool 3146
AMP Pro-Crimper II Tool 3147
Description 3147
Remove and Install Die Set and Locator Assembly 3147
Adjustments 3148
Contact Support 3148
Crimp Height 3149
Inspections and Maintenance 3150
Crimp Height Inspection 3150
Visual Inspection 3150
Maintenance 3151
How to Use Pro-Crimper II Tool 3151
AMP Superseal 1 5 Connector Assemblies 3152
Description 3152
Repair and Maintenance 3159
Panel Mount Option 3159
AMP Fastin-Faston Hand Tools 3160
Description – AMP Double Action Hand Tool 3160
Maintenance and Inspection Procedures 3160
Daily Maintenance 3160
Periodic Tool Inspection 3161
Lubrication 3161
Visual Inspection 3161
Crimp Height Inspection 3161
Certi-Crimp Ratchet Inspection 3162
How to Use AMP Double Action Hand Tool 3163
Description – AMP Extraction Tool 3164
Maintenance and Inspection 3165
How to Use AMP Extraction Tool 3165
AMP Fastin-Faston Receptacles and Housings 3167
Description 3167
Wire Repair 3175
Wire Splicing Requirements 3175
Deutsch Jiffy Splice 3176
Twisted/Shielded Cable and Leads Repair 3182
Special Tools 3184
524223769-2200YRM1128-(07-2020)-US-EN 3193
Series Code / Model Designation Reference Table 3199
General 3202
Deutsch Crimping Tool 3202
How to Strip a Wire for Use With Deutsch Crimping Tool 3202
How to Crimp With the Deutsch Crimping Tool 3203
Calibration Test for the Deutsch Crimping Tool 3205
Deutsch Connectors 3207
DT, DTM, and DTP Series Connectors 3207
HD Series Connectors 3249
Metri-Pack Connectors 3272
Remove and Install 3272
Micro-Pack Connectors 3274
Weather-Pack Connectors 3275
AMPSEAL Crimping Tools 3277
AMP Hand Crimping Tool With Certi-Crimp 3277
Description 3277
Stripping Wire for Use with AMP Hand Crimping Tool 3277
Insulation Crimp Adjustment 3278
Maintenance and Inspection for AMP Hand Crimping Tool 3278
AMP Hand Crimping Tool 3278
Crimp Height Inspection 3278
How to use AMP Hand Crimping Tool 3279
AMP Pro-Crimper II Tool 3279
Description 3279
Remove and Install Die Set and Locator Assembly 3280
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3281
Contact Support Adjustment 3281
Crimp Height Adjustment 3282
Maintenance and Inspection Procedures 3282
PRO-CRIMPER II Tool 3282
Crimp Height Inspection 3282
How to Use AMP PRO-CRIMPER II Tool 3283
AMPSEAL Connector Assemblies 3284
Description for Plug Connector Assembly 3284
Seal Plug 3285
Contact Crimping 3285
Description for Plug Connector and Header Assembly 3290
Voltage Reading 3292
Seal Plug 3292
Contact Crimping 3292
AMP Superseal 1 5 Crimping Tools 3299
Mini Mic Receptacle and Tab Contacts 3299
Description 3299
Crimping Conditions and Measurements 3299
Insertion of Rubber Seal on Cable 3301
AMP Hand Application Tool 3306
Description 3306
Maintenance and Inspection 3306
Crimp Height Inspection 3306
Crimp Height Adjustment 3307
How to Use AMP Hand Application Tool 3307
AMP Pro-Crimper II Tool 3308
Description 3308
Remove and Install Die Set and Locator Assembly 3309
Adjustments 3309
Contact Support 3309
Crimp Height 3310
Inspections and Maintenance 3311
Crimp Height Inspection 3311
Visual Inspection 3311
Maintenance 3312
How to Use Pro-Crimper II Tool 3312
AMP Superseal 1 5 Connector Assemblies 3313
Description 3313
Repair and Maintenance 3320
Panel Mount Option 3320
AMP Fastin-Faston Hand Tools 3321
Description – AMP Double Action Hand Tool 3321
Maintenance and Inspection Procedures 3321
Daily Maintenance 3321
Periodic Tool Inspection 3322
Lubrication 3322
Visual Inspection 3322
Crimp Height Inspection 3322
Certi-Crimp Ratchet Inspection 3323
How to Use AMP Double Action Hand Tool 3324
Description – AMP Extraction Tool 3325
Maintenance and Inspection 3325
How to Use AMP Extraction Tool 3326
AMP Fastin-Faston Receptacles and Housings 3327
Description 3327
Wire Repair 3334
Wire Splicing Requirements 3334
Deutsch Jiffy Splice 3335
Twisted/Shielded Cable and Leads Repair 3340
Special Tools 3343
524223770-2200YRM1130-(03-2020)-US-EN 3351
General 3355
Description 3355
Dash Display Menu Access 3355
Menu Navigation 3356
Standard Display 3356
Main Menu 3356
Passwords Menu 3357
Password Administration 3357
Add Password 3357
Delete Password 3358
Edit Password 3358
Other Password Functions 3359
Operator Passwords – Enable/Disable 3359
Password Time-Out Delay 3359
Passwords – Number Wrong to Disable 3360
Lockout Reset Password 3360
View Password Log 3361
View Versions 3362
VSM Versions 3362
Dash Display Versions 3363
Engine Controller Version 3364
Transmission (Xmsn) Controller Version 3365
Truck Serial Number 3366
Diagnostics 3367
View Fault Log 3367
Set Travel and Braking 3368
Speed Limit 3368
Acceleration Rate 3369
Auto-Deceleration Rate 3369
Set Power Reversal Rate 3370
Set Inching/Brake Overlap 3371
Setup Display Menu 3372
Set Operator Language 3372
Set Units 3373
Set Time Format (12/24 Hour) 3373
Set Daylight Saving Time 3373
Set Time 3376
Set Date Format 3377
Set Date 3377
Setup Hydraulics 3378
Return to Set Tilt Delay/On/Off 3378
Setup General Items 3379
Light Shutdown Time-Out 3379
Impact Sensor – Enable/Disable 3380
Impact Sensor – Soft Impact Settings 3381
Impact Sensor – Hard Impact Settings 3382
Adjust Impact Sensor Settings 3382
Initial Adjustment of Soft and Hard Impact Settings 3384
Readjustment of Soft and Hard Impact Settings 3384
Impact Sensor – Impact Alarm/Shutdown Reset 3385
Impact Sensor – Alarm Time Duration and Deactivation 3386
Impact Sensor – View Impact Event Log 3387
Engine Mode Indicator 3388
Generation 1 (ECO-eLo ONLY) 3388
Generation 2 3389
Operator Checklist 3390
Operator Checklist Off-On Mode 3390
Edit Operator Checklist 3390
Set Operator Checklist Expiration 3391
View Checklist Log 3391
Clear Operator Checklist Log 3392
Clear Operator Checklist Fault 3392
Calibrations 3393
Set Tilt Stop Point 3393
Calibrate Loaded Weight 3393
524223770-2200YRM1130-(05-2021)-US-EN 3395
General 3399
Description 3399
Dash Display Menu Access 3399
Menu Navigation 3400
Standard Display 3400
Main Menu 3400
Passwords Menu 3401
Password Administration 3401
Add Password 3401
Delete Password 3401
Edit Password 3402
Other Password Functions 3403
Operator Passwords – Enable/Disable 3403
Password Time-Out Delay 3403
Passwords – Number Wrong to Disable 3403
Lockout Reset Password 3404
View Password Log 3404
View Versions 3405
VSM Versions 3405
Dash Display Versions 3406
Engine Controller Version 3407
Transmission (Xmsn) Controller Version 3408
Truck Serial Number 3409
Diagnostics 3410
View Fault Log 3410
Set Travel and Braking 3411
Speed Limit 3411
Acceleration Rate 3412
Auto-Deceleration Rate 3412
Set Power Reversal Rate 3413
Set Inching/Brake Overlap 3414
Setup Display Menu 3415
Set Operator Language 3415
Set Units 3416
Set Time Format (12/24 Hour) 3416
Set Daylight Saving Time 3417
Set Time 3420
Set Date Format 3420
Set Date 3421
Setup Hydraulics 3422
Return to Set Tilt Delay/On/Off 3422
Setup General Items 3423
Light Shutdown Time-Out 3423
Impact Sensor – Enable/Disable 3424
Impact Sensor – Soft Impact Settings 3425
Impact Sensor – Hard Impact Settings 3425
Adjust Impact Sensor Settings 3426
Initial Adjustment of Soft and Hard Impact Settings 3428
Readjustment of Soft and Hard Impact Settings 3428
Impact Sensor – Impact Alarm/Shutdown Reset 3429
Impact Sensor – Alarm Time Duration and Deactivation 3430
Impact Sensor – View Impact Event Log 3431
Engine Mode Indicator 3431
Generation 1 (ECO-eLo ONLY) 3431
Generation 2 3432
Operator Checklist 3433
Operator Checklist Off-On Mode 3433
Edit Operator Checklist 3433
Set Operator Checklist Expiration 3433
View Checklist Log 3434
Clear Operator Checklist Log 3435
Clear Operator Checklist Fault 3435
Calibrations 3436
Set Tilt Stop Point 3436
Calibrate Loaded Weight 3436
524223771-2200YRM1131-(03-2020)-US-EN 3439
Series Code / Model Designation Reference Table 3445
General 3447
Description 3447
Dash Display Menu Access 3447
Menu Navigation 3448
Main Menu 3448
Passwords 3449
Adding Passwords 3449
Hourmeters 3451
View Versions 3452
VSM Versions 3452
Dash Display Versions 3453
Engine Controller Version 3454
Transmission (Xmsn) Controller Version 3455
Truck Serial Number 3456
Truck Configuration 3457
Diagnostics 3458
Clear Fault Log 3458
View Fault Log 3459
No-Run Data Display 3460
Engine Accelerator and Throttle Data Display 3460
Engine Speeds and Governor Data Display 3461
Engine Fuel and Emissions Data Display 3462
Engine General Data Display 3464
XMSN/Brake Data Display 3465
Hydraulic Data Display 3468
General Truck Data Display 3470
Set Travel and Braking 3471
Speed Limit 3471
Acceleration Rate 3472
Auto-Deceleration Rate 3473
Set Power Reversal Rate 3473
Set Inching/Brake Overlap 3474
Setup Hydraulics 3474
Lift Maximum Speed 3475
Lower Maximum Speed 3475
Tilt Maximum Speed 3476
Auxiliary Function One, Direction A, Maximum Speed 3478
Auxiliary Function One, Direction B, Maximum Speed 3480
Auxiliary Function Two, Direction A, Maximum Speed 3480
Auxiliary Function Two, Direction B, Maximum Speed 3481
Auxiliary Function Three, Direction A, Maximum Speed 3482
Auxiliary Function Three, Direction B, Maximum Speed 3482
Lift/Lower Ramp Rate 3483
Hydraulic Auxiliary Ramp Rate 3483
Return to Set Tilt Delay/On/Off 3484
Hydraulic Input Device 3485
Auxiliary Solenoid 3485
Dual Function 3486
Setup Display 3487
Set Service Language 3487
Setup General Items 3487
Motion Alarm Activation Type 3488
Light Shutdown Time-Out 3489
Restore Default Settings 3489
Restore Engine Controller Default Calibration 3490
Impact Sensor – Enable/Disable 3490
Impact Sensor – Soft Impact Settings 3491
Impact Sensor – Hard Impact Settings 3492
Adjust Impact Sensor Settings 3493
Initial Adjustment of Soft and Hard Impact Settings 3495
Readjustment of Soft and Hard Impact Settings 3495
Impact Sensor – Impact Alarm/Shutdown Reset 3496
Impact Sensor – Alarm Time Duration and Deactivation 3497
Impact Sensor – View Impact Event Log 3498
Engine Mode Indicator 3498
Generation 1 (ECO-eLo ONLY) 3498
Generation 2 3499
Diesel Particulate Filter (DPF) Display 3500
General Description 3500
Passive Regeneration Only 3500
Regeneration Level 0 3500
Auto/Active Regeneration Inhibited 3501
Auto/Active Regeneration 3501
Regeneration Level 1 3501
Parked Regeneration Request 3502
Regeneration Level 2 3502
Warning Level 3502
Regeneration Level 3 3502
Service Level 3503
Regeneration Level 4 3503
Display, Diesel Particulate Filter (DPF), Revised 3503
Operator Interface 3503
Refer to Operator Manual 3503
CAN Communication Lost 3504
Passive Regeneration Only 3504
Regeneration Level 0 3504
Auto/Active Regeneration Inhibited 3504
Auto/Active Regeneration 3505
Regeneration Level 1 3505
Idle-up Auto/Active Regeneration 3505
Parked Regeneration Request 3505
Regeneration Level 2 3505
Warning Level 3507
Regeneration Level 3 3507
Service Level 3507
Regeneration Level 4 3507
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3507
Display, Diesel Particulate Filter (DPF), Stage V Engine 3507
Operator Interface 3508
Refer to Operator Manual 3508
CAN Communication Lost 3508
Passive Regeneration Only 3508
Regeneration Level 0 3508
Auto/Active Regeneration Inhibited 3509
Auto/Active Regeneration 3509
Regeneration Level 1 3509
Idle-up Auto/Active Regeneration 3510
Parked Regeneration Request 3510
Regeneration Level 2 3510
Warning Level 3511
Regeneration Level 3 3511
Service Level 3512
Regeneration Level 4 3512
Stage V Content 3512
Emissions System Malfunction 3512
Ash Load 3512
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3513
Operator Interface 3513
Refer to Operator Manual 3513
CAN Communication Lost 3514
Passive Regeneration Only 3514
Regeneration Level 0 3514
Auto/Active Regeneration Inhibited 3514
Auto/Active Regeneration 3515
Regeneration Level 1 3515
Idle-up Auto/Active Regeneration 3515
Parked Regeneration Request 3515
Regeneration Level 2 3515
Warning Level 3517
Regeneration Level 3 3517
Service Level 3517
Regeneration Level 4 3517
Calibrations 3518
Calibrate Transmission Valve 3520
Set Tilt Stop Point 3520
Calibrate Loaded Weight 3520
Calibrate Travel Speed Sensor 3521
Calibrate Mazda LP and Gas Accelerator Pedal 3521
524223771-2200YRM1131-(05-2021)-US-EN 3523
Series Code / Model Designation Reference Table 3529
General 3531
Description 3531
Dash Display Menu Access 3531
Menu Navigation 3532
Main Menu 3533
Passwords 3533
Adding Passwords 3533
Hourmeters 3535
View Versions 3536
VSM Versions 3536
Dash Display Versions 3537
Engine Controller Version 3538
Transmission (Xmsn) Controller Version 3539
Truck Serial Number 3540
Truck Configuration 3541
Diagnostics 3542
Clear Fault Log 3542
View Fault Log 3543
No-Run Data Display 3544
Engine Accelerator and Throttle Data Display 3545
Engine Speeds and Governor Data Display 3547
Engine Fuel and Emissions Data Display 3548
Engine General Data Display 3550
XMSN/Brake Data Display 3551
Hydraulic Data Display 3553
General Truck Data Display 3556
Set Travel and Braking 3558
Speed Limit 3558
Acceleration Rate 3559
Auto-Deceleration Rate 3559
Set Power Reversal Rate 3560
Set Inching/Brake Overlap 3560
Setup Hydraulics 3561
Lift Maximum Speed 3561
Lower Maximum Speed 3562
Tilt Maximum Speed 3562
Auxiliary Function One, Direction A, Maximum Speed 3564
Auxiliary Function One, Direction B, Maximum Speed 3567
Auxiliary Function Two, Direction A, Maximum Speed 3567
Auxiliary Function Two, Direction B, Maximum Speed 3568
Auxiliary Function Three, Direction A, Maximum Speed 3569
Auxiliary Function Three, Direction B, Maximum Speed 3569
Lift/Lower Ramp Rate 3570
Hydraulic Auxiliary Ramp Rate 3570
Return to Set Tilt Delay/On/Off 3571
Hydraulic Input Device 3572
Auxiliary Solenoid 3572
Dual Function 3573
Setup Display 3574
Set Service Language 3574
Setup General Items 3574
Motion Alarm Activation Type 3575
Light Shutdown Time-Out 3576
Restore Default Settings 3576
Restore Engine Controller Default Calibration 3577
Impact Sensor – Enable/Disable 3577
Impact Sensor – Soft Impact Settings 3578
Impact Sensor – Hard Impact Settings 3578
Adjust Impact Sensor Settings 3579
Initial Adjustment of Soft and Hard Impact Settings 3581
Readjustment of Soft and Hard Impact Settings 3581
Impact Sensor – Impact Alarm/Shutdown Reset 3582
Impact Sensor – Alarm Time Duration and Deactivation 3583
Impact Sensor – View Impact Event Log 3584
Engine Mode Indicator 3584
Generation 1 (ECO-eLo ONLY) 3584
Generation 2 3585
Diesel Particulate Filter (DPF) Display 3586
General Description 3586
Passive Regeneration Only 3586
Regeneration Level 0 3586
Auto/Active Regeneration Inhibited 3587
Auto/Active Regeneration 3587
Regeneration Level 1 3587
Parked Regeneration Request 3588
Regeneration Level 2 3588
Warning Level 3589
Regeneration Level 3 3589
Service Level 3589
Regeneration Level 4 3589
Display, Diesel Particulate Filter (DPF), Revised 3589
Operator Interface 3590
Refer to Operator Manual 3590
CAN Communication Lost 3590
Passive Regeneration Only 3590
Regeneration Level 0 3590
Auto/Active Regeneration Inhibited 3591
Auto/Active Regeneration 3591
Regeneration Level 1 3591
Idle-up Auto/Active Regeneration 3591
Parked Regeneration Request 3592
Regeneration Level 2 3592
Warning Level 3593
Regeneration Level 3 3593
Service Level 3593
Regeneration Level 4 3593
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3594
Display, Diesel Particulate Filter (DPF), Stage V Engine 3594
Operator Interface 3594
Refer to Operator Manual 3594
CAN Communication Lost 3595
Passive Regeneration Only 3595
Regeneration Level 0 3595
Auto/Active Regeneration Inhibited 3595
Auto/Active Regeneration 3596
Regeneration Level 1 3596
Idle-up Auto/Active Regeneration 3596
Parked Regeneration Request 3596
Regeneration Level 2 3596
Warning Level 3598
Regeneration Level 3 3598
Service Level 3598
Regeneration Level 4 3598
Stage V Content 3598
Emissions System Malfunction 3598
Ash Load 3599
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3600
Operator Interface 3600
Refer to Operator Manual 3600
CAN Communication Lost 3601
Passive Regeneration Only 3601
Regeneration Level 0 3601
Auto/Active Regeneration Inhibited 3601
Auto/Active Regeneration 3602
Regeneration Level 1 3602
Idle-up Auto/Active Regeneration 3602
Parked Regeneration Request 3602
Regeneration Level 2 3602
Warning Level 3604
Regeneration Level 3 3604
Service Level 3604
Regeneration Level 4 3604
Calibrations 3605
Calibrate Transmission Valve 3607
Set Tilt Stop Point 3607
Calibrate Loaded Weight 3608
Calibrate Travel Speed Sensor 3608
Calibrate Mazda LP and Gas Accelerator Pedal 3609
524223772-2200YRM1142-(01-2020)-US-EN 3611
General 3621
Display Switch Cluster 3624
Remove 3624
Install 3627
Direction Control and Turn Signal Levers 3627
Remove 3627
Install 3629
Key Switch 3629
Remove 3629
Install 3630
Display Switch Cluster Panel Bezel and Overlay 3630
Remove 3630
Install 3630
Steering Column Repair 3630
Remove 3630
Disassemble 3633
Assemble 3633
Install 3633
Sensors and Switches 3634
General 3634
Dash and Kick Panel, Remove and Install 3634
Remove 3634
Install 3635
Accelerator Pedal Position Sensor 3636
Remove 3636
Install 3639
Brake Fluid Level Switch 3640
Remove 3640
Install 3642
Service Brake Pedal Position Sensor 3643
Remove 3643
Install 3646
Parking Brake Sensor 3647
Remove 3647
Install 3648
Service Brake Pressure Sensor 3649
Remove 3649
Install 3651
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3652
Remove 3652
Install 3652
Sensor Microswitch (Foot Directional Control Pedal) 3653
Remove 3653
Install 3656
Low Coolant Level Sensor 3657
Remove 3657
Install 3660
Fuel Level Sensor, Gas and Diesel Engines Only 3661
Remove 3661
Install 3662
Armrest Switch 3662
Remove 3662
Install 3664
Seat Sensor (Operator Presence System) 3664
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) 3664
Remove 3664
Install 3665
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3665
Remove 3665
Install 3666
Full Suspension Seats; All Lift Truck Models 3666
Remove 3666
Install 3666
Hood Shut Off Switch 3666
Remove 3666
Install 3669
Remote Key Switch 3670
Remove 3670
Install 3670
Hydraulic Filter Pressure Switch 3671
Remove 3671
Install 3673
Transmission Speed Sensor 3673
Remove 3673
Install 3676
Transmission Pressure Sensors 3677
Remove 3677
Install 3679
Transmission Temperature Sensor 3680
Remove 3680
Install 3682
Engine Speed Sensor 3684
Remove 3684
Install 3684
Intermediate Speed Sensor 3685
Remove 3685
Install 3685
Return to Set Tilt (Tilt Angle) Sensor 3685
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) 3685
Remove 3685
Install 3686
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) 3687
Remove 3687
Install 3688
Rear Horn Button Switch 3688
Remove 3688
Install 3689
Impact Sensor 3690
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) 3690
Remove 3690
Install 3693
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) 3693
Remove 3693
Install 3694
Load Weight Sensor 3695
Remove 3695
Install 3696
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3697
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3697
Crankshaft Position (CKP) Sensor 3697
Camshaft Position (CMP) Sensor 3697
Oil Pressure Sensor 3697
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3697
Engine Coolant Temperature (ECT) Sensor 3698
Air Flow Restriction Switch 3698
Remove for GM 2 4L Gas and LPG Trucks 3698
Install for GM 2 4L Gas and LPG Trucks 3698
Oxygen Sensor 3699
Remove 3699
Install 3702
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3703
Crankshaft Position (CKP) Sensor 3703
Camshaft Position (CMP) Sensor 3703
Oil Pressure Sensor 3703
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3703
Engine Coolant Temperature (ECT) Sensor 3703
Air Flow Restriction Switch 3703
Oxygen Sensor 3703
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3703
Low LPG Pressure Switch 3703
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3704
Air Filter Restriction Switch 3704
Remove 3704
Install 3704
Oil Pressure Sensor 3704
Remove 3704
Install 3704
Engine Speed Sensor 3704
Remove 3704
Install 3704
Engine Coolant Temperature (ECT) Sensor 3704
Remove 3704
Install 3704
Throttle Position Sensor (TPS) 3707
Remove 3707
Install 3708
Fuel/Water Separator Sensor 3708
Remove 3708
Install 3708
Glow Plug Relay 3709
Remove 3709
Install 3711
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3711
Air Filter Restriction Switch 3711
Remove 3711
Install 3711
Engine Oil Pressure Sensor 3716
Remove 3716
Install 3716
Engine Speed Sensor 3716
Remove 3716
Install 3717
Engine Coolant Temperature (ECT) Sensor 3717
Remove 3717
Install 3718
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3719
Remove 3719
Install 3719
Fuel/Water Separator Sensor 3720
Remove 3720
Install 3720
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3721
Intake Air Temperature Sensor 3721
Remove 3721
Install 3722
Intake Air Pressure Sensor 3722
Remove 3722
Install 3722
Air Inlet Heater 3722
Remove 3722
Install 3723
Engine Oil Pressure Sensor 3723
Remove 3723
Install 3723
Engine Coolant Temperature (ECT) Sensor 3723
Remove 3723
Install 3723
Crankshaft Position Sensor 3724
Remove 3724
Install 3724
Adjust Shim Procedure 3725
Camshaft Position Sensor 3726
Remove 3726
Install 3726
Air Flow Restriction Sensor 3727
Remove 3727
Install 3727
Fuel/Water Separator 3727
Remove 3727
Install 3728
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3728
Intake Air Temperature Sensor 3732
Remove 3732
Install 3733
Boost Sensor 3733
Remove 3733
Install 3734
Throttle Valve Assembly and Air Intake Heater 3734
Remove 3734
Install 3734
Engine Coolant Temperature (ECT) Sensor 3735
Remove 3735
Install 3735
Engine Oil Pressure Sensor 3735
Remove 3735
Install 3736
Crankshaft Position Sensor 3736
Remove 3736
Install 3736
Adjust Shim Procedure 3737
Camshaft Position Sensor 3738
Remove 3738
Install 3739
Differential Pressure Sensor 3739
Remove 3739
Install 3739
Mass Air Flow Sensor 3740
Remove 3740
Install 3741
Fuel/Water Separator 3741
Remove 3741
Install 3742
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3742
Engine Coolant Temperature (ECT) Sensor 3743
Remove 3743
Install 3743
Throttle Position Sensor 3744
Engine Oil Pressure Sensor 3744
Remove 3744
Install 3744
Engine Speed Sensor 3744
Remove 3744
Install 3744
Fuel Shut Off Solenoid 3744
Remove 3744
Install 3744
Vehicle System Manager (VSM) 3745
General 3745
VSM Replacement 3745
Remove 3745
Install 3747
Programming a New VSM and/or Display Switch Cluster 3747
General 3747
PC Service Tool Software 3748
Data Transferring 3748
New VSM 3748
New (Blank) Display Switch Cluster 3748
Used (Non-Blank) Display Switch Cluster 3748
Power Distribution Module (PDM) and Component Parts 3750
Remove 3750
PDM as a Unit 3750
Install 3754
PDM as a Unit 3754
Remove and Install 3755
PDM Component Parts 3755
Transmission Control Unit 3755
Remove 3755
Install 3759
Battery 3761
Remove 3761
Install 3761
Lights 3762
Work Lights (Front and Rear) 3762
Remove 3762
Install 3762
Strobe Light 3763
Remove 3763
Install 3763
LED Tail, Backup, and Brake Lights 3764
Remove 3764
Install 3765
Front Marker/Turn Signal Lights 3766
Replacing Whole Front Marker/Turn Signal Light Assembly 3766
Remove 3766
Install 3766
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3767
Remove 3767
Install 3767
Diesel Particulate Filter (DPF) Display 3767
Remove 3767
Clean and Inspect 3768
Install 3768
Electronic-Hydraulic Controls – Generation 1 3769
E-Hydraulic Controls – Test 3769
Mini-Levers 3769
Full Stroke Test 3769
Function Returns to Neutral Test 3769
Push Button Switch 3769
General 3770
Mini-Lever Replacement 3770
Remove 3770
Clean and Inspect 3771
Install 3771
Push Button Switch Replacement 3772
Remove 3772
Install 3774
Mini-Lever Module (MLM) 3774
Remove 3774
Install 3774
Joystick 3775
Remove and Disassemble 3775
Inspect 3775
Assemble and Install 3775
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3776
General 3776
Mini-levers, Remove and Install 3776
Armrest Assembly 3777
Remove 3777
Install 3780
Horn Button 3780
Remove 3780
Install 3780
Direction Control Switch 3781
Remove 3781
Install 3781
push (override) buttons and Toggle Switch 3781
Remove 3782
Install 3783
Joystick 3784
Remove and Disassemble 3784
Inspect 3784
Assemble and Install 3784
Joystick Armrest Slider Assembly 3785
Remove 3785
Install 3786
Electronic-Hydraulic Controls, After January, 2020 3786
E-Hydraulic Controls – TEST 3786
Mini-Levers 3786
Full Stroke Test 3786
Function Returns to Neutral Test 3786
Push (Override) Button 3787
General 3787
Mini-levers, Remove and Install 3787
Armrest Assembly 3788
Remove 3788
Install 3791
Horn Button 3791
Remove 3791
Install 3791
Direction Control Switch 3791
Remove 3791
Install 3792
Push (Override) buttons and Toggle Switch 3792
Remove 3793
Install 3795
Special Tools 3796
524223772-2200YRM1142-(08-2021)-US-EN 3799
General 3809
Display Switch Cluster 3813
Remove 3813
Install 3815
Direction Control and Turn Signal Levers 3815
Remove 3815
Install 3816
Key Switch 3817
Remove 3817
Install 3818
Display Switch Cluster Panel Bezel and Overlay 3818
Remove 3818
Install 3818
Steering Column Repair 3819
Remove 3819
Disassemble 3822
Assemble 3822
Install 3822
Sensors and Switches 3823
General 3823
Dash and Kick Panel, Remove and Install 3823
Remove 3823
Install 3824
Accelerator Pedal Position Sensor 3824
Remove 3824
Install 3828
Brake Fluid Level Switch 3829
Remove 3829
Install 3830
Service Brake Pedal Position Sensor 3832
Remove 3832
Install 3834
Parking Brake Sensor 3835
Remove 3835
Install 3837
Service Brake Pressure Sensor 3837
Remove 3837
Install 3839
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3841
Remove 3841
Install 3841
Sensor Microswitch (Foot Directional Control Pedal) 3841
Remove 3841
Install 3844
Low Coolant Level Sensor 3845
Remove 3845
Install 3848
Fuel Level Sensor, Gas and Diesel Engines Only 3849
Remove 3849
Install 3850
Armrest Switch 3850
Remove 3850
Install 3852
Seat Sensor (Operator Presence System) 3852
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) 3852
Remove 3852
Install 3853
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3853
Remove 3853
Install 3853
Full Suspension Seats; All Lift Truck Models 3854
Remove 3854
Install 3854
Hood Shut Off Switch 3855
Remove 3855
Install 3857
Remote Key Switch 3858
Remove 3858
Install 3858
Hydraulic Filter Pressure Switch 3859
Remove 3859
Install 3861
Transmission Speed Sensor 3861
Remove 3861
Install 3864
Transmission Pressure Sensors 3865
Remove 3865
Install 3867
Transmission Temperature Sensor 3868
Remove 3868
Install 3870
Engine Speed Sensor 3872
Remove 3872
Install 3873
Intermediate Speed Sensor 3873
Remove 3873
Install 3873
Return to Set Tilt (Tilt Angle) Sensor 3874
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) 3874
Remove 3874
Install 3874
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) 3874
Remove 3875
Install 3876
Rear Horn Button Switch 3877
Remove 3877
Install 3877
Impact Sensor 3878
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) 3878
Remove 3878
Install 3880
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) 3880
Remove 3880
Install 3881
Load Weight Sensor 3881
Remove 3881
Install 3883
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3884
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3884
Crankshaft Position (CKP) Sensor 3884
Camshaft Position (CMP) Sensor 3884
Oil Pressure Sensor 3884
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3884
Engine Coolant Temperature (ECT) Sensor 3885
Air Flow Restriction Switch 3885
Remove for GM 2 4L Gas and LPG Trucks 3885
Install for GM 2 4L Gas and LPG Trucks 3885
Oxygen Sensor 3886
Remove 3886
Install 3889
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3890
Crankshaft Position (CKP) Sensor 3890
Camshaft Position (CMP) Sensor 3890
Oil Pressure Sensor 3890
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3890
Engine Coolant Temperature (ECT) Sensor 3890
Air Flow Restriction Switch 3890
Oxygen Sensor 3890
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3890
Low LPG Pressure Switch 3890
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3891
Air Filter Restriction Switch 3891
Remove 3891
Install 3891
Oil Pressure Sensor 3891
Remove 3891
Install 3891
Engine Speed Sensor 3891
Remove 3891
Install 3891
Engine Coolant Temperature (ECT) Sensor 3891
Remove 3891
Install 3891
Throttle Position Sensor (TPS) 3894
Remove 3894
Install 3895
Fuel/Water Separator Sensor 3895
Remove 3895
Install 3895
Glow Plug Relay 3896
Remove 3896
Install 3898
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3898
Air Filter Restriction Switch 3898
Remove 3898
Install 3899
Engine Oil Pressure Sensor 3903
Remove 3903
Install 3903
Engine Speed Sensor 3903
Remove 3903
Install 3904
Engine Coolant Temperature (ECT) Sensor 3904
Remove 3904
Install 3905
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3906
Remove 3906
Install 3906
Fuel/Water Separator Sensor 3907
Remove 3907
Install 3907
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3908
Intake Air Temperature Sensor 3908
Remove 3908
Install 3909
Intake Air Pressure Sensor 3909
Remove 3909
Install 3909
Air Inlet Heater 3909
Remove 3909
Install 3910
Engine Oil Pressure Sensor 3910
Remove 3910
Install 3910
Engine Coolant Temperature (ECT) Sensor 3910
Remove 3910
Install 3910
Crankshaft Position Sensor 3911
Remove 3911
Install 3911
Adjust Shim Procedure 3912
Camshaft Position Sensor 3913
Remove 3913
Install 3913
Air Flow Restriction Sensor 3913
Remove 3913
Install 3914
Fuel/Water Separator 3914
Remove 3914
Install 3915
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3915
Intake Air Temperature Sensor 3919
Remove 3919
Install 3920
Boost Sensor 3920
Remove 3920
Install 3921
Throttle Valve Assembly and Air Intake Heater 3921
Remove 3921
Install 3921
Engine Coolant Temperature (ECT) Sensor 3922
Remove 3922
Install 3922
Engine Oil Pressure Sensor 3923
Remove 3923
Install 3923
Crankshaft Position Sensor 3923
Remove 3923
Install 3923
Adjust Shim Procedure 3924
Camshaft Position Sensor 3926
Remove 3926
Install 3926
Differential Pressure Sensor 3926
Remove 3926
Install 3927
Mass Air Flow Sensor 3927
Remove 3927
Install 3928
Fuel/Water Separator 3929
Remove 3929
Install 3930
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3931
Engine Coolant Temperature (ECT) Sensor 3932
Remove 3932
Install 3932
Throttle Position Sensor 3932
Engine Oil Pressure Sensor 3932
Remove 3932
Install 3932
Engine Speed Sensor 3932
Remove 3932
Install 3932
Fuel Shut Off Solenoid 3933
Remove 3933
Install 3933
Vehicle System Manager (VSM) 3934
General 3934
VSM Replacement 3934
Remove 3934
Install 3936
Programming a New VSM and/or Display Switch Cluster 3936
General 3936
PC Service Tool Software 3937
Data Transferring 3937
New VSM 3937
New (Blank) Display Switch Cluster 3937
Used (Non-Blank) Display Switch Cluster 3937
Power Distribution Module (PDM) and Component Parts 3940
Remove 3940
PDM as a Unit 3940
Install 3943
PDM as a Unit 3943
Remove and Install 3944
PDM Component Parts 3944
Transmission Control Unit (TCU) 3945
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) 3945
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) 3945
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3946
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3946
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 3946
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 3947
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 3948
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 3950
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 3950
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 3950
Battery 3951
Remove 3951
Install 3951
Lights 3952
Work Lights (Front and Rear) 3952
Remove 3952
Install 3952
Strobe Light 3953
Remove 3953
Install 3953
LED Tail, Backup, and Brake Lights 3954
Remove 3954
Install 3955
Front Marker/Turn Signal Lights 3956
Replacing Whole Front Marker/Turn Signal Light Assembly 3956
Remove 3956
Install 3956
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3957
Remove 3957
Install 3957
Diesel Particulate Filter (DPF) Display 3958
Remove 3958
Clean and Inspect 3959
Install 3959
Electronic-Hydraulic Controls – Generation 1 3960
E-Hydraulic Controls – Test 3960
Mini-Levers 3960
Full Stroke Test 3960
Function Returns to Neutral Test 3960
Push Button Switch 3960
General 3961
Mini-Lever Replacement 3961
Remove 3961
Clean and Inspect 3962
Install 3962
Push Button Switch Replacement 3963
Remove 3963
Install 3965
Mini-Lever Module (MLM) 3965
Remove 3965
Install 3965
Joystick 3966
Remove and Disassemble 3966
Inspect 3966
Assemble and Install 3966
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3967
General 3967
Mini-levers, Remove and Install 3967
Armrest Assembly 3968
Remove 3968
Install 3971
Horn Button 3971
Remove 3971
Install 3971
Direction Control Switch 3972
Remove 3972
Install 3972
push (override) buttons and Toggle Switch 3972
Remove 3973
Install 3974
Joystick 3975
Remove and Disassemble 3975
Inspect 3975
Assemble and Install 3975
Joystick Armrest Slider Assembly 3976
Remove 3976
Install 3977
Electronic-Hydraulic Controls, After January, 2020 3978
E-Hydraulic Controls – TEST 3978
Mini-Levers 3978
Full Stroke Test 3978
Function Returns to Neutral Test 3978
Push (Override) Button 3978
General 3979
Mini-levers, Remove and Install 3979
Armrest Assembly 3980
Remove 3980
Install 3983
Horn Button 3983
Remove 3983
Install 3983
Direction Control Switch 3983
Remove 3983
Install 3984
Push (Override) buttons and Toggle Switch 3984
Remove 3985
Install 3987
Special Tools 3988
524223773-2200YRM1143-(05-2005)-US-EN 3991
toc 3991
Electrical System 3991
Safety Precautions Maintenance and Repair 3992
Ignition System 3995
General 3995
Ignition Timing Adjustment, Gasoline and LPG 3995
Spark Plugs Check 3995
Spark Plug Wires Check 3995
Distributor Repair 3998
Remove 3998
Disassemble 3999
Inspect 3999
Assemble 4000
Install 4000
Igniter 4001
Remove 4001
Test 4001
Install 4001
Camshaft Position (CMP) Sensor 4002
Voltage Check 4002
Ignition Coil Check 4003
Primary Coil Winding 4003
Secondary Coil Winding 4003
Starter Repair 4004
General 4004
Remove 4004
No-Load Test 4005
Magnetic Switch Test 4005
Pull-Out Test 4005
Holding Coil Test 4006
Return Test 4006
Pinion Movement Inspection 4006
Install 4006
Alternator Repair 4007
General 4007
Charging System Inspection 4007
Output Current Check 4008
No-Load Adjusted Voltage Check 4008
Remove 4009
Inspect 4009
Rectifier Check 4009
Install 4010
tables 3991
Table 1 Spark Plug Wire 3995
Table 2 Starter Specifications 4004
Table 3 Problem Diagnosis Chart 4005
Table 4 Specifications 4008
Table 5 Rectifier Check Table 4009
524223776-4000YRM1148-(09-2015)-US-EN 4013
General 4017
Safety Procedures When Working Near Mast 4018
Fork Replacement 4020
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4020
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4022
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4023
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4023
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4024
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4025
Carriages Repair 4026
Standard Carriage 4026
Remove 4026
Repair 4027
Install 4027
Standard Carriage, Remove 4028
Hang-On Sideshift Carriage, Remove 4029
Standard Carriage and Hang-On Sideshift Carriage, Repair 4030
Standard Carriage, Install 4031
Hang-On Sideshift Carriage, Install 4031
Integral Sideshift Carriage 4032
Remove 4032
Clean and Inspect 4035
Repair 4036
Install 4036
Fork Positioner 4037
Remove 4037
Clean and Inspect 4042
Disassemble and Assemble 4042
Install 4042
Fork Positioner Hydraulic Hose Adjustment 4043
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4045
Connecting Attachment Hydraulic Quick Disconnect Hoses 4045
Mast Repair 4046
Mast, Remove 4046
Two-Stage LFL and Two-Stage FFL Masts 4049
Disassemble 4049
Clean and Inspect 4059
Three-Stage FFL Mast 4060
Disassemble 4060
Clean and Inspect 4068
Two-Stage LFL and Two-Stage FFL Mast 4070
Assemble 4070
Three-Stage FFL Mast 4073
Assemble 4073
Four-Stage FFL Mast – Manufactured Before July, 2009 4075
Disassemble 4075
Clean and Inspect 4080
Assemble 4082
Four-Stage FFL Mast – Manufactured After July, 2009 4083
Disassemble 4083
Clean and Inspect 4090
Assemble 4093
Mast, Install 4094
Header Hose Arrangement 4097
Two-Stage LFL 4097
Two-Stage FFL 4105
Three-Stage FFL 4120
Standard 4120
Optional Equipment Lift Truck GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4137
Four-Stage FFL Mast – Manufactured Before July, 2009 4145
Four-Stage FFL Mast – Manufactured After July, 2009 4154
Adjustment 4161
Lift Chains Adjustment 4161
Carriage Adjustments 4164
Mast Adjustments 4164
Load Roller Adjustment 4164
Mast Side Kicking Adjustment 4167
524223779-8000YRM1152-(03-2020)-US-EN 4171
General Information About Diagrams and Schematics 4175
Symbol Definitions 4175
Diagrams Manual Applications 4176
Diagrams and Schematics 4178
524223779-8000YRM1152-(06-2021)-US-EN 4241
General Information About Diagrams and Schematics 4245
Symbol Definitions 4245
Diagrams Manual Applications 4246
Diagrams and Schematics 4248
524223780-8000YRM1134-(03-2020)-US-EN 4309
Series Code / Model Designation Reference Table 4315
Description 4317
Proc_Cal_001: Service Password Entry 4319
When to Perform 4319
Why Perform 4319
How to Perform 4319
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 4320
When to Perform 4320
Calibration Order 4320
Why Perform 4320
How to Perform 4321
Proc_Cal_003: Save and Exit 4322
When to Perform 4322
Why Perform 4322
How to Perform 4322
Proc_Cal_004: Lift Valve Output Threshold 4323
When to Perform 4323
Calibration Order 4323
Why Perform 4323
How to Perform 4324
Proc_Cal_005: Lower Valve Output Threshold 4326
When to Perform 4326
Calibration Order 4326
Why Perform 4326
How to Perform 4326
Proc_Cal_006: Tilt Back Valve Output Threshold 4329
When to Perform 4329
Calibration Order 4329
Why Perform 4329
How to Perform 4329
Proc_Cal_007: Tilt Forward Valve Output Threshold 4332
When to Perform 4332
Calibration Order 4332
Why Perform 4332
How to Perform 4332
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 4335
When to Perform 4335
Calibration Order 4335
Why Perform 4335
How to Perform 4335
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 4338
When to Perform 4338
Calibration Order 4338
Why Perform 4338
How to Perform 4338
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 4341
When to Perform 4341
Calibration Order 4341
Why Perform 4341
How to Perform 4341
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 4344
When to Perform 4344
Calibration Order 4344
Why Perform 4344
How to Perform 4344
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 4347
When to Perform 4347
Calibration Order 4347
Why Perform 4347
How to Perform 4347
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 4350
When to Perform 4350
Calibration Order 4350
Why Perform 4350
How to Perform 4350
Proc_Cal_014: Load Weight Zero Point 4354
When to Perform 4354
Calibration Order 4354
Why Perform 4354
How to Perform 4354
Proc_Cal_015: Loaded Weight Calibration 4356
When to Perform 4356
Calibration Order 4356
Why Perform 4356
How to Perform 4356
Proc_Cal_016: Transmission Valve Calibration 4359
Applicable System/Option 4359
When to Perform 4359
Calibration Order 4359
Why Perform 4359
How to Perform 4359
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 4361
Applicable System/Option 4361
When to Perform 4361
Calibration Order 4361
Why Perform 4361
How to Perform 4361
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 4363
Applicable System/Option 4363
When to Perform 4363
Calibration Order 4363
Why Perform 4363
How to Perform 4364
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 4365
Required Tools 4365
When to Perform 4365
Calibration Order 4365
Why Perform 4366
How to Perform 4366
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 4367
When to Perform 4367
Why Perform 4367
How to Perform 4367
Proc_Cal_026: Travel Speed Calibration 4369
When to Perform 4369
Calibration Order 4369
Why Perform 4369
How to Perform 4369
524223780-8000YRM1134-(05-2022)-US-EN 4373
Series Code / Model Designation Reference Table 4379
Description 4382
Proc_Cal_001: Service Password Entry 4384
When to Perform 4384
Why Perform 4384
How to Perform 4384
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 4385
When to Perform 4385
Calibration Order 4385
Why Perform 4385
How to Perform 4385
Proc_Cal_003: Save and Exit 4387
When to Perform 4387
Why Perform 4387
How to Perform 4387
Proc_Cal_004: Lift Valve Output Threshold 4388
When to Perform 4388
Calibration Order 4388
Why Perform 4388
How to Perform 4388
Proc_Cal_005: Lower Valve Output Threshold 4391
When to Perform 4391
Calibration Order 4391
Why Perform 4391
How to Perform 4391
Proc_Cal_006: Tilt Back Valve Output Threshold 4394
When to Perform 4394
Calibration Order 4394
Why Perform 4394
How to Perform 4394
Proc_Cal_007: Tilt Forward Valve Output Threshold 4397
When to Perform 4397
Calibration Order 4397
Why Perform 4397
How to Perform 4397
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 4400
When to Perform 4400
Calibration Order 4400
Why Perform 4400
How to Perform 4400
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 4403
When to Perform 4403
Calibration Order 4403
Why Perform 4403
How to Perform 4403
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 4406
When to Perform 4406
Calibration Order 4406
Why Perform 4406
How to Perform 4406
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 4409
When to Perform 4409
Calibration Order 4409
Why Perform 4409
How to Perform 4409
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 4412
When to Perform 4412
Calibration Order 4412
Why Perform 4412
How to Perform 4412
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 4415
When to Perform 4415
Calibration Order 4415
Why Perform 4415
How to Perform 4415
Proc_Cal_014: Load Weight Zero Point 4418
When to Perform 4418
Calibration Order 4418
Why Perform 4418
How to Perform 4418
Proc_Cal_015: Loaded Weight Calibration 4420
When to Perform 4420
Calibration Order 4420
Why Perform 4420
How to Perform 4420
Proc_Cal_016: Transmission Valve Calibration 4423
Applicable System/Option 4423
When to Perform 4423
Calibration Order 4423
Why Perform 4423
How to Perform 4423
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 4425
Applicable System/Option 4425
When to Perform 4425
Calibration Order 4425
Why Perform 4425
How to Perform 4425
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 4428
Applicable System/Option 4428
When to Perform 4428
Calibration Order 4428
Why Perform 4428
How to Perform 4428
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 4431
Required Tools 4431
When to Perform 4431
Calibration Order 4431
Why Perform 4431
How to Perform 4431
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 4433
When to Perform 4433
Why Perform 4433
How to Perform 4433
Proc_Cal_026: Travel Speed Calibration 4435
When to Perform 4435
Calibration Order 4435
Why Perform 4435
How to Perform 4435
524240454-1400YRM1206-(11-2008)-US-EN 4439
toc 4439
Drive Axle and Differential Assembly Repair 4439
Safety Precautions Maintenance and Repair 4440
General 4443
Drive Axle Repair 4443
Remove and Disassemble 4443
Clean and Inspect 4445
Assemble and Install 4445
Differential Repair 4448
Remove 4448
Differential Assembly From Center Section Assembly 4448
Drive Pinion, Pinion Gear, and Bearings From Center Section 4452
Disassemble 4457
Differential Assembly 4457
Drop Box Housing 4461
Center Section 4462
Clean and Inspect 4464
Assemble 4464
Center Section 4464
Drop Box Housing 4467
Differential Assembly 4468
Install 4472
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 4472
Drive Pinion, Pinion Gear, and Bearings Into Center Section 4474
Differential Assembly Into Center Section 4477
Ring Gear Backlash, Adjust 4482
Ring Gear, Runout Check 4484
Gear Set, Tooth Contact Pattern Check 4484
Torque Specifications 4487
tables 4439
Table 1 Pinion Variation Numbers Examples 4473
Table 2 Ring and Pinion Tooth Contact Adjustment 4484
Table 3 Correct Tooth Contact 4485
Table 4 Incorrect Tooth Contact 4486
524240455-8000YRM1207-(08-2019)-US-EN 4491
General 4497
Serial Number Data 4497
How to Move Disabled Lift Truck 4497
How to Tow Lift Truck 4497
How to Put Lift Truck on Blocks 4498
How to Raise Drive Tires 4498
How to Raise Steering Tires 4499
How to Clean a Lift Truck 4499
Maintenance Schedule 4500
Maintenance Procedures Every 8 Hours or Daily 4519
How to Make Checks With Engine Stopped 4519
Tires and Wheels 4519
Safety Labels 4520
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4520
Operator Restraint System 4521
Emergency Locking Retractor (ELR) 4521
Adjust Seat – Full Suspension 4522
Adjust Seat – Internal Suspension 4523
Hood and Seat Latches 4524
Engine Compartment 4524
Fuel, Oil, and Coolant Leaks, Check 4524
Hydraulic Hoses 4524
Coolant Hoses 4524
Steering Column Gas Cylinder 4524
Transmission 4524
Hydraulic System Oil 4525
Engine Oil 4525
Air Filter 4529
Forks 4529
Remove 4529
Inspect 4531
Install 4531
Adjust 4532
How to Make Checks With Engine Running 4533
Indicator Lights, Horn, Fuses, and Relays 4533
Service Brakes 4535
Brake Fluid Level 4535
Operation, Check 4535
Parking Brake 4536
Engine Oil Pressure 4536
Cooling System 4537
Steering System 4537
Control Levers and Pedals 4538
Lift System, Operate 4538
First Service After First 100 Hours of Operation 4539
Mazda Engine Oil and Oil Filter 4539
Yanmar Engine Oil and Oil Filter 4539
Maintenance Procedures Every 250 Hours or 6 Months 4539
Mazda Engine Oil and Filter 4539
Drive Belt 4540
Mazda 2 0L Engines 4540
Fan and Alternator Drive Belt 4540
Drain Tar From LPG Regulator (Except 2007 Mazda Emission Compliant Engines) 4540
Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engines Only) 4541
Maintenance Procedures Every 500 Hours or 6 Months 4542
Hydraulic System Oil 4542
Hydraulic Tank Breather 4542
Inspect 4542
Battery 4543
Yanmar Engine Oil and Oil Filter 4543
Drive Belt 4543
Yanmar Diesel Engine 4543
Fan and Alternator Drive Belt 4543
PCV Valve 4544
Clean Debris From Radiator Core 4544
Transmission Oil Level 4544
Forks 4546
Mast Lubrication 4546
Header Hose Checks 4551
Lift Chain Lubrication 4551
Tilt Cylinder Lubrication 4551
Master Brake Cylinder Rod End Pin Lubrication 4552
Manual Hydraulic Levers Lubrication 4552
Brake Fluid 4552
Tie Rod Lubrication 4553
Differential and Drive Axle Oil (Dry Brake) 4553
Maintenance Procedures Every 1000 Hours or 6 Months 4554
Valve Clearance, Check and Adjust 4554
Ignition System 4554
Mazda EnginesFE 4554
LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 4555
LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines Only 4555
Remove 4555
Clean/Inspect 4556
Install 4556
Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant Engines Only 4556
Remove and Replace 4556
Fuel Filter Replacement, Yanmar Engine 4557
Priming the Fuel System (Yanmar) 4558
Lift Chains Wear Check 4559
Lift Chain Lubrication 4559
Integral Sideshift Carriage, Check Bearings 4560
Integral Sideshift Carriage, Check Lower Mounting Hooks 4560
Steering Axle 4561
Control Levers and Pedals 4561
Maintenance Procedures Every 2000 Hours or Annually 4562
Hydraulic System 4562
Hydraulic Filter, Replace 4562
Hydraulic Tank Breather, Replace 4563
Air Filter 4563
PCV Valve 4565
Oxygen Sensor 4565
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 4567
Remove and Replace 4567
Gasoline Fuel Filter 4567
Remove and Replace for Lift Trucks Equipped with GFI 4567
Timing Belt 4567
Mazda Engines 4567
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 4567
Gasoline Fuel Injector, Mazda Engines 4567
Fuel Injector, Yanmar Engines 4568
Forks 4568
Integral Sideshift Carriage 4568
Bearings, Replace 4568
Transmission Oil and Filter (Dry Brake), Replace 4568
Iron Transmission Housing 4568
Aluminum Transmission Housing 4569
Remove 4569
Clean and Inspect 4572
Install 4572
Brake Fluid (Master Cylinder), Change 4573
Brake Fluid (Dry Brake), Remove 4574
Steer Axle, Wheel Bearings Lubrication 4574
Service Brakes (Dry Brake) 4574
Differential (Dry Brake) 4575
Maintenance Procedures Every 4000 Hours or 2 Years 4576
Hydraulic Oil, Replace 4576
Cooling System 4577
Safety Procedures When Working Near Mast 4578
Hood Latch Check 4580
Lift Chain Adjustments 4581
Jump-Starting the Lift Truck 4583
Jump-Starting Using a Battery Charger 4583
Jump-Starting a Lift Truck Using Another Lift Truck 4583
Welding Repairs 4583
Overhead Guard Changes 4584
Wheel Repair 4584
General 4584
How to Change Solid Rubber Tire (GC Series) 4584
Remove and Install Tire on Wheel 4584
Pneumatic Tire With Tube, Repair 4585
Remove Wheels From Lift Truck 4585
Remove Tire From Wheel 4586
Install Wheel in Tire 4589
Add Air to Pneumatic Tires With Tube 4591
Wheels, Install 4592
Pneumatic Tubeless Tire, Repair 4592
Remove Wheels From Lift Truck 4592
Add Air to Pneumatic Tubeless Tire 4597
Wheels, Install 4597
Solid Rubber Tires on Pneumatic Wheels, Change 4598
Adhesives and Sealants 4601
524240456-8000YRM1208-(08-2019)-US-EN 4603
Lift Truck Lifting Capacity 4607
Counterweight Weights 4607
Tire Sizes 4607
Capacities 4608
Electrical System 4612
Transmission Oil Pressures 4613
Hydraulic System Relief Pressures 4614
Steering System 4615
Stall Speeds (in RPM ±100 rpm) 4616
Mazda (Except 2007 Emission Compliant Engines) 4616
Mazda (2007 Emission Compliant Engines Only) 4616
Yanmar 2 6L 4616
Mast Speeds 4616
Tilt Angles 4617
Front End Equipment – Mast Creep 4618
Mast Creep 4618
Engine Specifications 4619
Torque Specifications 4620
Frame 4620
Mast 4620
Steering System, Cushion Tire Trucks 4620
Steering System, Pneumatic Tire Trucks 4620
Drive Axle 4620
Transmission – Iron Housing 4621
Transmission – Aluminum Housing 4621
Engine – Mazda FE 4622
Engine – Yanmar 2 6L Diesel 4623
524289373-0900YRM1325-(12-2009)-US-EN 4625
toc 4625
Gasoline Fuel System 4625
Safety Precautions Maintenance and Repair 4626
General 4629
Abbreviations 4629
Intake-Air System 4629
Intake-Air System Manifold Vacuum Check 4629
Throttle Body 4630
Remove 4630
Install 4631
Intake Manifold 4631
Remove 4631
Install 4631
Fuel System 4632
Before Repair Procedure 4632
Fuel Line Safety Procedure 4632
After Repair Procedure 4635
Fuel Hose, Install 4635
Fuel Leakage Check 4635
Fuel Line Pressure Check 4636
Fuel Injectors 4637
Remove 4637
Install 4637
Pressure Regulator 4639
Remove 4639
Install 4639
Exhaust System 4640
Counterweight Exhaust System 4640
Remove and Disassemble 4640
Inspect 4640
Assemble and Install 4640
Overhead Exhaust System 4642
Remove and Disassemble 4642
Inspect 4642
Assemble and Install 4642
Exhaust Manifold 4644
Remove 4644
Install 4644
Positive Crankcase Ventilation (PCV) Valve 4646
Remove 4646
Inspect 4646
Install 4646
Oxygen Sensor 4647
Remove 4647
Install 4647
Control System 4649
Engine Control Unit (ECU) 4649
Remove 4649
Install 4650
Fuel Level Sensor 4651
Remove 4651
Install 4651
Technical Data 4652
tables 4625
Table 1 PCV Valve Specifications 4646
Table 2 Gasoline Fuel Systems Technical Data 4652
524289374-0900YRM1326-(04-2018)-US-EN 4655
General 4661
LPG Tank and Bracket Replacement 4661
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) 4661
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) 4663
Remove LPG Tank for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4664
LPG Tank Install for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4666
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) 4667
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) 4669
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) 4670
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) 4672
Remove LPG Bracket for Lift Truck Models and GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4673
Install LPG Bracket for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4673
Fuel Filter Unit Repair 4673
Fuel Filter Element 4673
Remove 4673
Clean/Inspect 4674
Install 4674
Fuel Filter Housing 4674
Remove 4674
Disassemble 4677
Assemble 4679
Install 4680
Electronic Throttle Body Repair 4680
Remove 4680
Install 4682
Electronic Pressure Regulator (EPR) Repair 4682
Remove 4683
Disassemble 4687
Assemble 4689
Install 4690
LPG Shutoff Valve Assembly 4690
Remove 4690
Install 4694
Fuel Mixer Repair 4696
Remove 4696
Install 4699
Control System 4699
Engine Control Unit (ECU) 4699
Remove 4699
Install 4701
Low LPG Pressure Switch 4701
Remove 4701
Install 4702
LPG Low Level Sensor 4702
Remove 4703
Install 4706
Exhaust System 4707
Counterweight Exhaust System 4707
Remove and Disassemble 4707
Inspect 4709
Assemble and Install 4709
Overhead Exhaust System 4709
Remove and Disassemble 4710
Inspect 4712
Assemble and Install 4712
Exhaust Manifold 4713
Remove 4713
Install 4714
Positive Crankcase Ventilation (PCV) Valve 4715
Remove 4715
Inspect 4715
Install 4715
Oxygen Sensor 4715
Remove 4715
Install 4717
LPG Fuel Testing 4718
General 4718
Available Fuel Tests 4718
Composition Test (ASTM D-2163) 4718
Ammonia Test (ASTM D-4490) 4718
Basic Nitrogen Test (ASTM UOP269-90) 4718
Residues Test (ASTM D-2158) 4718
Vapor Pressure Test (ASTM D-2598) 4718
Sulfur Compounds Test (ASTM D-5623) 4719
Methanol Test (ASTM D-4864) 4719
Copper Corrosion (ASTM D-1838) 4719
Where To Send LPG Fuel Samples For Testing 4719
524289375-2200YRM1327-(09-2012)-US-EN 4723
General 4727
Ignition System 4727
General 4727
Ignition Timing Adjustment, Gasoline and LPG 4727
Spark Plugs Check 4732
Spark Plug Wires Check 4732
Coil Replacement 4733
Remove 4733
Inspect 4734
Install 4734
Starter Repair 4735
General 4735
Remove 4735
No-Load Test 4736
Magnetic Switch Test 4737
Pull-Out Test 4737
Holding Coil Test 4737
Return Test 4737
Pinion Movement Inspection 4738
Install 4738
Alternator Repair 4738
General 4738
Charging System Inspection 4740
Output Current Check 4740
No-Load Adjusted Voltage Check 4741
Remove 4742
Inspect 4742
Rectifier Check 4742
Install 4743
Engine Sensors and Switches 4744
Oil Pressure Sensor, Gas and LPG Engines 4744
Remove 4744
Install 4744
Air Filter Restriction Switch, Gas and LPG Engines 4744
Remove 4744
Install 4744
Cam Angle Sensor, Gas and LPG Engines 4745
Remove 4745
Install 4746
Voltage Check 4746
Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Engines 4747
Remove 4747
Install 4748
Intake Air Temperature (IAT) Sensor, LPG Engines 4749
Remove 4749
Install 4749
Intake Air Temperature (IAT) Sensor, Gas Engines 4749
Remove 4749
Install 4749
Fuel Temperature Sensor, LPG Engines 4752
Remove 4752
Install 4752
Engine Coolant Temperature (ECT) Sensor 4753
2007 Emissions Compliant Gas Engines 4753
Remove 4753
Install 4753
2007 and 2010 Emissions Compliant LPG Engines 4754
Remove 4754
Install 4754
2010 Emissions Compliant Gas and LPG Engines 4756
Remove 4756
Install 4756
524329117-8000YRM1387-(03-2020)-US-EN 4761
General Information About Diagrams and Schematics 4765
Symbol Definitions 4765
Diagrams Manual Applications 4766
Diagrams and Schematics 4768
524329117-8000YRM1387-(06-2021)-US-EN 4833
General Information About Diagrams and Schematics 4837
Symbol Definitions 4837
Diagrams Manual Applications 4838
Diagrams and Schematics 4840
550001092-8000YRM1409-(03-2020)-US-EN 4903
General Information About Diagrams and Schematics 4907
Symbol Definitions 4907
Diagrams Manual Applications 4908
Diagrams and Schematics 4910
550001092-8000YRM1409-(06-2021)-US-EN 4991
General Information About Diagrams and Schematics 4995
Symbol Definitions 4995
Diagrams Manual Applications 4996
Diagrams and Schematics 4998
550010194-1300YRM1421-(08-2013)-US-EN 5073
toc 5073
Single Speed PowerShift 5073
Safety Precautions Maintenance and Repair 5074
General 5077
Serial Number 5077
Hydraulic Gear Pump 5078
Remove 5078
Install 5078
Charge Pump Repair 5079
Original Charge Pump 5079
Remove 5079
Disassemble 5080
Clean 5080
Inspect 5080
Assemble 5080
Install 5080
New Charge Pump, Manufactured After July, 2013 5081
Remove 5081
Clean 5082
Inspect 5082
Install 5083
Torque Converter Replacement 5085
Remove 5085
Clean and Inspect 5085
Install 5085
Stator Support Assembly Repair 5086
Remove 5086
Disassemble 5091
Clean 5092
Inspect 5092
Assemble 5093
Install 5093
Clutch Packs Repair 5095
Remove 5095
Engine, Torque Converter, and Transmission Assembly 5095
Transmission Components 5096
Disassemble 5098
Transmission 5098
Housings 5098
Forward Clutch Pack 5101
Reverse Clutch Pack 5106
Clean 5112
Inspect 5112
Assemble 5113
Transmission 5113
Reverse Clutch Pack 5113
Forward Clutch Pack 5120
Housings 5126
Install 5128
Transmission Components 5128
Engine, Torque Converter, and Transmission Assembly 5131
Inching Overlap Adjustment 5131
Proportional and Enable Solenoid Valves 5132
Proportional Valves 5132
Remove 5132
Disassemble 5134
Clean and Inspect 5134
Assemble 5134
Install 5134
Enable Solenoid Valve 5134
Remove 5134
Disassemble 5134
Clean and Inspect 5134
Assemble 5135
Install 5135
Foot Directional Control Pedal Repair 5135
Remove and Disassembly 5135
Clean and Inspect 5139
Assemble and Install 5139
550030170-1300YRM1447-(08-2013)-US-EN 5143
toc 5143
Single Speed Powershift 5143
Safety Precautions Maintenance and Repair 5144
General 5147
Serial Number 5147
Hydraulic Gear Pump 5148
Remove 5148
Install 5148
Housing Fittings Replacement 5148
Remove 5148
Disassemble 5149
Assemble 5149
Install 5149
Charge Pump Repair 5149
Lift Trucks Manufactured Before July, 2013 5149
Remove 5149
Disassemble 5151
Clean 5151
Inspect 5151
Assemble 5151
Install 5151
Lift Trucks Manufactured After July, 2013 5153
Remove 5153
Clean 5153
Inspect 5153
Install 5154
Torque Converter Replacement 5157
Remove 5157
Clean and Inspect 5157
Install 5157
Stator Support Assembly Repair 5159
Remove 5159
Disassemble 5164
Clean 5168
Inspect 5168
Assemble 5169
Install 5169
Clutch Packs Repair 5172
Remove 5172
Disassemble 5173
Housings 5173
Clutch Packs 5178
Forward Clutch Pack 5178
Reverse Clutch Pack 5183
Clean 5189
Inspect 5189
Assemble 5190
Clutch Packs 5190
Reverse Clutch Pack 5190
Forward Clutch Pack 5197
Housings 5204
Install 5204
Drive Chains and Sprockets 5210
Remove 5210
Clean 5212
Inspect 5212
Install 5212
Proportional and Enable Solenoid Valves 5213
Proportional Valves 5213
Remove 5213
Disassemble 5213
Clean and Inspect 5213
Assemble 5216
Install 5216
Enable Solenoid Valve 5216
Remove 5216
Disassemble 5217
Clean and Inspect 5217
Assemble 5217
Install 5217
Foot Directional Control Pedal Repair 5219
Remove and Disassemble 5219
Clean and Inspect 5223
Assemble and Install 5223
550043436-1300YRM1529-(11-2018)-US-EN 5229
General 5233
Serial Number 5233
Charge Pump Repair 5233
Lift Trucks Manufactured Before July, 2013 5233
Remove 5233
Inspect 5233
Install 5233
Lift Trucks Manufactured After July, 2013 5234
Remove 5234
Inspect 5234
Install 5234
Torque Converter Replace 5235
Remove 5235
Install 5244
Housings and Chain Drive Repair 5250
Remove 5250
Clean 5261
Inspect 5261
Install 5261
Clutch Packs Repair 5268
Remove and Disassemble 5268
Transmission, Remove and Disassemble 5268
Clean 5287
Inspect 5287
Assemble and Install 5288
Transmission, Assemble and Install 5296
Control Valve Repair 5300
Remove and Disassemble 5300
Clean 5304
Inspect 5304
Assemble and Install 5304
Foot Directional Control Pedal Repair 5305
Remove and Disassemble 5305
Assemble and Install 5309
Direction Control Lever 5310
Remove 5310
Install 5310
550055283-8000YRM1585-(06-2021)-US-EN 5315
General Information About Diagrams and Schematics 5319
Symbol Definitions 5319
Diagrams Manual Applications 5320
Diagrams and Schematics 5322
550055283-8000YRM1585-(07-2020)-US-EN 5411
General Information About Diagrams and Schematics 5415
Symbol Definitions 5415
Diagrams Manual Applications 5416
Diagrams and Schematics 5418
550073240-1900YRM1620-(01-2023)-US-EN 5507
Proper Flushing after Major Hydraulic Repairs 5513
Introduction 5513
The Phases of Wear 5513
Causes of Hydraulic System Failure 5513
Progression of Contaminant Caused Hydraulic System Failure 5514
Hydraulic System Flushing Techniques 5514
Double Oil and Filter Change 5514
Mechanical Cleaning 5515
Cleaning of Components 5515
How to Clean Tubes and Hoses 5515
Filter Caddy 5515
Start-Up Procedure for Cleaned System 5516
Contaminated Oil Coolers 5516
Additional Filter Caddy Functions 5517
How to Handle Different Fluids 5517
Water Removal Filters 5517
Fluid Conditioning and System Flushing Procedures 5518
Operation of the Filter Caddy 5518
Filter Caddy operation 5518
Fluid Conditioning Procedure 5518
Filter Caddy Start-Up 5519
System Flushing Procedure 5519
Component Cleaning Procedure 5520
Reservoir Cleaning Procedure 5520
Cylinder Cleaning Procedure 5520
Hose and Tube Cleaning Procedure 5520
Valve Cleaning Procedure 5521
Front-End Attachment Cleaning Procedure 5522
System Flushing Procedure 5522
Filter Caddy Start-Up 5523
System Start-Up and Flushing 5523
Reservoir Fluid Cleaning Times 5524
Dealing With Different Fluid Types 5525
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5525
Filter Caddy Maintenance 5525
Servicing the Strainer 5525
DC Motor 5525
Hydraulic Oil Sampling Method and Procedure 5526
Hydraulic Oil Sampling Method 5526
Objective 5526
General Guidelines 5526
Synopsis 5527
Hydraulic Oil Analysis Report Guidelines 5528
Sampling Conditions 5528
Equipment 5528
Sampling Procedure 5529
Hydraulic Oil Sampling 5529
Sample Labeling 5529
Results Documentation 5529
550073240-1900YRM1620-(03-2020)-US-EN 5531
Proper Flushing after Major Hydraulic Repairs 5535
Introduction 5535
The Phases of Wear 5535
Causes of Hydraulic System Failure 5535
Progression of Contaminant Caused Hydraulic System Failure 5536
Hydraulic System Flushing Techniques 5536
Double Oil and Filter Change 5536
Mechanical Cleaning 5537
Cleaning of Components 5537
How to Clean Tubes and Hoses 5537
Filter Caddy 5537
Start-Up Procedure for Cleaned System 5538
Contaminated Oil Coolers 5538
Additional Filter Caddy Functions 5538
How to Handle Different Fluids 5538
Water Removal Filters 5539
Fluid Conditioning and System Flushing Procedures 5539
Operation of the Filter Caddy 5539
Filter Caddy operation 5539
Fluid Conditioning Procedure 5540
Filter Caddy Start-Up 5540
System Flushing Procedure 5541
Component Cleaning Procedure 5541
Reservoir Cleaning Procedure 5541
Cylinder Cleaning Procedure 5541
Hose and Tube Cleaning Procedure 5542
Valve Cleaning Procedure 5542
Front-End Attachment Cleaning Procedure 5543
System Flushing Procedure 5543
Filter Caddy Start-Up 5544
System Start-Up and Flushing 5544
Reservoir Fluid Cleaning Times 5545
Dealing With Different Fluid Types 5545
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5545
Filter Caddy Maintenance 5546
Servicing the Strainer 5546
DC Motor 5546
Hydraulic Oil Sampling Method and Procedure 5546
Hydraulic Oil Sampling Method 5546
Objective 5546
General Guidelines 5546
Synopsis 5547
Hydraulic Oil Analysis Report Guidelines 5548
Sampling Conditions 5549
Equipment 5549
Sampling Procedure 5549
Hydraulic Oil Sampling 5549
Sample Labeling 5550
Results Documentation 5550
550096331-8000YRM1689-(03-2020)-US-EN 5553
General Information About Diagrams and Schematics 5557
Symbol Definitions 5557
Diagrams Manual Applications 5558
Diagrams and Schematics 5560
550096331-8000YRM1689-(06-2021)-US-EN 5663
General Information About Diagrams and Schematics 5667
Symbol Definitions 5667
Diagrams Manual Applications 5668
Diagrams and Schematics 5670

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