Yale Forklift C879 (GLC_GDC60VX, GLC_GDC70VX) Service Manual PDF

Description

Yale Forklift C879 (GLC_GDC60VX, GLC_GDC70VX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift C879 (GLC_GDC60VX, GLC_GDC70VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5990
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift C879 (GLC_GDC60VX, GLC_GDC70VX) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-UK-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524208014-2200YRM1097-(03-2020)-US-EN 43
Series Code / Model Designation Reference Table 47
Description 48
Distributor Ignition (DI) System 48
Crankshaft Position (CKP) Sensor 48
Camshaft Position (CMP) Sensor 48
Ignition Coil and Ignition Control Module (ICM) 48
Secondary Ignition Components 48
Spark Plugs and Wires 49
Spark Plug Wire Inspection 49
Spark Plug Wire Replacement 49
Remove 49
Install 50
Spark Plug Inspection 50
Usage 50
Inspection 50
Visual Inspection 52
Spark Plug Replacement 52
Remove 52
Install 52
Distributor Repair 53
Inspect 53
Overhaul 53
Disassemble 53
Assemble 56
Replace 57
Remove 57
Install Procedure 1 59
Install Procedure 2 60
Ignition Coil Replacement 61
Remove 61
Install 61
Ignition Control Module Replacement 62
Remove 62
Install 62
Starter Replacement 63
Remove 63
Install 66
Sensors and Switches 67
Gas and LPG Trucks 67
Crankshaft Position (CKP) Sensor 67
Remove 67
Install 67
Camshaft Position (CMP) Sensor 68
Remove 68
Install 70
Oil Pressure Sensor 70
Remove 70
Install 71
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 72
Remove 72
Install 72
Engine Coolant Temperature (ECT) Sensor 73
Remove 73
Install 74
Air Flow Restriction Switch 74
Remove 74
Install 75
Specifications and Special Tools 76
524221866-9000YRM1112-(10-2020)-US-EN 81
SECTION 9010 Operational Diagnostic Procedures 97
Group 05 – Operational Checkout 99
SECTION 9020 Engine 117
Group 10 – Principles of Operation 127
Group 30 – Observed Symptoms 325
Group 40 – Tests and Adjustments 427
SECTION 9030 Electrical System 459
Group 03 – General Maintenance and Diagnostic Data 483
Group 10 – Principles of Operation 577
Group 20 – Diagnostic Trouble Codes 601
Group 30 – Observed Symptoms 1573
SECTION 9040 Drive Train 1629
Group 10 – Principles of Operation 1633
Group 30 – Observed Symptoms 1689
Group 40 – Tests and Adjustments 1739
SECTION 9050 Hydraulic Systems 1749
Group 10 – Principles of Operation 1753
Group 30 – Observed Symptoms 1811
Group 33 – Observed Symptoms-Gear Pump 1813
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1901
Group 40 – Tests and Adjustments 1945
Group 43 – Tests and Adjustments-Gear Pump 1947
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1971
SECTION 9060 Operators Station 1989
Group 10 – Principles of Operation 1991
SECTION 9070 Front End (Mast) and Chassis 2027
Group 10 – Principles of Operation 2029
Group 30 – Observed Symptoms 2051
SECTION 9080 Supplementary Data 2109
Group 50 – Abbreviations and Acronyms 2111
Group 60 – Special Tools List 2119
Group 70 – Fault Mode Indicator Reference 2129
Group 80 – Supplier Specification Data 2131
524223757-0700YRM1123-(06-2016)-UK-EN 2135
General 2139
Cooling System Checks 2139
Exhaust Leaks Into Cooling System 2139
Water Flow Restrictions in Radiator 2139
Radiator Hoses 2139
Water Pump 2140
Flushing the Cooling System 2140
Cooling System, Clean 2140
Radiator Replacement 2141
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) 2142
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 2157
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2160
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) 2163
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) 2170
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 2175
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2177
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) 2180
Fan Assembly Replacement 2192
Fan Removal 2192
Inspect 2207
Fan Installation 2207
524223757-0700YRM1123-(06-2021)-US-EN 2213
General 2217
Cooling System Checks 2217
Exhaust Leaks Into Cooling System 2217
Water Flow Restrictions in Radiator 2217
Radiator Hoses 2217
Water Pump 2217
Flushing the Cooling System 2219
Cooling System, Clean 2219
Radiator Replacement 2221
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) 2221
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) 2236
Radiator, Remove for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2239
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) 2242
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) 2248
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) 2252
Radiator, Install for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2253
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) 2256
Fan Assembly Replacement 2267
Fan Removal 2267
Inspect 2281
Fan Installation 2282
524223764-1600YRM1133-(07-2013)-UK-EN 2287
toc 2287
Steering Axle 2287
Safety Precautions Maintenance and Repair 2288
General 2291
Steering Axle Assembly Repair 2293
Remove 2293
Disassemble 2294
Clean 2302
Inspect 2302
Assemble 2302
Install 2308
Spindles, Bearings, and Tie Rods Repair 2310
Spindles and Bearings 2310
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2310
Remove 2310
Disassemble 2312
Clean 2313
Inspect 2313
Assemble 2313
Install 2314
Spindles and Bearings 2317
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2317
Remove and Disassemble 2317
Assemble and Install 2318
Tie Rods 2318
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2318
Remove 2318
Install 2319
Tie Rods 2320
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2320
Remove 2320
Install 2326
Steering Cylinder Repair 2326
Remove and Disassemble 2326
Clean and Inspect 2327
Assemble and Install 2327
Torque Specifications 2328
524223764-1600YRM1133-(07-2013)-US-EN 2333
toc 2333
Steering Axle 2333
Safety Precautions Maintenance and Repair 2334
General 2337
Steering Axle Assembly Repair 2339
Remove 2339
Disassemble 2340
Clean 2348
Inspect 2348
Assemble 2348
Install 2354
Spindles, Bearings, and Tie Rods Repair 2356
Spindles and Bearings 2356
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2356
Remove 2356
Disassemble 2358
Clean 2359
Inspect 2359
Assemble 2359
Install 2360
Spindles and Bearings 2363
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2363
Remove and Disassemble 2363
Assemble and Install 2364
Tie Rods 2364
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2364
Remove 2364
Install 2365
Tie Rods 2366
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2366
Remove 2366
Install 2372
Steering Cylinder Repair 2372
Remove and Disassemble 2372
Clean and Inspect 2373
Assemble and Install 2373
Torque Specifications 2374
524223766-1900YRM1136-(01-2022)-US-EN 2379
General 2383
Hydraulic Gear Pump Assembly 2384
Variable Displacement Pump Assembly 2385
Single Gear Pump Assembly Repair 2386
Remove 2386
Disassemble 2392
Clean 2394
Inspect 2394
Assemble 2394
Install 2394
Tandem Gear Pump Assembly 2399
Remove 2399
Disassemble 2400
Clean 2403
Inspect 2403
Assemble 2403
Install 2404
Gear Pump Specifications 2405
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2411
Remove 2411
Disassemble 2421
Clean 2424
Inspect 2425
Assemble 2425
Install 2425
63 0 cc/rev – Variable Displacement Pump Repair 2430
Remove 2430
Disassemble 2433
Clean 2435
Inspect 2435
Assemble 2435
Install 2435
Variable Displacement Pump Checks and Adjustments (Single Pump) 2439
Margin Pressure Check 2439
Flow Compensator Adjustment 2440
Pressure Compensator Adjustment 2440
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2442
Variable Displacement Pump Specifications 2445
Torque Specifications 2447
Hydraulic Gear Pump 2447
Variable Displacement Pump 2448
Special Tools 2449
524223766-1900YRM1136-(11-2017)-UK-EN 2451
General 2455
Hydraulic Gear Pump Assembly 2456
Variable Displacement Pump Assembly 2457
Single Gear Pump Assembly Repair 2457
Remove 2457
Disassemble 2464
Clean 2464
Inspect 2466
Assemble 2466
Install 2466
Tandem Gear Pump Assembly 2470
Remove 2471
Disassemble 2473
Clean 2475
Inspect 2475
Assemble 2475
Install 2476
Gear Pump Specifications 2476
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2482
Remove 2482
Disassemble 2492
Clean 2495
Inspect 2495
Assemble 2495
Install 2496
63 0 cc/rev – Variable Displacement Pump Repair 2499
Remove 2499
Disassemble 2502
Clean 2502
Inspect 2502
Assemble 2504
Install 2504
Variable Displacement Pump Checks and Adjustments (Single Pump) 2506
Margin Pressure Check 2506
Flow Compensator Adjustment 2507
Pressure Compensator Adjustment 2507
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2508
Variable Displacement Pump Specifications 2511
Torque Specifications 2512
Hydraulic Gear Pump 2513
Variable Displacement Pump 2514
Special Tools 2514
524223767-2000YRM1137-(01-2017)-UK-EN 2519
General 2525
Electro-Hydraulic Main Control Valve 2526
Description 2526
Remove 2534
Electro-Hydraulic Control Valve Sections 2539
General 2539
Outlet Control Valve Section 2539
Remove 2539
Disassemble 2540
Clean 2542
Inspect 2542
Assemble 2542
Install 2543
Auxiliary Control Valve Sections 2543
Remove 2543
Disassemble 2550
Clean 2551
Inspect 2552
Assemble 2552
Install 2554
Tilt Control Valve Section 2555
Remove 2555
Disassemble 2555
Clean 2561
Inspect 2561
Assemble 2561
Install 2562
Lift/Lower Control Valve Section 2563
Remove 2563
Disassemble 2563
Clean 2572
Inspect 2572
Assemble 2572
Install 2573
Mid-Inlet Section 2573
Remove 2573
Clean 2574
Inspect 2574
Install 2574
Install 2574
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2579
Lift Pilot Pin 2579
Lower Pilot Pin 2583
Abnormal/Erroneous EHPV Adjustment 2585
Manual Main Control Valve 2586
Description 2586
Remove 2590
OPS Solenoid Assembly 2598
General 2598
Remove 2599
Clean and Inspect 2602
Install 2602
Manual Control Valve Sections 2603
General 2603
Outlet Control Valve Section 2603
Remove 2603
Disassemble 2603
Clean 2606
Inspect 2606
Assemble 2606
Install 2607
Auxiliary Control Valve Sections 2607
Remove 2607
Disassemble 2607
Clean 2610
Inspect 2610
Assemble 2610
Install 2611
Lift/Tilt Control Valve Section 2611
Remove 2611
Disassemble 2611
Clean 2618
Inspect 2618
Assemble 2619
Install 2620
Mid-Inlet Section 2621
Remove 2621
Clean 2621
Inspect 2621
Install 2621
Install 2622
Pressure Relief Valve Check and Adjustment 2628
Primary Relief Valve 2629
Secondary Relief Valve 2633
Steering Control Unit Repair 2640
Steering Control Unit, Remove 2640
Steering Control Unit, Disassemble 2644
Steering Control Unit, Clean 2646
Steering Control Unit, Inspect 2646
Steering Control Unit, Assemble 2646
Relief Valve, Disassemble 2647
Relief Valve, Clean 2647
Relief Valve, Inspect 2648
Relief Valve, Assemble 2648
Steering Control Unit, Install 2648
524223767-2000YRM1137-(06-2021)-US-EN 2653
General 2657
Electro-Hydraulic Main Control Valve 2658
Description 2658
Remove 2666
Electro-Hydraulic Control Valve Sections 2671
General 2671
Outlet Control Valve Section 2671
Remove 2671
Disassemble 2671
Clean 2674
Inspect 2674
Assemble 2675
Install 2675
Auxiliary Control Valve Sections 2675
Remove 2676
Disassemble 2681
Clean 2683
Inspect 2683
Assemble 2683
Install 2685
Tilt Control Valve Section 2686
Remove 2686
Disassemble 2687
Clean 2691
Inspect 2691
Assemble 2692
Install 2693
Lift/Lower Control Valve Section 2693
Remove 2693
Disassemble 2693
Clean 2699
Inspect 2699
Assemble 2699
Install 2700
Mid-Inlet Section 2700
Remove 2700
Clean 2701
Inspect 2701
Install 2701
Install 2701
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2706
Lift Pilot Pin 2706
Lower Pilot Pin 2709
Abnormal/Erroneous EHPV Adjustment 2711
Manual Main Control Valve 2712
Description 2712
Remove 2716
OPS Solenoid Assembly 2724
General 2724
Remove 2725
Clean and Inspect 2727
Install 2727
Manual Control Valve Sections 2728
General 2728
Outlet Control Valve Section 2728
Remove 2728
Disassemble 2728
Clean 2731
Inspect 2731
Assemble 2731
Install 2731
Auxiliary Control Valve Sections 2732
Remove 2732
Disassemble 2732
Clean 2735
Inspect 2735
Assemble 2735
Install 2735
Lift/Tilt Control Valve Section 2736
Remove 2736
Disassemble 2736
Clean 2742
Inspect 2742
Assemble 2742
Install 2744
Mid-Inlet Section 2744
Remove 2744
Clean 2745
Inspect 2745
Install 2745
Install 2745
Pressure Relief Valve Check and Adjustment 2753
Primary Relief Valve 2753
Secondary Relief Valve 2756
Steering Control Unit Repair 2761
Steering Control Unit, Remove 2761
Steering Control Unit, Disassemble 2765
Steering Control Unit, Clean 2767
Steering Control Unit, Inspect 2767
Steering Control Unit, Assemble 2767
Relief Valve, Disassemble 2768
Relief Valve, Clean 2768
Relief Valve, Inspect 2769
Relief Valve, Assemble 2769
Steering Control Unit, Install 2769
524223769-2200YRM1128-(01-2023)-US-EN 2773
Series Code / Model Designation Reference Table 2781
General 2783
Deutsch Crimping Tool 2784
How to Strip a Wire for Use With Deutsch Crimping Tool 2784
How to Crimp With the Deutsch Crimping Tool 2785
Calibration Test for the Deutsch Crimping Tool 2787
Deutsch Connectors 2789
DT, DTM, and DTP Series Connectors 2789
HD Series Connectors 2832
Metri-Pack Connectors 2854
Remove and Install 2854
Micro-Pack Connectors 2857
Weather-Pack Connectors 2858
AMPSEAL Crimping Tools 2860
AMP Hand Crimping Tool With Certi-Crimp 2860
Description 2860
Stripping Wire for Use with AMP Hand Crimping Tool 2861
Insulation Crimp Adjustment 2862
Maintenance and Inspection for AMP Hand Crimping Tool 2862
AMP Hand Crimping Tool 2862
Crimp Height Inspection 2862
How to use AMP Hand Crimping Tool 2863
AMP Pro-Crimper II Tool 2863
Description 2863
Remove and Install Die Set and Locator Assembly 2864
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2864
Contact Support Adjustment 2865
Crimp Height Adjustment 2866
Maintenance and Inspection Procedures 2866
PRO-CRIMPER II Tool 2866
Crimp Height Inspection 2866
How to Use AMP PRO-CRIMPER II Tool 2867
AMPSEAL Connector Assemblies 2868
Description for Plug Connector Assembly 2868
Seal Plug 2869
Contact Crimping 2869
Description for Plug Connector and Header Assembly 2874
Voltage Reading 2877
Seal Plug 2877
Contact Crimping 2877
AMP Superseal 1 5 Crimping Tools 2884
Mini Mic Receptacle and Tab Contacts 2884
Description 2884
Crimping Conditions and Measurements 2884
Insertion of Rubber Seal on Cable 2886
AMP Hand Application Tool 2891
Description 2891
Maintenance and Inspection 2891
Crimp Height Inspection 2891
Crimp Height Adjustment 2892
How to Use AMP Hand Application Tool 2892
AMP Pro-Crimper II Tool 2893
Description 2893
Remove and Install Die Set and Locator Assembly 2893
Adjustments 2894
Contact Support 2894
Crimp Height 2895
Inspections and Maintenance 2896
Crimp Height Inspection 2896
Visual Inspection 2896
Maintenance 2897
How to Use Pro-Crimper II Tool 2897
AMP Superseal 1 5 Connector Assemblies 2898
Description 2898
Repair and Maintenance 2905
Panel Mount Option 2905
AMP Fastin-Faston Hand Tools 2906
Description – AMP Double Action Hand Tool 2906
Maintenance and Inspection Procedures 2906
Daily Maintenance 2906
Periodic Tool Inspection 2907
Lubrication 2907
Visual Inspection 2907
Crimp Height Inspection 2907
Certi-Crimp Ratchet Inspection 2908
How to Use AMP Double Action Hand Tool 2909
Description – AMP Extraction Tool 2910
Maintenance and Inspection 2911
How to Use AMP Extraction Tool 2911
AMP Fastin-Faston Receptacles and Housings 2913
Description 2913
Wire Repair 2921
Wire Splicing Requirements 2921
Deutsch Jiffy Splice 2922
Twisted/Shielded Cable and Leads Repair 2928
Special Tools 2930
524223769-2200YRM1128-(07-2020)-UK-EN 2939
Series Code / Model Designation Reference Table 2945
General 2948
Deutsch Crimping Tool 2948
How to Strip a Wire for Use With Deutsch Crimping Tool 2948
How to Crimp With the Deutsch Crimping Tool 2949
Calibration Test for the Deutsch Crimping Tool 2951
Deutsch Connectors 2953
DT, DTM, and DTP Series Connectors 2953
HD Series Connectors 2995
Metri-Pack Connectors 3018
Remove and Install 3018
Micro-Pack Connectors 3020
Weather-Pack Connectors 3021
AMPSEAL Crimping Tools 3023
AMP Hand Crimping Tool With Certi-Crimp 3023
Description 3023
Stripping Wire for Use with AMP Hand Crimping Tool 3023
Insulation Crimp Adjustment 3024
Maintenance and Inspection for AMP Hand Crimping Tool 3024
AMP Hand Crimping Tool 3024
Crimp Height Inspection 3024
How to use AMP Hand Crimping Tool 3025
AMP Pro-Crimper II Tool 3025
Description 3025
Remove and Install Die Set and Locator Assembly 3026
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3027
Contact Support Adjustment 3027
Crimp Height Adjustment 3028
Maintenance and Inspection Procedures 3028
PRO-CRIMPER II Tool 3028
Crimp Height Inspection 3028
How to Use AMP PRO-CRIMPER II Tool 3029
AMPSEAL Connector Assemblies 3030
Description for Plug Connector Assembly 3030
Seal Plug 3031
Contact Crimping 3031
Description for Plug Connector and Header Assembly 3036
Voltage Reading 3038
Seal Plug 3038
Contact Crimping 3038
AMP Superseal 1 5 Crimping Tools 3045
Mini Mic Receptacle and Tab Contacts 3045
Description 3045
Crimping Conditions and Measurements 3045
Insertion of Rubber Seal on Cable 3047
AMP Hand Application Tool 3052
Description 3052
Maintenance and Inspection 3052
Crimp Height Inspection 3052
Crimp Height Adjustment 3053
How to Use AMP Hand Application Tool 3053
AMP Pro-Crimper II Tool 3054
Description 3054
Remove and Install Die Set and Locator Assembly 3055
Adjustments 3055
Contact Support 3055
Crimp Height 3056
Inspections and Maintenance 3057
Crimp Height Inspection 3057
Visual Inspection 3057
Maintenance 3058
How to Use Pro-Crimper II Tool 3058
AMP Superseal 1 5 Connector Assemblies 3059
Description 3059
Repair and Maintenance 3066
Panel Mount Option 3066
AMP Fastin-Faston Hand Tools 3067
Description – AMP Double Action Hand Tool 3067
Maintenance and Inspection Procedures 3067
Daily Maintenance 3067
Periodic Tool Inspection 3068
Lubrication 3068
Visual Inspection 3068
Crimp Height Inspection 3068
Certi-Crimp Ratchet Inspection 3069
How to Use AMP Double Action Hand Tool 3070
Description – AMP Extraction Tool 3071
Maintenance and Inspection 3071
How to Use AMP Extraction Tool 3072
AMP Fastin-Faston Receptacles and Housings 3073
Description 3073
Wire Repair 3080
Wire Splicing Requirements 3080
Deutsch Jiffy Splice 3081
Twisted/Shielded Cable and Leads Repair 3086
Special Tools 3089
524223770-2200YRM1130-(03-2020)-UK-EN 3097
General 3101
Description 3101
Dash Display Menu Access 3101
Menu Navigation 3102
Standard Display 3102
Main Menu 3102
Passwords Menu 3103
Password Administration 3103
Add Password 3103
Delete Password 3104
Edit Password 3104
Other Password Functions 3105
Operator Passwords – Enable/Disable 3105
Password Time-Out Delay 3105
Passwords – Number Wrong to Disable 3106
Lockout Reset Password 3106
View Password Log 3107
View Versions 3108
VSM Versions 3108
Dash Display Versions 3109
Engine Controller Version 3110
Transmission (Xmsn) Controller Version 3111
Truck Serial Number 3112
Diagnostics 3113
View Fault Log 3113
Set Travel and Braking 3114
Speed Limit 3114
Acceleration Rate 3115
Auto-Deceleration Rate 3115
Set Power Reversal Rate 3116
Set Inching/Brake Overlap 3117
Setup Display Menu 3118
Set Operator Language 3118
Set Units 3119
Set Time Format (12/24 Hour) 3119
Set Daylight Saving Time 3119
Set Time 3122
Set Date Format 3123
Set Date 3123
Setup Hydraulics 3124
Return to Set Tilt Delay/On/Off 3124
Setup General Items 3125
Light Shutdown Time-Out 3125
Impact Sensor – Enable/Disable 3126
Impact Sensor – Soft Impact Settings 3127
Impact Sensor – Hard Impact Settings 3128
Adjust Impact Sensor Settings 3128
Initial Adjustment of Soft and Hard Impact Settings 3130
Readjustment of Soft and Hard Impact Settings 3130
Impact Sensor – Impact Alarm/Shutdown Reset 3131
Impact Sensor – Alarm Time Duration and Deactivation 3132
Impact Sensor – View Impact Event Log 3133
Engine Mode Indicator 3134
Generation 1 (ECO-eLo ONLY) 3134
Generation 2 3135
Operator Checklist 3136
Operator Checklist Off-On Mode 3136
Edit Operator Checklist 3136
Set Operator Checklist Expiration 3137
View Checklist Log 3137
Clear Operator Checklist Log 3138
Clear Operator Checklist Fault 3138
Calibrations 3139
Set Tilt Stop Point 3139
Calibrate Loaded Weight 3139
524223770-2200YRM1130-(05-2021)-US-EN 3141
General 3145
Description 3145
Dash Display Menu Access 3145
Menu Navigation 3146
Standard Display 3146
Main Menu 3146
Passwords Menu 3147
Password Administration 3147
Add Password 3147
Delete Password 3147
Edit Password 3148
Other Password Functions 3149
Operator Passwords – Enable/Disable 3149
Password Time-Out Delay 3149
Passwords – Number Wrong to Disable 3149
Lockout Reset Password 3150
View Password Log 3150
View Versions 3151
VSM Versions 3151
Dash Display Versions 3152
Engine Controller Version 3153
Transmission (Xmsn) Controller Version 3154
Truck Serial Number 3155
Diagnostics 3156
View Fault Log 3156
Set Travel and Braking 3157
Speed Limit 3157
Acceleration Rate 3158
Auto-Deceleration Rate 3158
Set Power Reversal Rate 3159
Set Inching/Brake Overlap 3160
Setup Display Menu 3161
Set Operator Language 3161
Set Units 3162
Set Time Format (12/24 Hour) 3162
Set Daylight Saving Time 3163
Set Time 3166
Set Date Format 3166
Set Date 3167
Setup Hydraulics 3168
Return to Set Tilt Delay/On/Off 3168
Setup General Items 3169
Light Shutdown Time-Out 3169
Impact Sensor – Enable/Disable 3170
Impact Sensor – Soft Impact Settings 3171
Impact Sensor – Hard Impact Settings 3171
Adjust Impact Sensor Settings 3172
Initial Adjustment of Soft and Hard Impact Settings 3174
Readjustment of Soft and Hard Impact Settings 3174
Impact Sensor – Impact Alarm/Shutdown Reset 3175
Impact Sensor – Alarm Time Duration and Deactivation 3176
Impact Sensor – View Impact Event Log 3177
Engine Mode Indicator 3177
Generation 1 (ECO-eLo ONLY) 3177
Generation 2 3178
Operator Checklist 3179
Operator Checklist Off-On Mode 3179
Edit Operator Checklist 3179
Set Operator Checklist Expiration 3179
View Checklist Log 3180
Clear Operator Checklist Log 3181
Clear Operator Checklist Fault 3181
Calibrations 3182
Set Tilt Stop Point 3182
Calibrate Loaded Weight 3182
524223771-2200YRM1131-(03-2020)-UK-EN 3185
Series Code / Model Designation Reference Table 3191
General 3193
Description 3193
Dash Display Menu Access 3193
Menu Navigation 3194
Main Menu 3194
Passwords 3195
Adding Passwords 3195
Hourmeters 3197
View Versions 3198
VSM Versions 3198
Dash Display Versions 3199
Engine Controller Version 3200
Transmission (Xmsn) Controller Version 3201
Truck Serial Number 3202
Truck Configuration 3203
Diagnostics 3204
Clear Fault Log 3204
View Fault Log 3205
No-Run Data Display 3206
Engine Accelerator and Throttle Data Display 3206
Engine Speeds and Governor Data Display 3207
Engine Fuel and Emissions Data Display 3208
Engine General Data Display 3210
XMSN/Brake Data Display 3211
Hydraulic Data Display 3214
General Truck Data Display 3216
Set Travel and Braking 3217
Speed Limit 3217
Acceleration Rate 3218
Auto-Deceleration Rate 3219
Set Power Reversal Rate 3219
Set Inching/Brake Overlap 3220
Setup Hydraulics 3220
Lift Maximum Speed 3221
Lower Maximum Speed 3221
Tilt Maximum Speed 3222
Auxiliary Function One, Direction A, Maximum Speed 3224
Auxiliary Function One, Direction B, Maximum Speed 3226
Auxiliary Function Two, Direction A, Maximum Speed 3226
Auxiliary Function Two, Direction B, Maximum Speed 3227
Auxiliary Function Three, Direction A, Maximum Speed 3228
Auxiliary Function Three, Direction B, Maximum Speed 3228
Lift/Lower Ramp Rate 3229
Hydraulic Auxiliary Ramp Rate 3229
Return to Set Tilt Delay/On/Off 3230
Hydraulic Input Device 3231
Auxiliary Solenoid 3231
Dual Function 3232
Setup Display 3233
Set Service Language 3233
Setup General Items 3233
Motion Alarm Activation Type 3234
Light Shutdown Time-Out 3235
Restore Default Settings 3235
Restore Engine Controller Default Calibration 3236
Impact Sensor – Enable/Disable 3236
Impact Sensor – Soft Impact Settings 3237
Impact Sensor – Hard Impact Settings 3238
Adjust Impact Sensor Settings 3239
Initial Adjustment of Soft and Hard Impact Settings 3241
Readjustment of Soft and Hard Impact Settings 3241
Impact Sensor – Impact Alarm/Shutdown Reset 3242
Impact Sensor – Alarm Time Duration and Deactivation 3243
Impact Sensor – View Impact Event Log 3244
Engine Mode Indicator 3244
Generation 1 (ECO-eLo ONLY) 3244
Generation 2 3245
Diesel Particulate Filter (DPF) Display 3246
General Description 3246
Passive Regeneration Only 3246
Regeneration Level 0 3246
Auto/Active Regeneration Inhibited 3247
Auto/Active Regeneration 3247
Regeneration Level 1 3247
Parked Regeneration Request 3248
Regeneration Level 2 3248
Warning Level 3248
Regeneration Level 3 3248
Service Level 3249
Regeneration Level 4 3249
Display, Diesel Particulate Filter (DPF), Revised 3249
Operator Interface 3249
Refer to Operator Manual 3249
CAN Communication Lost 3250
Passive Regeneration Only 3250
Regeneration Level 0 3250
Auto/Active Regeneration Inhibited 3250
Auto/Active Regeneration 3251
Regeneration Level 1 3251
Idle-up Auto/Active Regeneration 3251
Parked Regeneration Request 3251
Regeneration Level 2 3251
Warning Level 3253
Regeneration Level 3 3253
Service Level 3253
Regeneration Level 4 3253
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3253
Display, Diesel Particulate Filter (DPF), Stage V Engine 3253
Operator Interface 3254
Refer to Operator Manual 3254
CAN Communication Lost 3254
Passive Regeneration Only 3254
Regeneration Level 0 3254
Auto/Active Regeneration Inhibited 3255
Auto/Active Regeneration 3255
Regeneration Level 1 3255
Idle-up Auto/Active Regeneration 3256
Parked Regeneration Request 3256
Regeneration Level 2 3256
Warning Level 3257
Regeneration Level 3 3257
Service Level 3258
Regeneration Level 4 3258
Stage V Content 3258
Emissions System Malfunction 3258
Ash Load 3258
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3259
Operator Interface 3259
Refer to Operator Manual 3259
CAN Communication Lost 3260
Passive Regeneration Only 3260
Regeneration Level 0 3260
Auto/Active Regeneration Inhibited 3260
Auto/Active Regeneration 3261
Regeneration Level 1 3261
Idle-up Auto/Active Regeneration 3261
Parked Regeneration Request 3261
Regeneration Level 2 3261
Warning Level 3263
Regeneration Level 3 3263
Service Level 3263
Regeneration Level 4 3263
Calibrations 3264
Calibrate Transmission Valve 3266
Set Tilt Stop Point 3266
Calibrate Loaded Weight 3266
Calibrate Travel Speed Sensor 3267
Calibrate Mazda LP and Gas Accelerator Pedal 3267
524223771-2200YRM1131-(05-2021)-US-EN 3269
Series Code / Model Designation Reference Table 3275
General 3277
Description 3277
Dash Display Menu Access 3277
Menu Navigation 3278
Main Menu 3279
Passwords 3279
Adding Passwords 3279
Hourmeters 3281
View Versions 3282
VSM Versions 3282
Dash Display Versions 3283
Engine Controller Version 3284
Transmission (Xmsn) Controller Version 3285
Truck Serial Number 3286
Truck Configuration 3287
Diagnostics 3288
Clear Fault Log 3288
View Fault Log 3289
No-Run Data Display 3290
Engine Accelerator and Throttle Data Display 3291
Engine Speeds and Governor Data Display 3293
Engine Fuel and Emissions Data Display 3294
Engine General Data Display 3296
XMSN/Brake Data Display 3297
Hydraulic Data Display 3299
General Truck Data Display 3302
Set Travel and Braking 3304
Speed Limit 3304
Acceleration Rate 3305
Auto-Deceleration Rate 3305
Set Power Reversal Rate 3306
Set Inching/Brake Overlap 3306
Setup Hydraulics 3307
Lift Maximum Speed 3307
Lower Maximum Speed 3308
Tilt Maximum Speed 3308
Auxiliary Function One, Direction A, Maximum Speed 3310
Auxiliary Function One, Direction B, Maximum Speed 3313
Auxiliary Function Two, Direction A, Maximum Speed 3313
Auxiliary Function Two, Direction B, Maximum Speed 3314
Auxiliary Function Three, Direction A, Maximum Speed 3315
Auxiliary Function Three, Direction B, Maximum Speed 3315
Lift/Lower Ramp Rate 3316
Hydraulic Auxiliary Ramp Rate 3316
Return to Set Tilt Delay/On/Off 3317
Hydraulic Input Device 3318
Auxiliary Solenoid 3318
Dual Function 3319
Setup Display 3320
Set Service Language 3320
Setup General Items 3320
Motion Alarm Activation Type 3321
Light Shutdown Time-Out 3322
Restore Default Settings 3322
Restore Engine Controller Default Calibration 3323
Impact Sensor – Enable/Disable 3323
Impact Sensor – Soft Impact Settings 3324
Impact Sensor – Hard Impact Settings 3324
Adjust Impact Sensor Settings 3325
Initial Adjustment of Soft and Hard Impact Settings 3327
Readjustment of Soft and Hard Impact Settings 3327
Impact Sensor – Impact Alarm/Shutdown Reset 3328
Impact Sensor – Alarm Time Duration and Deactivation 3329
Impact Sensor – View Impact Event Log 3330
Engine Mode Indicator 3330
Generation 1 (ECO-eLo ONLY) 3330
Generation 2 3331
Diesel Particulate Filter (DPF) Display 3332
General Description 3332
Passive Regeneration Only 3332
Regeneration Level 0 3332
Auto/Active Regeneration Inhibited 3333
Auto/Active Regeneration 3333
Regeneration Level 1 3333
Parked Regeneration Request 3334
Regeneration Level 2 3334
Warning Level 3335
Regeneration Level 3 3335
Service Level 3335
Regeneration Level 4 3335
Display, Diesel Particulate Filter (DPF), Revised 3335
Operator Interface 3336
Refer to Operator Manual 3336
CAN Communication Lost 3336
Passive Regeneration Only 3336
Regeneration Level 0 3336
Auto/Active Regeneration Inhibited 3337
Auto/Active Regeneration 3337
Regeneration Level 1 3337
Idle-up Auto/Active Regeneration 3337
Parked Regeneration Request 3338
Regeneration Level 2 3338
Warning Level 3339
Regeneration Level 3 3339
Service Level 3339
Regeneration Level 4 3339
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3340
Display, Diesel Particulate Filter (DPF), Stage V Engine 3340
Operator Interface 3340
Refer to Operator Manual 3340
CAN Communication Lost 3341
Passive Regeneration Only 3341
Regeneration Level 0 3341
Auto/Active Regeneration Inhibited 3341
Auto/Active Regeneration 3342
Regeneration Level 1 3342
Idle-up Auto/Active Regeneration 3342
Parked Regeneration Request 3342
Regeneration Level 2 3342
Warning Level 3344
Regeneration Level 3 3344
Service Level 3344
Regeneration Level 4 3344
Stage V Content 3344
Emissions System Malfunction 3344
Ash Load 3345
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3346
Operator Interface 3346
Refer to Operator Manual 3346
CAN Communication Lost 3347
Passive Regeneration Only 3347
Regeneration Level 0 3347
Auto/Active Regeneration Inhibited 3347
Auto/Active Regeneration 3348
Regeneration Level 1 3348
Idle-up Auto/Active Regeneration 3348
Parked Regeneration Request 3348
Regeneration Level 2 3348
Warning Level 3350
Regeneration Level 3 3350
Service Level 3350
Regeneration Level 4 3350
Calibrations 3351
Calibrate Transmission Valve 3353
Set Tilt Stop Point 3353
Calibrate Loaded Weight 3354
Calibrate Travel Speed Sensor 3354
Calibrate Mazda LP and Gas Accelerator Pedal 3355
524223772-2200YRM1142-(01-2020)-UK-EN 3357
General 3367
Display Switch Cluster 3370
Remove 3370
Install 3373
Direction Control and Turn Signal Levers 3373
Remove 3373
Install 3375
Key Switch 3375
Remove 3375
Install 3376
Display Switch Cluster Panel Bezel and Overlay 3376
Remove 3376
Install 3376
Steering Column Repair 3376
Remove 3376
Disassemble 3379
Assemble 3379
Install 3379
Sensors and Switches 3380
General 3380
Dash and Kick Panel, Remove and Install 3380
Remove 3380
Install 3381
Accelerator Pedal Position Sensor 3382
Remove 3382
Install 3385
Brake Fluid Level Switch 3386
Remove 3386
Install 3388
Service Brake Pedal Position Sensor 3389
Remove 3389
Install 3392
Parking Brake Sensor 3393
Remove 3393
Install 3394
Service Brake Pressure Sensor 3395
Remove 3395
Install 3397
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3398
Remove 3398
Install 3398
Sensor Microswitch (Foot Directional Control Pedal) 3399
Remove 3399
Install 3402
Low Coolant Level Sensor 3403
Remove 3403
Install 3406
Fuel Level Sensor, Gas and Diesel Engines Only 3407
Remove 3407
Install 3408
Armrest Switch 3408
Remove 3408
Install 3410
Seat Sensor (Operator Presence System) 3410
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) 3410
Remove 3410
Install 3411
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3411
Remove 3411
Install 3412
Full Suspension Seats; All Lift Truck Models 3412
Remove 3412
Install 3412
Hood Shut Off Switch 3412
Remove 3412
Install 3415
Remote Key Switch 3416
Remove 3416
Install 3416
Hydraulic Filter Pressure Switch 3417
Remove 3417
Install 3419
Transmission Speed Sensor 3419
Remove 3419
Install 3422
Transmission Pressure Sensors 3423
Remove 3423
Install 3425
Transmission Temperature Sensor 3426
Remove 3426
Install 3428
Engine Speed Sensor 3430
Remove 3430
Install 3430
Intermediate Speed Sensor 3431
Remove 3431
Install 3431
Return to Set Tilt (Tilt Angle) Sensor 3431
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) 3431
Remove 3431
Install 3432
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) 3433
Remove 3433
Install 3434
Rear Horn Button Switch 3434
Remove 3434
Install 3435
Impact Sensor 3436
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) 3436
Remove 3436
Install 3439
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) 3439
Remove 3439
Install 3440
Load Weight Sensor 3441
Remove 3441
Install 3442
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3443
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3443
Crankshaft Position (CKP) Sensor 3443
Camshaft Position (CMP) Sensor 3443
Oil Pressure Sensor 3443
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3443
Engine Coolant Temperature (ECT) Sensor 3444
Air Flow Restriction Switch 3444
Remove for GM 2 4L Gas and LPG Trucks 3444
Install for GM 2 4L Gas and LPG Trucks 3444
Oxygen Sensor 3445
Remove 3445
Install 3448
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3449
Crankshaft Position (CKP) Sensor 3449
Camshaft Position (CMP) Sensor 3449
Oil Pressure Sensor 3449
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3449
Engine Coolant Temperature (ECT) Sensor 3449
Air Flow Restriction Switch 3449
Oxygen Sensor 3449
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3449
Low LPG Pressure Switch 3449
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3450
Air Filter Restriction Switch 3450
Remove 3450
Install 3450
Oil Pressure Sensor 3450
Remove 3450
Install 3450
Engine Speed Sensor 3450
Remove 3450
Install 3450
Engine Coolant Temperature (ECT) Sensor 3450
Remove 3450
Install 3450
Throttle Position Sensor (TPS) 3453
Remove 3453
Install 3454
Fuel/Water Separator Sensor 3454
Remove 3454
Install 3454
Glow Plug Relay 3455
Remove 3455
Install 3457
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3457
Air Filter Restriction Switch 3457
Remove 3457
Install 3457
Engine Oil Pressure Sensor 3462
Remove 3462
Install 3462
Engine Speed Sensor 3462
Remove 3462
Install 3463
Engine Coolant Temperature (ECT) Sensor 3463
Remove 3463
Install 3464
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3465
Remove 3465
Install 3465
Fuel/Water Separator Sensor 3466
Remove 3466
Install 3466
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3467
Intake Air Temperature Sensor 3467
Remove 3467
Install 3468
Intake Air Pressure Sensor 3468
Remove 3468
Install 3468
Air Inlet Heater 3468
Remove 3468
Install 3469
Engine Oil Pressure Sensor 3469
Remove 3469
Install 3469
Engine Coolant Temperature (ECT) Sensor 3469
Remove 3469
Install 3469
Crankshaft Position Sensor 3470
Remove 3470
Install 3470
Adjust Shim Procedure 3471
Camshaft Position Sensor 3472
Remove 3472
Install 3472
Air Flow Restriction Sensor 3473
Remove 3473
Install 3473
Fuel/Water Separator 3473
Remove 3473
Install 3474
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3474
Intake Air Temperature Sensor 3478
Remove 3478
Install 3479
Boost Sensor 3479
Remove 3479
Install 3480
Throttle Valve Assembly and Air Intake Heater 3480
Remove 3480
Install 3480
Engine Coolant Temperature (ECT) Sensor 3481
Remove 3481
Install 3481
Engine Oil Pressure Sensor 3481
Remove 3481
Install 3482
Crankshaft Position Sensor 3482
Remove 3482
Install 3482
Adjust Shim Procedure 3483
Camshaft Position Sensor 3484
Remove 3484
Install 3485
Differential Pressure Sensor 3485
Remove 3485
Install 3485
Mass Air Flow Sensor 3486
Remove 3486
Install 3487
Fuel/Water Separator 3487
Remove 3487
Install 3488
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3488
Engine Coolant Temperature (ECT) Sensor 3489
Remove 3489
Install 3489
Throttle Position Sensor 3490
Engine Oil Pressure Sensor 3490
Remove 3490
Install 3490
Engine Speed Sensor 3490
Remove 3490
Install 3490
Fuel Shut Off Solenoid 3490
Remove 3490
Install 3490
Vehicle System Manager (VSM) 3491
General 3491
VSM Replacement 3491
Remove 3491
Install 3493
Programming a New VSM and/or Display Switch Cluster 3493
General 3493
PC Service Tool Software 3494
Data Transferring 3494
New VSM 3494
New (Blank) Display Switch Cluster 3494
Used (Non-Blank) Display Switch Cluster 3494
Power Distribution Module (PDM) and Component Parts 3496
Remove 3496
PDM as a Unit 3496
Install 3500
PDM as a Unit 3500
Remove and Install 3501
PDM Component Parts 3501
Transmission Control Unit 3501
Remove 3501
Install 3505
Battery 3507
Remove 3507
Install 3507
Lights 3508
Work Lights (Front and Rear) 3508
Remove 3508
Install 3508
Strobe Light 3509
Remove 3509
Install 3509
LED Tail, Backup, and Brake Lights 3510
Remove 3510
Install 3511
Front Marker/Turn Signal Lights 3512
Replacing Whole Front Marker/Turn Signal Light Assembly 3512
Remove 3512
Install 3512
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3513
Remove 3513
Install 3513
Diesel Particulate Filter (DPF) Display 3513
Remove 3513
Clean and Inspect 3514
Install 3514
Electronic-Hydraulic Controls – Generation 1 3515
E-Hydraulic Controls – Test 3515
Mini-Levers 3515
Full Stroke Test 3515
Function Returns to Neutral Test 3515
Push Button Switch 3515
General 3516
Mini-Lever Replacement 3516
Remove 3516
Clean and Inspect 3517
Install 3517
Push Button Switch Replacement 3518
Remove 3518
Install 3520
Mini-Lever Module (MLM) 3520
Remove 3520
Install 3520
Joystick 3521
Remove and Disassemble 3521
Inspect 3521
Assemble and Install 3521
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3522
General 3522
Mini-levers, Remove and Install 3522
Armrest Assembly 3523
Remove 3523
Install 3526
Horn Button 3526
Remove 3526
Install 3526
Direction Control Switch 3527
Remove 3527
Install 3527
push (override) buttons and Toggle Switch 3527
Remove 3528
Install 3529
Joystick 3530
Remove and Disassemble 3530
Inspect 3530
Assemble and Install 3530
Joystick Armrest Slider Assembly 3531
Remove 3531
Install 3532
Electronic-Hydraulic Controls, After January, 2020 3532
E-Hydraulic Controls – TEST 3532
Mini-Levers 3532
Full Stroke Test 3532
Function Returns to Neutral Test 3532
Push (Override) Button 3533
General 3533
Mini-levers, Remove and Install 3533
Armrest Assembly 3534
Remove 3534
Install 3537
Horn Button 3537
Remove 3537
Install 3537
Direction Control Switch 3537
Remove 3537
Install 3538
Push (Override) buttons and Toggle Switch 3538
Remove 3539
Install 3541
Special Tools 3542
524223772-2200YRM1142-(08-2021)-US-EN 3545
General 3555
Display Switch Cluster 3559
Remove 3559
Install 3561
Direction Control and Turn Signal Levers 3561
Remove 3561
Install 3562
Key Switch 3563
Remove 3563
Install 3564
Display Switch Cluster Panel Bezel and Overlay 3564
Remove 3564
Install 3564
Steering Column Repair 3565
Remove 3565
Disassemble 3568
Assemble 3568
Install 3568
Sensors and Switches 3569
General 3569
Dash and Kick Panel, Remove and Install 3569
Remove 3569
Install 3570
Accelerator Pedal Position Sensor 3570
Remove 3570
Install 3574
Brake Fluid Level Switch 3575
Remove 3575
Install 3576
Service Brake Pedal Position Sensor 3578
Remove 3578
Install 3580
Parking Brake Sensor 3581
Remove 3581
Install 3583
Service Brake Pressure Sensor 3583
Remove 3583
Install 3585
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3587
Remove 3587
Install 3587
Sensor Microswitch (Foot Directional Control Pedal) 3587
Remove 3587
Install 3590
Low Coolant Level Sensor 3591
Remove 3591
Install 3594
Fuel Level Sensor, Gas and Diesel Engines Only 3595
Remove 3595
Install 3596
Armrest Switch 3596
Remove 3596
Install 3598
Seat Sensor (Operator Presence System) 3598
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) 3598
Remove 3598
Install 3599
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3599
Remove 3599
Install 3599
Full Suspension Seats; All Lift Truck Models 3600
Remove 3600
Install 3600
Hood Shut Off Switch 3601
Remove 3601
Install 3603
Remote Key Switch 3604
Remove 3604
Install 3604
Hydraulic Filter Pressure Switch 3605
Remove 3605
Install 3607
Transmission Speed Sensor 3607
Remove 3607
Install 3610
Transmission Pressure Sensors 3611
Remove 3611
Install 3613
Transmission Temperature Sensor 3614
Remove 3614
Install 3616
Engine Speed Sensor 3618
Remove 3618
Install 3619
Intermediate Speed Sensor 3619
Remove 3619
Install 3619
Return to Set Tilt (Tilt Angle) Sensor 3620
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) 3620
Remove 3620
Install 3620
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) 3620
Remove 3621
Install 3622
Rear Horn Button Switch 3623
Remove 3623
Install 3623
Impact Sensor 3624
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) 3624
Remove 3624
Install 3626
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) 3626
Remove 3626
Install 3627
Load Weight Sensor 3627
Remove 3627
Install 3629
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3630
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3630
Crankshaft Position (CKP) Sensor 3630
Camshaft Position (CMP) Sensor 3630
Oil Pressure Sensor 3630
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3630
Engine Coolant Temperature (ECT) Sensor 3631
Air Flow Restriction Switch 3631
Remove for GM 2 4L Gas and LPG Trucks 3631
Install for GM 2 4L Gas and LPG Trucks 3631
Oxygen Sensor 3632
Remove 3632
Install 3635
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3636
Crankshaft Position (CKP) Sensor 3636
Camshaft Position (CMP) Sensor 3636
Oil Pressure Sensor 3636
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3636
Engine Coolant Temperature (ECT) Sensor 3636
Air Flow Restriction Switch 3636
Oxygen Sensor 3636
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3636
Low LPG Pressure Switch 3636
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3637
Air Filter Restriction Switch 3637
Remove 3637
Install 3637
Oil Pressure Sensor 3637
Remove 3637
Install 3637
Engine Speed Sensor 3637
Remove 3637
Install 3637
Engine Coolant Temperature (ECT) Sensor 3637
Remove 3637
Install 3637
Throttle Position Sensor (TPS) 3640
Remove 3640
Install 3641
Fuel/Water Separator Sensor 3641
Remove 3641
Install 3641
Glow Plug Relay 3642
Remove 3642
Install 3644
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3644
Air Filter Restriction Switch 3644
Remove 3644
Install 3645
Engine Oil Pressure Sensor 3649
Remove 3649
Install 3649
Engine Speed Sensor 3649
Remove 3649
Install 3650
Engine Coolant Temperature (ECT) Sensor 3650
Remove 3650
Install 3651
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3652
Remove 3652
Install 3652
Fuel/Water Separator Sensor 3653
Remove 3653
Install 3653
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3654
Intake Air Temperature Sensor 3654
Remove 3654
Install 3655
Intake Air Pressure Sensor 3655
Remove 3655
Install 3655
Air Inlet Heater 3655
Remove 3655
Install 3656
Engine Oil Pressure Sensor 3656
Remove 3656
Install 3656
Engine Coolant Temperature (ECT) Sensor 3656
Remove 3656
Install 3656
Crankshaft Position Sensor 3657
Remove 3657
Install 3657
Adjust Shim Procedure 3658
Camshaft Position Sensor 3659
Remove 3659
Install 3659
Air Flow Restriction Sensor 3659
Remove 3659
Install 3660
Fuel/Water Separator 3660
Remove 3660
Install 3661
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3661
Intake Air Temperature Sensor 3665
Remove 3665
Install 3666
Boost Sensor 3666
Remove 3666
Install 3667
Throttle Valve Assembly and Air Intake Heater 3667
Remove 3667
Install 3667
Engine Coolant Temperature (ECT) Sensor 3668
Remove 3668
Install 3668
Engine Oil Pressure Sensor 3669
Remove 3669
Install 3669
Crankshaft Position Sensor 3669
Remove 3669
Install 3669
Adjust Shim Procedure 3670
Camshaft Position Sensor 3672
Remove 3672
Install 3672
Differential Pressure Sensor 3672
Remove 3672
Install 3673
Mass Air Flow Sensor 3673
Remove 3673
Install 3674
Fuel/Water Separator 3675
Remove 3675
Install 3676
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3677
Engine Coolant Temperature (ECT) Sensor 3678
Remove 3678
Install 3678
Throttle Position Sensor 3678
Engine Oil Pressure Sensor 3678
Remove 3678
Install 3678
Engine Speed Sensor 3678
Remove 3678
Install 3678
Fuel Shut Off Solenoid 3679
Remove 3679
Install 3679
Vehicle System Manager (VSM) 3680
General 3680
VSM Replacement 3680
Remove 3680
Install 3682
Programming a New VSM and/or Display Switch Cluster 3682
General 3682
PC Service Tool Software 3683
Data Transferring 3683
New VSM 3683
New (Blank) Display Switch Cluster 3683
Used (Non-Blank) Display Switch Cluster 3683
Power Distribution Module (PDM) and Component Parts 3686
Remove 3686
PDM as a Unit 3686
Install 3689
PDM as a Unit 3689
Remove and Install 3690
PDM Component Parts 3690
Transmission Control Unit (TCU) 3691
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) 3691
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) 3691
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3692
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3692
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 3692
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 3693
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 3694
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 3696
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 3696
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 3696
Battery 3697
Remove 3697
Install 3697
Lights 3698
Work Lights (Front and Rear) 3698
Remove 3698
Install 3698
Strobe Light 3699
Remove 3699
Install 3699
LED Tail, Backup, and Brake Lights 3700
Remove 3700
Install 3701
Front Marker/Turn Signal Lights 3702
Replacing Whole Front Marker/Turn Signal Light Assembly 3702
Remove 3702
Install 3702
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3703
Remove 3703
Install 3703
Diesel Particulate Filter (DPF) Display 3704
Remove 3704
Clean and Inspect 3705
Install 3705
Electronic-Hydraulic Controls – Generation 1 3706
E-Hydraulic Controls – Test 3706
Mini-Levers 3706
Full Stroke Test 3706
Function Returns to Neutral Test 3706
Push Button Switch 3706
General 3707
Mini-Lever Replacement 3707
Remove 3707
Clean and Inspect 3708
Install 3708
Push Button Switch Replacement 3709
Remove 3709
Install 3711
Mini-Lever Module (MLM) 3711
Remove 3711
Install 3711
Joystick 3712
Remove and Disassemble 3712
Inspect 3712
Assemble and Install 3712
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3713
General 3713
Mini-levers, Remove and Install 3713
Armrest Assembly 3714
Remove 3714
Install 3717
Horn Button 3717
Remove 3717
Install 3717
Direction Control Switch 3718
Remove 3718
Install 3718
push (override) buttons and Toggle Switch 3718
Remove 3719
Install 3720
Joystick 3721
Remove and Disassemble 3721
Inspect 3721
Assemble and Install 3721
Joystick Armrest Slider Assembly 3722
Remove 3722
Install 3723
Electronic-Hydraulic Controls, After January, 2020 3724
E-Hydraulic Controls – TEST 3724
Mini-Levers 3724
Full Stroke Test 3724
Function Returns to Neutral Test 3724
Push (Override) Button 3724
General 3725
Mini-levers, Remove and Install 3725
Armrest Assembly 3726
Remove 3726
Install 3729
Horn Button 3729
Remove 3729
Install 3729
Direction Control Switch 3729
Remove 3729
Install 3730
Push (Override) buttons and Toggle Switch 3730
Remove 3731
Install 3733
Special Tools 3734
524223779-8000YRM1152-(03-2020)-UK-EN 3737
General Information About Diagrams and Schematics 3741
Symbol Definitions 3741
Diagrams Manual Applications 3742
Diagrams and Schematics 3744
524223779-8000YRM1152-(06-2021)-US-EN 3807
General Information About Diagrams and Schematics 3811
Symbol Definitions 3811
Diagrams Manual Applications 3812
Diagrams and Schematics 3814
524223780-8000YRM1134-(03-2020)-UK-EN 3875
Series Code / Model Designation Reference Table 3881
Description 3883
Proc_Cal_001: Service Password Entry 3885
When to Perform 3885
Why Perform 3885
How to Perform 3885
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3886
When to Perform 3886
Calibration Order 3886
Why Perform 3886
How to Perform 3887
Proc_Cal_003: Save and Exit 3888
When to Perform 3888
Why Perform 3888
How to Perform 3888
Proc_Cal_004: Lift Valve Output Threshold 3889
When to Perform 3889
Calibration Order 3889
Why Perform 3889
How to Perform 3890
Proc_Cal_005: Lower Valve Output Threshold 3892
When to Perform 3892
Calibration Order 3892
Why Perform 3892
How to Perform 3892
Proc_Cal_006: Tilt Back Valve Output Threshold 3895
When to Perform 3895
Calibration Order 3895
Why Perform 3895
How to Perform 3895
Proc_Cal_007: Tilt Forward Valve Output Threshold 3898
When to Perform 3898
Calibration Order 3898
Why Perform 3898
How to Perform 3898
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3901
When to Perform 3901
Calibration Order 3901
Why Perform 3901
How to Perform 3901
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3904
When to Perform 3904
Calibration Order 3904
Why Perform 3904
How to Perform 3904
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3907
When to Perform 3907
Calibration Order 3907
Why Perform 3907
How to Perform 3907
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3910
When to Perform 3910
Calibration Order 3910
Why Perform 3910
How to Perform 3910
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3913
When to Perform 3913
Calibration Order 3913
Why Perform 3913
How to Perform 3913
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3916
When to Perform 3916
Calibration Order 3916
Why Perform 3916
How to Perform 3916
Proc_Cal_014: Load Weight Zero Point 3920
When to Perform 3920
Calibration Order 3920
Why Perform 3920
How to Perform 3920
Proc_Cal_015: Loaded Weight Calibration 3922
When to Perform 3922
Calibration Order 3922
Why Perform 3922
How to Perform 3922
Proc_Cal_016: Transmission Valve Calibration 3925
Applicable System/Option 3925
When to Perform 3925
Calibration Order 3925
Why Perform 3925
How to Perform 3925
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3927
Applicable System/Option 3927
When to Perform 3927
Calibration Order 3927
Why Perform 3927
How to Perform 3927
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3929
Applicable System/Option 3929
When to Perform 3929
Calibration Order 3929
Why Perform 3929
How to Perform 3930
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3931
Required Tools 3931
When to Perform 3931
Calibration Order 3931
Why Perform 3932
How to Perform 3932
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3933
When to Perform 3933
Why Perform 3933
How to Perform 3933
Proc_Cal_026: Travel Speed Calibration 3935
When to Perform 3935
Calibration Order 3935
Why Perform 3935
How to Perform 3935
524223780-8000YRM1134-(05-2022)-US-EN 3939
Series Code / Model Designation Reference Table 3945
Description 3948
Proc_Cal_001: Service Password Entry 3950
When to Perform 3950
Why Perform 3950
How to Perform 3950
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3951
When to Perform 3951
Calibration Order 3951
Why Perform 3951
How to Perform 3951
Proc_Cal_003: Save and Exit 3953
When to Perform 3953
Why Perform 3953
How to Perform 3953
Proc_Cal_004: Lift Valve Output Threshold 3954
When to Perform 3954
Calibration Order 3954
Why Perform 3954
How to Perform 3954
Proc_Cal_005: Lower Valve Output Threshold 3957
When to Perform 3957
Calibration Order 3957
Why Perform 3957
How to Perform 3957
Proc_Cal_006: Tilt Back Valve Output Threshold 3960
When to Perform 3960
Calibration Order 3960
Why Perform 3960
How to Perform 3960
Proc_Cal_007: Tilt Forward Valve Output Threshold 3963
When to Perform 3963
Calibration Order 3963
Why Perform 3963
How to Perform 3963
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3966
When to Perform 3966
Calibration Order 3966
Why Perform 3966
How to Perform 3966
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3969
When to Perform 3969
Calibration Order 3969
Why Perform 3969
How to Perform 3969
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3972
When to Perform 3972
Calibration Order 3972
Why Perform 3972
How to Perform 3972
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3975
When to Perform 3975
Calibration Order 3975
Why Perform 3975
How to Perform 3975
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3978
When to Perform 3978
Calibration Order 3978
Why Perform 3978
How to Perform 3978
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3981
When to Perform 3981
Calibration Order 3981
Why Perform 3981
How to Perform 3981
Proc_Cal_014: Load Weight Zero Point 3984
When to Perform 3984
Calibration Order 3984
Why Perform 3984
How to Perform 3984
Proc_Cal_015: Loaded Weight Calibration 3986
When to Perform 3986
Calibration Order 3986
Why Perform 3986
How to Perform 3986
Proc_Cal_016: Transmission Valve Calibration 3989
Applicable System/Option 3989
When to Perform 3989
Calibration Order 3989
Why Perform 3989
How to Perform 3989
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3991
Applicable System/Option 3991
When to Perform 3991
Calibration Order 3991
Why Perform 3991
How to Perform 3991
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3994
Applicable System/Option 3994
When to Perform 3994
Calibration Order 3994
Why Perform 3994
How to Perform 3994
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3997
Required Tools 3997
When to Perform 3997
Calibration Order 3997
Why Perform 3997
How to Perform 3997
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3999
When to Perform 3999
Why Perform 3999
How to Perform 3999
Proc_Cal_026: Travel Speed Calibration 4001
When to Perform 4001
Calibration Order 4001
Why Perform 4001
How to Perform 4001
524262275-0900YRM1242-(04-2018)-US-EN 4005
General 4011
Hoses Replacement 4011
LPG Tank and Bracket Replacement 4012
LPG Tank, Lift Truck Models GLC40, 45, 55VX; GLC55SVX; GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813, H813), and GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879) 4012
Remove 4012
Install 4015
LPG Tank Bracket, Lift Truck Models GLC40, 45, 55VX; GLC55SVX; GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813, H813), and GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879) 4016
Remove 4016
Install 4016
LPG Tank Bracket Alignment Pin, Lift Truck Models GLC40, 45, 55VX; GLC55SVX; GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813, H813), and GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879) 4016
Remove 4016
Install 4018
LPG Tank, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 4019
Remove 4019
Install 4021
LPG Tank Bracket, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 4021
Remove 4021
Install 4021
High Pressure Fuel Filter Unit Repair 4021
Fuel Filter Element 4022
Remove 4022
Clean/Inspect 4023
Install 4023
Fuel Filter Housing 4023
Remove 4023
Disassemble 4024
Assemble 4024
Install 4024
Electronic Throttle Body Repair 4025
Remove 4025
Clean/Inspect 4026
Install 4026
Fuel Injector Repair 4027
Fuel Rail 4027
Remove for Lift Trucks Built Before January, 2010 4027
Remove for Lift Trucks Built After January, 2010 4029
Install for Lift Trucks Built Before January, 2010 4030
Install for Lift Trucks Built After January, 2010 4031
Fuel Injectors and Adapters 4031
Remove for Lift Trucks Built Before January, 2010 4031
Remove for Lift Trucks Built After January, 2010 4033
Clean 4034
Install for Lift Trucks Built Before January, 2010 4034
Install for Lift Trucks Built After January, 2010 4036
LPG Regulator Repair 4036
LPG Regulator 4036
Remove for Lift Trucks Built Before January, 2010 4036
Remove for Lift Trucks Built After January, 2010 4037
Install for Lift Trucks Built Before January, 2010 4039
Install for Lift Trucks Built After January, 2010 4039
LPG Regulator Fuel Filter 4040
Remove 4040
Install 4041
Lock-Off Solenoid and Cartridge 4041
Remove 4041
Install 4042
Control System 4042
Electronic Control Unit (ECU) and Injector Driver Modules Assembly 4042
Remove 4042
Install 4043
Electronic Control Unit (ECU) 4044
Remove 4044
Install 4044
Injector Driver Modules 4045
Remove 4045
Install 4045
Fuel Pressure Sensor 4046
Remove 4046
Install 4046
Low LPG Pressure Switch 4046
Remove 4046
Install 4047
LPG Pressure Sensor 4047
Remove 4047
Install 4048
Oxygen Sensor 4048
Exhaust System Repair 4049
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 4049
Remove for Lift Trucks Built Before January, 2010 4049
Remove for Lift Trucks Built After January, 2010 4051
Inspect 4053
Install for Lift Trucks Built Before January, 2010 4053
Install for Lift Trucks Built After January, 2010 4053
GM 4 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) 4054
Remove for Lift Trucks Built Before January, 2010 4054
Remove for Lift Trucks Built After January, 2010 4056
Inspect 4059
Install for Lift Trucks Built Before January, 2010 4059
Install for Lift Trucks Built After January, 2010 4060
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 4061
Remove for Lift Trucks Built Before January, 2010 4061
Remove for Lift Trucks Built After January, 2010 4064
Inspect 4065
Install for Lift Trucks Built Before January, 2010 4066
Install for Lift Trucks Built After January, 2010 4066
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4067
Remove for Lift Trucks Built Before January, 2010 4067
Remove for Lift Trucks Built After January, 2010 4070
Inspect 4071
Install for Lift Trucks Built Before January, 2010 4072
Install for Lift Trucks Built After January, 2010 4072
Oxygen Sensor 4073
Remove 4073
Install 4074
LPG Fuel Testing 4074
General 4074
Available Fuel Tests 4074
Composition Test (ASTM D-2163) 4074
Ammonia Test (ASTM D-4490) 4075
Basic Nitrogen Test (ASTM UOP269-90) 4075
Residues Test (ASTM D-2158) 4075
Vapor Pressure Test (ASTM D-2598) 4075
Sulfur Compounds Test (ASTM D-5623) 4075
Methanol Test (ASTM D-4864) 4075
Copper Corrosion (ASTM D-1838) 4075
Where To Send LPG Fuel Samples For Testing 4075
524262276-0900YRM1244-(06-2012)-US-EN 4079
toc 4079
Gasoline Fuel System 4079
Safety Precautions Maintenance and Repair 4080
General 4083
Electronic Throttle Body Repair 4083
Electronic Throttle Body 4083
Remove 4083
Clean/Inspect 4083
Install 4084
Fuel System Repair 4085
Before Repair Procedure 4085
After Repair Procedure 4085
Fuel Leakage Check for Lift Trucks Built Before January, 2010 4085
Fuel Leakage Check for Lift Trucks Built After January, 2010 4086
Fuel Line Pressure Check 4088
Fuel Injector Repair 4089
Remove 4089
Install 4099
Control System 4100
Electronic Control Unit (ECU) 4100
Remove for Lift Trucks Built Before January, 2010 4100
Remove for Lift Trucks Built After January, 2010 4101
Install for Lift Trucks Built Before January, 2010 4102
Install for Lift Trucks Built After January, 2010 4103
Exhaust System Repair 4104
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; ( 4104
Remove for Lift Trucks Built Before January, 2010 4104
Remove for Lift Trucks Built After January, 2010 4106
Inspect 4106
Install for Lift Trucks Built Before January, 2010 4108
Install for Lift Trucks Built After January, 2010 4108
GM 4 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45 4109
Remove for Lift Trucks Built Before January, 2010 4109
Remove for Lift Trucks Built After January, 2010 4111
Inspect 4113
Install for Lift Trucks Built Before January, 2010 4113
Install for Lift Trucks Built After January, 2010 4114
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (G 4115
Remove for Lift Trucks Built Before January, 2010 4115
Remove for Lift Trucks Built After January, 2010 4117
Inspect 4119
Install for Lift Trucks Built Before January, 2010 4119
Install for Lift Trucks Built After January, 2010 4120
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (G 4120
Remove for Lift Trucks Built Before January, 2010 4120
Remove for Lift Trucks Built After January, 2010 4123
Inspect 4123
Install for Lift Trucks Built Before January, 2010 4125
Install for Lift Trucks Built After January, 2010 4125
Oxygen Sensor 4126
Remove 4126
Install 4126
524262279-1800YRM1247-(06-2021)-US-EN 4129
General 4133
Dry Brake System 4133
Wet Brake System 4133
Service Brakes Repair (Dry Brake) 4137
Remove and Disassemble 4137
Clean 4139
Inspect 4140
Assemble and Install 4141
Adjust 4144
Parking Brake Repair 4145
Dry Brake System 4145
Remove and Disassembly 4145
Assemble and Install 4147
Wet Brake System 4147
Remove and Install 4147
Assemble and Install 4154
Adjust 4154
Dry Brake System 4154
Wet Brake System 4155
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 4155
Master Cylinder Repair 4157
Remove 4157
Disassemble 4161
Clean and Inspect 4162
Assemble 4163
Install and Adjust 4163
Accumulator 4166
Pre-Charge Check 4166
Remove 4167
Install 4169
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 4170
Remove 4170
Modulating Brake Valve 4172
Disassemble 4172
Clean and Inspect 4173
Assemble 4173
Accumulator Charge Valve 4174
Disassemble 4174
Clean and Inspect 4176
Assemble 4176
Install 4177
Pressure Checks 4178
Accumulator Charge Valve Check 4178
Accumulator Check 4178
Service Brakes Adjustment (Dry Brake) 4179
Service Brakes Adjustment 4179
Brake System Air Removal 4181
Using Pressure Bleed System 4181
Using Brake Pedal Pressure 4181
Lift Truck Models with Master Cylinder 4181
Lift Truck Models with Modulating Brake Valve 4182
Brake Pedal Adjustment 4183
For Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813), GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879), and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4183
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4184
Free Pedal Adjustment 4186
Torque Specifications 4187
524262279-1800YRM1247-(09-2018)-UK-EN 4189
General 4193
Dry Brake System 4193
Wet Brake System 4194
Service Brakes Repair (Dry Brake) 4198
Remove and Disassemble 4198
Clean 4200
Inspect 4201
Assemble and Install 4201
Adjust 4205
Parking Brake Repair 4205
Dry Brake System 4206
Remove and Disassembly 4206
Assemble and Install 4208
Wet Brake System 4208
Remove and Install 4209
Assemble and Install 4215
Adjust 4215
Dry Brake System 4215
Wet Brake System 4216
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 4216
Master Cylinder Repair 4217
Remove 4217
Disassemble 4222
Clean and Inspect 4223
Assemble 4224
Install and Adjust 4224
Accumulator 4226
Pre-Charge Check 4227
Remove 4228
Install 4230
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 4230
Remove 4231
Modulating Brake Valve 4232
Disassemble 4232
Clean and Inspect 4234
Assemble 4234
Accumulator Charge Valve 4235
Disassemble 4235
Clean and Inspect 4237
Assemble 4237
Install 4238
Pressure Checks 4239
Accumulator Charge Valve Check 4239
Accumulator Check 4239
Service Brakes Adjustment (Dry Brake) 4240
Service Brakes Adjustment 4240
Brake System Air Removal 4241
Using Pressure Bleed System 4241
Using Brake Pedal Pressure 4242
Lift Truck Models with Master Cylinder 4242
Lift Truck Models with Modulating Brake Valve 4242
Brake Pedal Adjustment 4243
For Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4243
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4244
Free Pedal Adjustment 4246
Torque Specifications 4247
524265337-0600YRM1251-(09-2015)-US-EN 4251
General 4257
Engine Removal and Installation 4257
Cylinder Head Repair 4257
Remove and Disassemble 4257
Clean and Inspect 4259
Valve Oil Seals 4262
Remove and Disassemble 4262
Cylinder Leak Down Test 4262
Clean and Inspect 4263
Assemble and Install 4263
Valve Guides and Seats, Repairs 4265
Valves, Repair 4265
Valve Seats, Repair 4266
Valve Springs 4267
Assemble and Install 4268
Engine Block Cleaning and Inspection 4271
Clean and Inspect 4272
Piston Bore Preparation 4274
Engine Mounts Installation 4274
Remove 4274
Clean and Inspect 4275
Install 4275
Lubrication System Repair 4276
Oil Pump, Remove and Disassemble 4276
Clean and Inspect 4277
Oil Pump, Assemble and Install 4278
Oil Pan, Install 4280
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4282
Timing Cover 4282
Remove 4282
Install 4284
Timing Sprockets 4284
Remove 4284
Install 4284
Camshaft 4284
Remove 4284
Inspect 4285
Install 4285
Balance Shaft 4286
Remove 4286
Install 4287
Valve Lifters 4288
Remove 4288
Clean and Inspect 4288
Install 4289
Crankshaft Repair 4289
Remove 4290
Inspect and Repair 4290
How to Check Clearance Between Main Bearings and Their Journals 4291
Install 4292
Piston and Connecting Rod Assemblies Repair 4294
Connecting Rod Bearings, Replace 4294
Piston and Connecting Rod Assemblies, Remove 4295
Disassemble 4295
Piston, Clean and Inspect 4296
Cylinder Bores, Inspect and Repair 4296
Piston Rings 4297
Assemble 4298
Piston and Connecting Rod Assemblies, Install 4298
Flywheel and Flywheel Housing Repair 4298
Flywheel, Remove 4299
Clean 4299
Inspect 4299
Flywheel, Install 4300
Coolant Pump Repair 4300
Remove 4300
Clean and Inspect 4301
Install 4301
Thermostat Replacement 4301
Remove 4302
Thermostat Operation Check 4302
Install 4302
Starter Replacement 4303
4303
Remove 4303
Install 4306
Fan Assembly Replacement 4307
Remove 4307
Inspect 4309
Install 4309
Drive Belt Installation 4310
Remove 4310
Clean 4310
Inspect 4310
Installation 4311
Compression Check 4312
Engine Specifications 4312
Engine Data 4312
Cylinder Head 4312
Hydraulic Valve Lifter 4313
Camshaft 4313
Pistons 4313
Crankshaft 4314
Connecting Rods 4314
Balance Shaft 4315
Cooling System 4315
Lubrication System 4315
Torque Specifications 4316
524265342-4000YRM1250-(06-2021)-US-EN 4321
Safety Procedures When Working Near Mast 4327
Fork Replacement 4330
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4330
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4331
Remove, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 4333
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4334
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4335
Install, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017 GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 4336
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4336
Checks, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 4337
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4338
Fixed Carriage Replacement 4340
Remove, Carriage With Hook Forks 4340
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4348
Install, Carriage With Hook Forks 4349
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4349
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4350
Connecting Attachment Hydraulic Quick Disconnect Hoses 4350
Integral Sideshift Carriage Repair 4351
Remove, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 4351
Disassemble 4351
Clean and Inspect 4354
Assemble 4354
Install, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 4355
Hang On Sideshift Carriage Repair 4356
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 4356
Disassemble 4368
Clean and Inspect 4377
Assemble 4378
Install 4379
Hang-On Sideshift Carriage Repair 4381
Remove 4381
Disassemble Carriage 4383
Clean and Inspect 4386
Assemble 4386
Install 4389
Fork Positioner 4392
Two-Stage Mast With Limited Free-Lift Repair 4393
Remove 4393
Disassemble 4396
Clean and Inspect 4399
Assemble 4417
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4419
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879), and ERC35-55HG (ERC70-120HH) (C839) 4421
Header Hose Alignment 4432
Two-Stage Mast With Full Free-Lift Repair 4443
Remove 4443
Disassemble 4445
Clean and Inspect 4456
Assemble 4457
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 4459
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and ERC35-55HG (ERC70-120HH) (C839) 4462
Header Hose Installation and Adjustment 4466
Installation 4466
Adjustment 4467
Three-Stage Mast With Full Free-Lift Repair 4468
Remove 4468
Disassemble 4470
Clean and Inspect 4500
Assemble 4502
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX, (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4505
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GC/GLC/GDC60VX, GC/GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879), and ERC35-55HG (ERC70-120HH) (C839) 4510
Header Hose Alignment for GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813), and ERC35-55HG (ERC70-120HH) (C839) 4517
Header Hose Alignment for GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GC/GLC/GDC60VX, GC/GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 4524
Mast Operation Check 4528
Tilt Cylinder Adjustment 4529
Lift Chains Adjustment 4529
Mast Adjustments 4531
Load Roller Adjustment 4531
Mast Side Kicking Adjustment 4533
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4534
Carriage Adjustments 4536
Series Code / Model Designation Reference Table 4537
524265342-4000YRM1250-(09-2018)-UK-EN 4541
Safety Procedures When Working Near Mast 4547
Fork Replacement 4549
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4549
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4551
Remove, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 4552
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4553
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4554
Install, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017 GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 4555
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4555
Checks, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 4557
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4557
Fixed Carriage Replacement 4559
Remove, Carriage With Hook Forks 4559
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4568
Install, Carriage With Hook Forks 4569
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4569
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4570
Connecting Attachment Hydraulic Quick Disconnect Hoses 4570
Integral Sideshift Carriage Repair 4571
Remove, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 4571
Disassemble 4571
Clean and Inspect 4574
Assemble 4574
Install, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 4575
Hang On Sideshift Carriage Repair 4575
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4575
Disassemble 4587
Clean and Inspect 4596
Assemble 4597
Install 4598
Bolzoni Hang-On Sideshift Carriage Repair 4600
Remove 4600
Disassemble Carriage 4602
Clean and Inspect 4605
Assemble 4605
Install 4608
Fork Positioner 4610
Two-Stage Mast With Limited Free-Lift Repair 4611
Remove 4611
Disassemble 4615
Clean and Inspect 4618
Assemble 4635
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4637
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), and ERC35-55HG (ERC70-120HH) (C839) 4638
Header Hose Alignment 4650
Two-Stage Mast With Full Free-Lift Repair 4660
Remove 4660
Disassemble 4662
Clean and Inspect 4674
Assemble 4675
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 4677
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and ERC35-55HG (ERC70-120HH) (C839) 4680
Header Hose Installation and Adjustment 4684
Installation 4684
Adjustment 4684
Three-Stage Mast With Full Free-Lift Repair 4685
Remove 4685
Disassemble 4687
Clean and Inspect 4717
Assemble 4718
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX, (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4722
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), and ERC35-55HG (ERC70-120HH) (C839) 4727
Header Hose Alignment for GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813), and ERC35-55HG (ERC70-120HH) (C839) 4734
Header Hose Alignment for GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4740
Mast Operation Check 4744
Tilt Cylinder Adjustment 4744
Lift Chains Adjustment 4745
Mast Adjustments 4746
Load Roller Adjustment 4746
Mast Side Kicking Adjustment 4748
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4749
Carriage Adjustments 4752
524288189-0100YRM1316-(01-2022)-US-EN 4755
General 4759
Description 4760
Hood, Seat, Dash, and Side Covers Replacement 4762
Remove 4762
Install 4768
Steering Column 4772
Description 4772
Steering Column Repair 4772
Remove 4772
Disassemble 4773
Clean 4775
Inspect 4775
Assemble 4775
Install 4775
LPG Tank and Bracket Replacement 4775
Counterweight Replacement 4776
Remove 4776
Install 4777
Tow Pin, Remove and Install 4779
Overhead Guard Replacement 4780
Remove 4780
Install 4781
LED Tail, Backup, and Brake Lights, Replace 4782
Operator Restraint System Replacement 4783
Description 4783
Engine Replacement 4785
Remove Engine Only 4785
Install Engine only 4811
Remove Engine and Transmission 4814
Install Engine and Transmission 4816
Electronic Throttle Replacement 4820
Cummins 4 5L Diesel Engine With Electronic Throttle 4820
Remove 4820
Install 4824
Pull Actuator Linkage Adjustment 4826
Low Idle Adjustment 4826
Throttle Pedal and Cable Adjustment 4827
Cummins 4 5L Diesel Engine 4827
Exhaust System Repair 4829
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4829
PSI 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4829
Cummins QSB 3 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4829
Remove 4829
Inspect 4829
Install 4832
Cummins 4 5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4832
Remove 4832
Inspect 4834
Install 4834
Kubota 3 8L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 4834
Remove 4834
Inspect 4837
Install 4837
Kubota 3 8L Diesel Engine w/DPF for Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) 4837
Remove 4837
Inspect 4840
Install 4840
Kubota 3 8L Diesel Engine w/DOC for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) 4840
Remove 4840
Inspect 4843
Install 4843
Cooling System 4844
Description 4844
Hydraulic Filter Assembly Repair 4845
Remove 4845
Disassemble 4845
Clean 4846
Inspect 4846
Assemble 4846
Install 4846
Fuel and Hydraulic Tanks Repair 4847
Inspect 4847
Clean 4847
Steam Method of Cleaning 4847
Chemical Solution Method of Cleaning 4848
Additional Preparations for Repair 4849
Small Leaks, Repair 4849
Large Leaks, Repair 4849
Preparations for Use After Repair 4849
Safety Labels 4850
524288189-0100YRM1316-(11-2017)-UK-EN 4857
General 4861
Description 4861
Hood, Seat, Dash, and Side Covers Replacement 4862
Remove 4863
Install 4868
Steering Column 4871
Description 4871
Steering Column Repair 4871
Remove 4871
Disassemble 4873
Clean 4874
Inspect 4874
Assemble 4874
Install 4874
LPG Tank and Bracket Replacement 4874
Counterweight Replacement 4874
Remove 4875
Install 4876
Tow Pin, Remove and Install 4878
Overhead Guard Replacement 4878
Remove 4878
Install 4879
LED Tail, Backup, and Brake Lights, Replace 4880
Operator Restraint System Replacement 4880
Description 4881
Engine Replacement 4882
Remove Engine Only 4882
Install Engine only 4904
Remove Engine and Transmission 4908
Install Engine and Transmission 4911
Electronic Throttle Replacement 4913
Cummins 4 5L Diesel Engine With Electronic Throttle 4913
Remove 4913
Install 4917
Pull Actuator Linkage Adjustment 4919
Low Idle Adjustment 4919
Throttle Pedal and Cable Adjustment 4919
Cummins 4 5L Diesel Engine 4920
Exhaust System Repair 4921
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4922
PSI 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4922
Cummins QSB 3 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4922
Remove 4922
Inspect 4922
Install 4924
Cummins 4 5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4924
Remove 4924
Inspect 4925
Install 4925
Kubota 3 8L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 4927
Remove 4927
Inspect 4927
Install 4928
Kubota 3 8L Diesel Engine w/DPF for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4929
Remove 4929
Inspect 4931
Install 4931
Kubota 3 8L Diesel Engine w/DOC for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4931
Remove 4931
Inspect 4932
Install 4932
Cooling System 4935
Description 4936
Hydraulic Filter Assembly Repair 4936
Remove 4936
Disassemble 4936
Clean 4936
Inspect 4937
Assemble 4937
Install 4937
Fuel and Hydraulic Tanks Repair 4937
Inspect 4938
Clean 4938
Steam Method of Cleaning 4938
Chemical Solution Method of Cleaning 4939
Additional Preparations for Repair 4940
Small Leaks, Repair 4940
Large Leaks, Repair 4940
Preparations for Use After Repair 4940
Safety Labels 4940
524288194-1300YRM1317-(03-2020)-UK-EN 4947
Transmission Repair 4951
Remove 4951
Torque Converter, Remove 4951
Disassemble 4952
Clean and Inspect 5001
Housings 5001
Oil Seals and Gaskets 5001
Bearings 5001
Gears and Shafts 5002
Assemble 5002
Torque Converter, Install 5043
Install 5044
Control Valve Repair 5045
Remove 5045
Disassemble 5045
Clean 5047
Inspect 5047
Assemble 5047
Install 5048
Torque Specification 5049
524288194-1300YRM1317-(06-2021)-US-EN 5051
Transmission Repair 5055
Remove 5055
Torque Converter, Remove 5055
Disassemble 5056
Clean and Inspect 5107
Housings 5107
Oil Seals and Gaskets 5107
Bearings 5107
Gears and Shafts 5108
Assemble 5108
Torque Converter, Install 5150
Install 5151
Control Valve Repair 5152
Remove 5152
Disassemble 5152
Clean 5154
Inspect 5154
Assemble 5154
Install 5155
Torque Specification 5156
524288199-1400YRM1318-(06-2021)-US-EN 5159
General 5163
Identification Plate 5163
Drive Axle Removal 5163
Planetary Reduction Gear Repair 5171
Clean and Inspect 5178
Brake Repair 5186
Clean and Inspect 5193
Wet Brake Noise Reduction 5204
General 5204
Adding Additive To Transmission 5204
Differential Repair 5206
Clean and Inspect 5215
Bevel Pinion 5227
Clean and Inspect 5231
Drive Axle Installation 5242
Special Tools 5250
Torque Specifications 5251
524288199-1400YRM1318-(09-2018)-UK-EN 5253
General 5257
Identification Plate 5257
Drive Axle Removal 5257
Planetary Reduction Gear Repair 5264
Clean and Inspect 5272
Brake Repair 5279
Clean and Inspect 5287
Wet Brake Noise Reduction 5297
General 5297
Adding Additive To Transmission 5297
Differential Repair 5298
Clean and Inspect 5308
Bevel Pinion 5320
Clean and Inspect 5324
Drive Axle Installation 5334
Special Tools 5341
Torque Specifications 5341
524288204-8000YRM1319-(12-2018)-US-EN 5345
General 5351
Serial Number Data 5351
How to Move Disabled Lift Truck 5352
How to Tow Lift Truck 5352
How to Put Lift Truck on Blocks 5353
How to Raise Drive Tires 5353
How to Raise Steering Tires 5353
How to Clean a Lift Truck 5354
Maintenance Schedule 5355
Maintenance Procedures Every 8 Hours or Daily 5374
How to Make Checks With Engine Stopped 5375
Tires and Wheels 5375
Safety Labels 5375
Mast, Carriage, Lift Chains, Header Hoses, Attachment 5376
Operator Restraint System 5376
Emergency Locking Retractor (ELR) 5376
Adjust Seat – Full Suspension 5377
Adjust Seat – Internal Suspension 5379
Hood and Seat Latches 5379
Engine Compartment 5380
Paper Application 5380
Fuel, Oil, and Coolant Leaks, Check 5380
Hydraulic Hoses 5381
Coolant Hoses 5381
Steering Column Gas Cylinder 5381
Transmission 5381
Hydraulic System Oil 5381
Engine Oil 5383
Air Filter 5387
Forks 5387
Remove 5387
Inspect 5388
Install 5388
Adjust 5389
Hang On Sideshift Carriage 5389
How to Make Checks With Engine Running 5390
Indicator Lights, Horn, Fuses, and Relays 5390
Service Brakes 5392
Brake Oil Level 5392
Operation, Check 5393
Parking Brake 5393
Engine Oil Pressure 5393
Cooling System 5393
Steering System 5394
Control Levers and Pedals 5394
Lift System, Operate 5395
Air Filter 5395
Fuel/Water Separator Filter, Cummins 4 5L and QSB 3 3L Diesel Engine 5395
First Service After First 100 Hours of Operation 5395
GM 4 3L Engine Oil and Oil Filter 5396
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 5396
Maintenance Procedures Every 250 Hours or 6 Months 5396
GM 4 3L Engine Oil and Oil Filter Change 5396
Drive Belt 5397
GM 4 3L Engine 5397
Fan and Alternator Drive Belt 5397
Drain Tar From LPG Regulator 5398
Drain Tar From LPG Converter 5399
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine 5400
Maintenance Procedures Every 500 Hours or 6 Months 5401
Hydraulic System Oil 5402
Hydraulic Tank Breather 5404
Inspect 5404
Battery 5405
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 5405
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 5406
Remove 5406
Install 5406
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 5408
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 5409
Controlled Venting 5409
Manual Bleeding 5409
Low Idle Speed Adjustment, Cummins 4 5L Engine Only 5409
Drive Belt 5410
Cummins 4 5L and QSB 3 3L Diesel Engine 5410
Fan and Alternator Drive Belt 5410
Clean Debris From Radiator Core 5411
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 5411
Wet Brake Center Body Oil Level Check 5412
Forks 5416
Mast Lubrication 5416
Header Hose Checks 5421
Lift Chain Lubrication 5421
Tilt Cylinder Lubrication 5421
Master Brake Cylinder Rod End Pin Lubrication 5422
Manual Hydraulic Levers Lubrication 5423
Brake Oil 5423
Tie Rod Lubrication 5424
Parking Brake Adjustment 5424
Maintenance Procedures Every 1000 Hours or 6 Months 5425
Valve Clearance, Check and Adjust 5425
Ignition System 5425
GM 4 3L Engine 5425
LPG Fuel Filter Element Replace, GM 4 3L Engine 5425
Remove 5425
Install 5426
In-Line Filter Replacement, Cummins 4 5L Engine 5426
Remove 5426
Install 5427
Lift Chains Wear Check 5428
Lift Chain Lubrication 5428
Hang On Sideshift Carriage, Check Sliding Surfaces 5429
Steering Axle Spindle Bearings 5432
Control Levers and Pedals 5433
Inspect Engine Electrical System, Connectors 5433
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 5434
Parking Brake Lever Lubrication, Wet Brake Axle 5438
Normal Operating Environment 5438
Heavy Duty or Contaminated Environment 5439
Remove 5439
Clean and Inspect 5440
Install 5440
Maintenance Procedures Every 2000 Hours or Annually 5440
Hydraulic System 5441
Hydraulic Filter Assembly, Replace 5441
Hydraulic Tank Breather, Replace 5442
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 5442
Cooling System Check 5442
Air Filter 5444
Oxygen Sensor, GM 4 3L Engine Equipped With GFI Installed 5446
LPG Regulator Fuel Filter, GM 4 3L Engines with GFI Installed 5447
Remove 5447
Install 5448
Gasoline Fuel Filter 5448
Remove and Replace 5448
LPG Fuel Injector, GM 4 3L Engines with GFI Installed 5449
Gasoline Fuel Injector, GM Engines 5449
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 5449
Forks 5449
Brake Oil (Master Cylinder), Change 5449
Test Regulator PressureLPG/GAS 5450
Check Throttle Shaft for Sticking 5450
Inspect Exhaust Manifold and Piping for Leaks 5450
Transmission Automatic Clutch Calibration 5450
Brake System Accumulator 5450
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 5450
Wheel Bearings 5451
Steer Wheels, Lubrication 5451
Maintenance Procedures Every 4000 Hours or 2 Years 5451
Hydraulic Oil, Replace 5452
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 5454
Safety Procedures When Working Near Mast 5456
Fuel Filter Water Removal 5459
Hood Latch Check 5459
Lift Chain Adjustments 5460
Jump-Starting the Lift Truck 5462
Jump-Starting Using a Battery Charger 5462
Jump-Starting a Lift Truck Using Another Lift Truck 5462
Welding Repairs 5463
Overhead Guard Changes 5463
Wheel and Tire Replacement 5464
General 5464
Solid Rubber Tire, Change 5464
Remove and Install Tire on Wheel 5464
Adhesives and Sealants 5466
524288207-8000YRM1319-(05-2019)-UK-EN 5469
General 5475
Serial Number Data 5475
How to Move Disabled Lift Truck 5475
How to Tow Lift Truck 5475
How to Put Lift Truck on Blocks 5477
How to Raise Drive Tires 5477
How to Raise Steering Tires 5477
How to Clean a Lift Truck 5478
Maintenance Schedule 5479
Maintenance Procedures Every 8 Hours or Daily 5496
How to Make Checks With Engine Stopped 5497
Tires and Wheels 5497
Safety Labels 5497
Mast, Carriage, Lift Chains, Header Hoses, Attachment 5498
Operator Restraint System 5498
Emergency Locking Retractor (ELR) 5498
Adjust Seat – Full Suspension 5499
Adjust Seat – Internal Suspension 5501
Hood and Seat Latches 5501
Engine Compartment 5501
Paper Application 5502
Fuel, Oil, and Coolant Leaks, Check 5502
Hydraulic Hoses 5503
Coolant Hoses 5503
Steering Column Gas Cylinder 5503
Transmission 5503
Hydraulic System Oil 5503
Engine Oil 5505
Air Filter 5508
Forks 5508
Remove 5508
Inspect 5509
Install 5509
Adjust 5510
Hang On Sideshift Carriage 5510
How to Make Checks With Engine Running 5511
Indicator Lights, Horn, Fuses, and Relays 5511
Service Brakes 5513
Brake Oil Level 5513
Operation, Check 5514
Parking Brake 5514
Engine Oil Pressure 5514
Cooling System 5514
Steering System 5515
Control Levers and Pedals 5515
Lift System, Operate 5516
Air Filter 5516
Fuel/Water Separator Filter, Cummins 4 5L and QSB 3 3L Diesel Engine 5516
First Service After First 100 Hours of Operation 5516
GM 4 3L Engine Oil and Oil Filter 5517
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 5517
Maintenance Procedures Every 500 Hours or 1 Year 5517
Hydraulic System Oil 5518
Hydraulic Tank Breather 5520
Inspect 5520
Battery 5521
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 5521
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 5522
Remove 5522
Install 5522
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 5524
Priming The Fuel System, Cummins 4 5L and QSB 3 3L Engines 5524
Controlled Venting 5524
Manual Bleeding 5524
Low Idle Speed Adjustment, Cummins 4 5L Engine Only 5525
GM 4 3L Engine Oil and Oil Filter 5525
Drain Tar From LPG Regulator 5526
Drain Tar From LPG Converter 5526
Drive Belt 5527
Cummins 4 5L and QSB 3 3L Diesel Engine and GM 4 3L Engine 5527
Fan and Alternator Drive Belt 5527
Clean Debris From Radiator Core 5529
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 5529
Wet Brake Center Body Oil Level Check 5530
Forks 5533
Mast Lubrication 5534
Header Hose Checks 5536
Lift Chain Lubrication 5536
Tilt Cylinder Lubrication 5536
Master Brake Cylinder Rod End Pin Lubrication 5537
Manual Hydraulic Levers Lubrication 5538
Brake Oil 5538
Tie Rod Lubrication 5539
Parking Brake Adjustment 5539
Maintenance Procedures Every 1000 Hours or 1 Year 5540
Valve Clearance, Check and Adjust 5540
Ignition System 5540
GM 4 3L Engine 5540
LPG Fuel Filter Element Replace, GM 4 3L Engine 5540
Remove 5540
Install 5541
In-Line Filter Replacement, Cummins 4 5L Engine 5541
Remove 5541
Install 5542
Lift Chains Wear Check 5543
Lift Chain Lubrication 5543
Hang On Sideshift Carriage, Check Sliding Surfaces 5543
Steering Axle Spindle Bearings 5546
Control Levers and Pedals 5547
Inspect Engine Electrical System, Connectors 5547
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 5547
Parking Brake Lever Lubrication, Wet Brake Axle 5552
Normal Operating Environment 5552
Heavy Duty or Contaminated Environment 5553
Remove 5553
Clean and Inspect 5553
Install 5554
Maintenance Procedures Every 2000 Hours or Annually 5554
Hydraulic System 5554
Hydraulic Filter Assembly, Replace 5554
Hydraulic Tank Breather, Replace 5556
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 5556
Cooling System Check 5556
Air Filter 5557
Oxygen Sensor, GM 4 3L Engine Equipped With GFI Installed 5559
LPG Regulator Fuel Filter, GM 4 3L Engines with GFI Installed 5560
Remove 5560
Install 5561
LPG Fuel Injector, GM 4 3L Engines with GFI Installed 5561
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 5561
Forks 5561
Brake Oil (Master Cylinder), Change 5562
Test Regulator PressureLPG 5562
Check Throttle Shaft for Sticking 5562
Inspect Exhaust Manifold and Piping for Leaks 5563
Transmission Automatic Clutch Calibration 5563
Brake System Accumulator 5563
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 5563
Wheel Bearings 5564
Steer Wheels, Lubrication 5564
Maintenance Procedures Every 4000 Hours or 2 Years 5564
Hydraulic Oil, Replace 5564
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 5567
Safety Procedures When Working Near Mast 5570
Fuel Filter Water Removal 5572
Hood Latch Check 5572
Lift Chain Adjustments 5573
Jump-Starting the Lift Truck 5575
Jump-Starting Using a Battery Charger 5575
Jump-Starting a Lift Truck Using Another Lift Truck 5575
Welding Repairs 5576
Overhead Guard Changes 5576
Wheel and Tire Replacement 5576
General 5576
Solid Rubber Tire, Change 5576
Remove and Install Tire on Wheel 5577
Adhesives and Sealants 5577
524288212-8000YRM1320-(06-2019)-US-EN 5581
Lift Truck Lifting Capacity 5585
Counterweight Weights 5585
Tire Sizes 5585
Capacities 5586
Electrical System 5593
Transmission Oil Pressures 5594
Hydraulic System Relief Pressures 5598
Steering System 5599
Stall Speeds (in RPM ±100 rpm) 5600
GM 4 3L Gas GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 5600
GM 4 3L LPG GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 5600
GM 4 3L Gas GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 5600
GM 4 3L LPG GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 5600
Cummins 4 5L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879) 5601
Cummins QSB 3 3L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879) 5601
Cummins 4 5L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878) 5601
Cummins QSB 3 3L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 5601
Mast Speeds 5602
Tilt Angles 5603
Front End Equipment – Mast Creep 5604
Mast Creep 5604
Engine Specifications 5604
Torque Specifications 5606
Frame 5606
Mast, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 5606
Mast, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 5607
Hang On Sideshift Carriage With Fork Positioner, Lift Truck Models Manufactured After August, 2012GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 5607
Steering System 5607
Transmission 5608
Engine – GM 4 3L 5608
Engine – Cummins 4 5L and QSB 3 3L Diesel 5609
524294873-1300YRM1343-(06-2021)-US-EN 5611
Transmission Repair 5615
Remove 5615
Torque Converter, Remove 5615
Disassemble 5617
Clean and Inspect 5658
Housings 5658
Oil Seals and Gaskets 5658
Bearings 5658
Gears and Shafts 5659
Assemble 5659
Torque Converter, Install 5697
Install 5698
Control Valve Repair 5699
Remove 5699
Disassemble 5699
Control Valve Assembly 5699
Control Valve Body 5699
Clean 5702
Inspect 5702
Assemble 5702
Control Valve Body 5702
Control Valve Assembly 5703
Install 5703
Torque Specification 5705
524294873-1300YRM1343-(11-2019)-UK-EN 5707
Transmission Repair 5711
Remove 5711
Torque Converter, Remove 5711
Disassemble 5712
Clean and Inspect 5752
Housings 5752
Oil Seals and Gaskets 5752
Bearings 5753
Gears and Shafts 5753
Assemble 5753
Torque Converter, Install 5791
Install 5792
Control Valve Repair 5793
Remove 5793
Disassemble 5793
Control Valve Assembly 5793
Control Valve Body 5793
Clean 5796
Inspect 5796
Assemble 5796
Control Valve Body 5796
Control Valve Assembly 5796
Install 5797
Torque Specification 5799
524294878-2100YRM1328-(06-2021)-US-EN 5801
General 5805
Safety Procedures When Working Near Mast 5805
Tilt Cylinder Repair 5808
Remove 5808
Disassemble 5812
Clean 5814
Inspect 5814
Assemble 5814
Install 5816
Tilt Cylinders, Adjust 5818
Tilt Cylinder Leak Check 5820
Lift Cylinder Repair 5821
Remove 5821
Disassemble 5830
Clean 5833
Inspect 5833
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 5833
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5833
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 5834
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5834
Free-Lift Cylinder Repair 5836
Remove 5836
Disassemble 5842
Clean 5844
Inspect 5844
Assemble, Lift Truck Models and 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) 5845
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5845
Install, Lift Truck Models and 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) 5845
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5846
Sideshift Cylinder Repair 5847
Remove 5847
Disassemble 5848
Clean 5851
Inspect 5851
Assemble 5852
Install 5853
Bolzoni Sideshift Cylinder Repair 5854
Remove 5854
Disassemble 5854
Clean 5855
Inspect 5855
Assemble 5856
Install 5856
Fork Positioner Cylinder Repair 5857
Remove 5857
Disassemble 5860
Clean 5864
Inspect 5864
Assemble 5865
Install 5866
Lift Cylinder Leak Check 5868
Seal Kit Installation 5869
External Installation (Seal and Back-Up Ring) 5869
Internal Installation (Piston Rod Assembly) 5869
Special Tools 5870
Torque Specifications 5871
For Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5871
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5871
524294878-2100YRM1328-(09-2018)-UK-EN 5873
General 5877
Safety Procedures When Working Near Mast 5877
Tilt Cylinder Repair 5879
Remove 5879
Disassemble 5884
Clean 5886
Inspect 5886
Assemble 5886
Install 5888
Tilt Cylinders, Adjust 5890
Tilt Cylinder Leak Check 5891
Lift Cylinder Repair 5892
Remove 5892
Disassemble 5902
Clean 5905
Inspect 5905
Assemble, Lift Truck Models and 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) 5905
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5905
Install, Lift Truck Models and 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) 5906
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5906
Free-Lift Cylinder Repair 5907
Remove 5907
Disassemble 5913
Clean 5915
Inspect 5915
Assemble, Lift Truck Models and 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) 5916
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5916
Install, Lift Truck Models and 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) 5916
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5917
Sideshift Cylinder Repair 5918
Remove 5918
Disassemble 5919
Clean 5922
Inspect 5922
Assemble 5923
Install 5924
Bolzoni Sideshift Cylinder Repair 5925
Remove 5925
Disassemble 5925
Clean 5926
Inspect 5926
Assemble 5927
Install 5927
Fork Positioner Cylinder Repair 5927
Remove 5928
Disassemble 5931
Clean 5935
Inspect 5935
Assemble 5936
Install 5937
Lift Cylinder Leak Check 5938
Seal Kit Installation 5938
External Installation (Seal and Back-Up Ring) 5938
Internal Installation (Piston Rod Assembly) 5939
Special Tools 5940
Torque Specifications 5941
For Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5941
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5941
550073240-1900YRM1620-(01-2023)-US-EN 5945
Proper Flushing after Major Hydraulic Repairs 5951
Introduction 5951
The Phases of Wear 5951
Causes of Hydraulic System Failure 5951
Progression of Contaminant Caused Hydraulic System Failure 5952
Hydraulic System Flushing Techniques 5952
Double Oil and Filter Change 5952
Mechanical Cleaning 5953
Cleaning of Components 5953
How to Clean Tubes and Hoses 5953
Filter Caddy 5953
Start-Up Procedure for Cleaned System 5954
Contaminated Oil Coolers 5954
Additional Filter Caddy Functions 5955
How to Handle Different Fluids 5955
Water Removal Filters 5955
Fluid Conditioning and System Flushing Procedures 5956
Operation of the Filter Caddy 5956
Filter Caddy operation 5956
Fluid Conditioning Procedure 5956
Filter Caddy Start-Up 5957
System Flushing Procedure 5957
Component Cleaning Procedure 5958
Reservoir Cleaning Procedure 5958
Cylinder Cleaning Procedure 5958
Hose and Tube Cleaning Procedure 5958
Valve Cleaning Procedure 5959
Front-End Attachment Cleaning Procedure 5960
System Flushing Procedure 5960
Filter Caddy Start-Up 5961
System Start-Up and Flushing 5961
Reservoir Fluid Cleaning Times 5962
Dealing With Different Fluid Types 5963
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5963
Filter Caddy Maintenance 5963
Servicing the Strainer 5963
DC Motor 5963
Hydraulic Oil Sampling Method and Procedure 5964
Hydraulic Oil Sampling Method 5964
Objective 5964
General Guidelines 5964
Synopsis 5965
Hydraulic Oil Analysis Report Guidelines 5966
Sampling Conditions 5966
Equipment 5966
Sampling Procedure 5967
Hydraulic Oil Sampling 5967
Sample Labeling 5967
Results Documentation 5967
550073240-1900YRM1620-(03-2020)-UK-EN 5969
Proper Flushing after Major Hydraulic Repairs 5973
Introduction 5973
The Phases of Wear 5973
Causes of Hydraulic System Failure 5973
Progression of Contaminant Caused Hydraulic System Failure 5974
Hydraulic System Flushing Techniques 5974
Double Oil and Filter Change 5974
Mechanical Cleaning 5975
Cleaning of Components 5975
How to Clean Tubes and Hoses 5975
Filter Caddy 5975
Start-Up Procedure for Cleaned System 5976
Contaminated Oil Coolers 5976
Additional Filter Caddy Functions 5976
How to Handle Different Fluids 5976
Water Removal Filters 5977
Fluid Conditioning and System Flushing Procedures 5977
Operation of the Filter Caddy 5977
Filter Caddy operation 5977
Fluid Conditioning Procedure 5978
Filter Caddy Start-Up 5978
System Flushing Procedure 5979
Component Cleaning Procedure 5979
Reservoir Cleaning Procedure 5979
Cylinder Cleaning Procedure 5979
Hose and Tube Cleaning Procedure 5980
Valve Cleaning Procedure 5980
Front-End Attachment Cleaning Procedure 5981
System Flushing Procedure 5981
Filter Caddy Start-Up 5982
System Start-Up and Flushing 5982
Reservoir Fluid Cleaning Times 5983
Dealing With Different Fluid Types 5983
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5983
Filter Caddy Maintenance 5984
Servicing the Strainer 5984
DC Motor 5984
Hydraulic Oil Sampling Method and Procedure 5984
Hydraulic Oil Sampling Method 5984
Objective 5984
General Guidelines 5984
Synopsis 5985
Hydraulic Oil Analysis Report Guidelines 5986
Sampling Conditions 5987
Equipment 5987
Sampling Procedure 5987
Hydraulic Oil Sampling 5987
Sample Labeling 5988
Results Documentation 5988

S.V 06/24