Yale Forklift D879 (GC_GLC_GDC135VX, GC_GLC_GDC155VX) Service Manual PDF

Description

Yale Forklift D879 (GC_GLC_GDC135VX, GC_GLC_GDC155VX) Service Manual – PDF DOWNLOAD

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Yale Forklift D879 (GC_GLC_GDC135VX, GC_GLC_GDC155VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5982
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift D879 (GC_GLC_GDC135VX, GC_GLC_GDC155VX) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
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-(06-2021)-US-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 2139
Flushing the Cooling System 2141
Cooling System, Clean 2141
Radiator Replacement 2143
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) 2143
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) 2158
Radiator, Remove for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2161
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) 2164
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) 2170
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) 2174
Radiator, Install for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2175
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) 2178
Fan Assembly Replacement 2189
Fan Removal 2189
Inspect 2203
Fan Installation 2204
524223764-1600YRM1133-(07-2013)-US-EN 2209
toc 2209
Steering Axle 2209
Safety Precautions Maintenance and Repair 2210
General 2213
Steering Axle Assembly Repair 2215
Remove 2215
Disassemble 2216
Clean 2224
Inspect 2224
Assemble 2224
Install 2230
Spindles, Bearings, and Tie Rods Repair 2232
Spindles and Bearings 2232
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2232
Remove 2232
Disassemble 2234
Clean 2235
Inspect 2235
Assemble 2235
Install 2236
Spindles and Bearings 2239
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2239
Remove and Disassemble 2239
Assemble and Install 2240
Tie Rods 2240
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2240
Remove 2240
Install 2241
Tie Rods 2242
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2242
Remove 2242
Install 2248
Steering Cylinder Repair 2248
Remove and Disassemble 2248
Clean and Inspect 2249
Assemble and Install 2249
Torque Specifications 2250
524223766-1900YRM1136-(01-2022)-US-EN 2255
General 2259
Hydraulic Gear Pump Assembly 2260
Variable Displacement Pump Assembly 2261
Single Gear Pump Assembly Repair 2262
Remove 2262
Disassemble 2268
Clean 2270
Inspect 2270
Assemble 2270
Install 2270
Tandem Gear Pump Assembly 2275
Remove 2275
Disassemble 2276
Clean 2279
Inspect 2279
Assemble 2279
Install 2280
Gear Pump Specifications 2281
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2287
Remove 2287
Disassemble 2297
Clean 2300
Inspect 2301
Assemble 2301
Install 2301
63 0 cc/rev – Variable Displacement Pump Repair 2306
Remove 2306
Disassemble 2309
Clean 2311
Inspect 2311
Assemble 2311
Install 2311
Variable Displacement Pump Checks and Adjustments (Single Pump) 2315
Margin Pressure Check 2315
Flow Compensator Adjustment 2316
Pressure Compensator Adjustment 2316
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2318
Variable Displacement Pump Specifications 2321
Torque Specifications 2323
Hydraulic Gear Pump 2323
Variable Displacement Pump 2324
Special Tools 2325
524223766-1900YRM1136-(11-2017)-US-EN 2327
General 2331
Hydraulic Gear Pump Assembly 2332
Variable Displacement Pump Assembly 2333
Single Gear Pump Assembly Repair 2333
Remove 2333
Disassemble 2340
Clean 2340
Inspect 2342
Assemble 2342
Install 2342
Tandem Gear Pump Assembly 2346
Remove 2347
Disassemble 2349
Clean 2351
Inspect 2351
Assemble 2351
Install 2352
Gear Pump Specifications 2352
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2358
Remove 2358
Disassemble 2368
Clean 2371
Inspect 2371
Assemble 2371
Install 2372
63 0 cc/rev – Variable Displacement Pump Repair 2375
Remove 2375
Disassemble 2378
Clean 2378
Inspect 2378
Assemble 2380
Install 2380
Variable Displacement Pump Checks and Adjustments (Single Pump) 2382
Margin Pressure Check 2382
Flow Compensator Adjustment 2383
Pressure Compensator Adjustment 2383
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2384
Variable Displacement Pump Specifications 2387
Torque Specifications 2388
Hydraulic Gear Pump 2389
Variable Displacement Pump 2390
Special Tools 2390
524223767-2000YRM1137-(01-2017)-US-EN 2395
General 2401
Electro-Hydraulic Main Control Valve 2402
Description 2402
Remove 2410
Electro-Hydraulic Control Valve Sections 2415
General 2415
Outlet Control Valve Section 2415
Remove 2415
Disassemble 2416
Clean 2418
Inspect 2418
Assemble 2418
Install 2419
Auxiliary Control Valve Sections 2419
Remove 2419
Disassemble 2426
Clean 2427
Inspect 2428
Assemble 2428
Install 2430
Tilt Control Valve Section 2431
Remove 2431
Disassemble 2431
Clean 2437
Inspect 2437
Assemble 2437
Install 2438
Lift/Lower Control Valve Section 2439
Remove 2439
Disassemble 2439
Clean 2448
Inspect 2448
Assemble 2448
Install 2449
Mid-Inlet Section 2449
Remove 2449
Clean 2450
Inspect 2450
Install 2450
Install 2450
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2455
Lift Pilot Pin 2455
Lower Pilot Pin 2459
Abnormal/Erroneous EHPV Adjustment 2461
Manual Main Control Valve 2462
Description 2462
Remove 2466
OPS Solenoid Assembly 2474
General 2474
Remove 2475
Clean and Inspect 2478
Install 2478
Manual Control Valve Sections 2479
General 2479
Outlet Control Valve Section 2479
Remove 2479
Disassemble 2479
Clean 2482
Inspect 2482
Assemble 2482
Install 2483
Auxiliary Control Valve Sections 2483
Remove 2483
Disassemble 2483
Clean 2486
Inspect 2486
Assemble 2486
Install 2487
Lift/Tilt Control Valve Section 2487
Remove 2487
Disassemble 2487
Clean 2494
Inspect 2494
Assemble 2495
Install 2496
Mid-Inlet Section 2497
Remove 2497
Clean 2497
Inspect 2497
Install 2497
Install 2498
Pressure Relief Valve Check and Adjustment 2504
Primary Relief Valve 2505
Secondary Relief Valve 2509
Steering Control Unit Repair 2516
Steering Control Unit, Remove 2516
Steering Control Unit, Disassemble 2520
Steering Control Unit, Clean 2522
Steering Control Unit, Inspect 2522
Steering Control Unit, Assemble 2522
Relief Valve, Disassemble 2523
Relief Valve, Clean 2523
Relief Valve, Inspect 2524
Relief Valve, Assemble 2524
Steering Control Unit, Install 2524
524223767-2000YRM1137-(06-2021)-US-EN 2529
General 2533
Electro-Hydraulic Main Control Valve 2534
Description 2534
Remove 2542
Electro-Hydraulic Control Valve Sections 2547
General 2547
Outlet Control Valve Section 2547
Remove 2547
Disassemble 2547
Clean 2550
Inspect 2550
Assemble 2551
Install 2551
Auxiliary Control Valve Sections 2551
Remove 2552
Disassemble 2557
Clean 2559
Inspect 2559
Assemble 2559
Install 2561
Tilt Control Valve Section 2562
Remove 2562
Disassemble 2563
Clean 2567
Inspect 2567
Assemble 2568
Install 2569
Lift/Lower Control Valve Section 2569
Remove 2569
Disassemble 2569
Clean 2575
Inspect 2575
Assemble 2575
Install 2576
Mid-Inlet Section 2576
Remove 2576
Clean 2577
Inspect 2577
Install 2577
Install 2577
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2582
Lift Pilot Pin 2582
Lower Pilot Pin 2585
Abnormal/Erroneous EHPV Adjustment 2587
Manual Main Control Valve 2588
Description 2588
Remove 2592
OPS Solenoid Assembly 2600
General 2600
Remove 2601
Clean and Inspect 2603
Install 2603
Manual Control Valve Sections 2604
General 2604
Outlet Control Valve Section 2604
Remove 2604
Disassemble 2604
Clean 2607
Inspect 2607
Assemble 2607
Install 2607
Auxiliary Control Valve Sections 2608
Remove 2608
Disassemble 2608
Clean 2611
Inspect 2611
Assemble 2611
Install 2611
Lift/Tilt Control Valve Section 2612
Remove 2612
Disassemble 2612
Clean 2618
Inspect 2618
Assemble 2618
Install 2620
Mid-Inlet Section 2620
Remove 2620
Clean 2621
Inspect 2621
Install 2621
Install 2621
Pressure Relief Valve Check and Adjustment 2629
Primary Relief Valve 2629
Secondary Relief Valve 2632
Steering Control Unit Repair 2637
Steering Control Unit, Remove 2637
Steering Control Unit, Disassemble 2641
Steering Control Unit, Clean 2643
Steering Control Unit, Inspect 2643
Steering Control Unit, Assemble 2643
Relief Valve, Disassemble 2644
Relief Valve, Clean 2644
Relief Valve, Inspect 2645
Relief Valve, Assemble 2645
Steering Control Unit, Install 2645
524223769-2200YRM1128-(01-2023)-US-EN 2649
Series Code / Model Designation Reference Table 2657
General 2659
Deutsch Crimping Tool 2660
How to Strip a Wire for Use With Deutsch Crimping Tool 2660
How to Crimp With the Deutsch Crimping Tool 2661
Calibration Test for the Deutsch Crimping Tool 2663
Deutsch Connectors 2665
DT, DTM, and DTP Series Connectors 2665
HD Series Connectors 2708
Metri-Pack Connectors 2730
Remove and Install 2730
Micro-Pack Connectors 2733
Weather-Pack Connectors 2734
AMPSEAL Crimping Tools 2736
AMP Hand Crimping Tool With Certi-Crimp 2736
Description 2736
Stripping Wire for Use with AMP Hand Crimping Tool 2737
Insulation Crimp Adjustment 2738
Maintenance and Inspection for AMP Hand Crimping Tool 2738
AMP Hand Crimping Tool 2738
Crimp Height Inspection 2738
How to use AMP Hand Crimping Tool 2739
AMP Pro-Crimper II Tool 2739
Description 2739
Remove and Install Die Set and Locator Assembly 2740
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2740
Contact Support Adjustment 2741
Crimp Height Adjustment 2742
Maintenance and Inspection Procedures 2742
PRO-CRIMPER II Tool 2742
Crimp Height Inspection 2742
How to Use AMP PRO-CRIMPER II Tool 2743
AMPSEAL Connector Assemblies 2744
Description for Plug Connector Assembly 2744
Seal Plug 2745
Contact Crimping 2745
Description for Plug Connector and Header Assembly 2750
Voltage Reading 2753
Seal Plug 2753
Contact Crimping 2753
AMP Superseal 1 5 Crimping Tools 2760
Mini Mic Receptacle and Tab Contacts 2760
Description 2760
Crimping Conditions and Measurements 2760
Insertion of Rubber Seal on Cable 2762
AMP Hand Application Tool 2767
Description 2767
Maintenance and Inspection 2767
Crimp Height Inspection 2767
Crimp Height Adjustment 2768
How to Use AMP Hand Application Tool 2768
AMP Pro-Crimper II Tool 2769
Description 2769
Remove and Install Die Set and Locator Assembly 2769
Adjustments 2770
Contact Support 2770
Crimp Height 2771
Inspections and Maintenance 2772
Crimp Height Inspection 2772
Visual Inspection 2772
Maintenance 2773
How to Use Pro-Crimper II Tool 2773
AMP Superseal 1 5 Connector Assemblies 2774
Description 2774
Repair and Maintenance 2781
Panel Mount Option 2781
AMP Fastin-Faston Hand Tools 2782
Description – AMP Double Action Hand Tool 2782
Maintenance and Inspection Procedures 2782
Daily Maintenance 2782
Periodic Tool Inspection 2783
Lubrication 2783
Visual Inspection 2783
Crimp Height Inspection 2783
Certi-Crimp Ratchet Inspection 2784
How to Use AMP Double Action Hand Tool 2785
Description – AMP Extraction Tool 2786
Maintenance and Inspection 2787
How to Use AMP Extraction Tool 2787
AMP Fastin-Faston Receptacles and Housings 2789
Description 2789
Wire Repair 2797
Wire Splicing Requirements 2797
Deutsch Jiffy Splice 2798
Twisted/Shielded Cable and Leads Repair 2804
Special Tools 2806
524223769-2200YRM1128-(07-2020)-US-EN 2815
Series Code / Model Designation Reference Table 2821
General 2824
Deutsch Crimping Tool 2824
How to Strip a Wire for Use With Deutsch Crimping Tool 2824
How to Crimp With the Deutsch Crimping Tool 2825
Calibration Test for the Deutsch Crimping Tool 2827
Deutsch Connectors 2829
DT, DTM, and DTP Series Connectors 2829
HD Series Connectors 2871
Metri-Pack Connectors 2894
Remove and Install 2894
Micro-Pack Connectors 2896
Weather-Pack Connectors 2897
AMPSEAL Crimping Tools 2899
AMP Hand Crimping Tool With Certi-Crimp 2899
Description 2899
Stripping Wire for Use with AMP Hand Crimping Tool 2899
Insulation Crimp Adjustment 2900
Maintenance and Inspection for AMP Hand Crimping Tool 2900
AMP Hand Crimping Tool 2900
Crimp Height Inspection 2900
How to use AMP Hand Crimping Tool 2901
AMP Pro-Crimper II Tool 2901
Description 2901
Remove and Install Die Set and Locator Assembly 2902
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2903
Contact Support Adjustment 2903
Crimp Height Adjustment 2904
Maintenance and Inspection Procedures 2904
PRO-CRIMPER II Tool 2904
Crimp Height Inspection 2904
How to Use AMP PRO-CRIMPER II Tool 2905
AMPSEAL Connector Assemblies 2906
Description for Plug Connector Assembly 2906
Seal Plug 2907
Contact Crimping 2907
Description for Plug Connector and Header Assembly 2912
Voltage Reading 2914
Seal Plug 2914
Contact Crimping 2914
AMP Superseal 1 5 Crimping Tools 2921
Mini Mic Receptacle and Tab Contacts 2921
Description 2921
Crimping Conditions and Measurements 2921
Insertion of Rubber Seal on Cable 2923
AMP Hand Application Tool 2928
Description 2928
Maintenance and Inspection 2928
Crimp Height Inspection 2928
Crimp Height Adjustment 2929
How to Use AMP Hand Application Tool 2929
AMP Pro-Crimper II Tool 2930
Description 2930
Remove and Install Die Set and Locator Assembly 2931
Adjustments 2931
Contact Support 2931
Crimp Height 2932
Inspections and Maintenance 2933
Crimp Height Inspection 2933
Visual Inspection 2933
Maintenance 2934
How to Use Pro-Crimper II Tool 2934
AMP Superseal 1 5 Connector Assemblies 2935
Description 2935
Repair and Maintenance 2942
Panel Mount Option 2942
AMP Fastin-Faston Hand Tools 2943
Description – AMP Double Action Hand Tool 2943
Maintenance and Inspection Procedures 2943
Daily Maintenance 2943
Periodic Tool Inspection 2944
Lubrication 2944
Visual Inspection 2944
Crimp Height Inspection 2944
Certi-Crimp Ratchet Inspection 2945
How to Use AMP Double Action Hand Tool 2946
Description – AMP Extraction Tool 2947
Maintenance and Inspection 2947
How to Use AMP Extraction Tool 2948
AMP Fastin-Faston Receptacles and Housings 2949
Description 2949
Wire Repair 2956
Wire Splicing Requirements 2956
Deutsch Jiffy Splice 2957
Twisted/Shielded Cable and Leads Repair 2962
Special Tools 2965
524223770-2200YRM1130-(03-2020)-US-EN 2973
General 2977
Description 2977
Dash Display Menu Access 2977
Menu Navigation 2978
Standard Display 2978
Main Menu 2978
Passwords Menu 2979
Password Administration 2979
Add Password 2979
Delete Password 2980
Edit Password 2980
Other Password Functions 2981
Operator Passwords – Enable/Disable 2981
Password Time-Out Delay 2981
Passwords – Number Wrong to Disable 2982
Lockout Reset Password 2982
View Password Log 2983
View Versions 2984
VSM Versions 2984
Dash Display Versions 2985
Engine Controller Version 2986
Transmission (Xmsn) Controller Version 2987
Truck Serial Number 2988
Diagnostics 2989
View Fault Log 2989
Set Travel and Braking 2990
Speed Limit 2990
Acceleration Rate 2991
Auto-Deceleration Rate 2991
Set Power Reversal Rate 2992
Set Inching/Brake Overlap 2993
Setup Display Menu 2994
Set Operator Language 2994
Set Units 2995
Set Time Format (12/24 Hour) 2995
Set Daylight Saving Time 2995
Set Time 2998
Set Date Format 2999
Set Date 2999
Setup Hydraulics 3000
Return to Set Tilt Delay/On/Off 3000
Setup General Items 3001
Light Shutdown Time-Out 3001
Impact Sensor – Enable/Disable 3002
Impact Sensor – Soft Impact Settings 3003
Impact Sensor – Hard Impact Settings 3004
Adjust Impact Sensor Settings 3004
Initial Adjustment of Soft and Hard Impact Settings 3006
Readjustment of Soft and Hard Impact Settings 3006
Impact Sensor – Impact Alarm/Shutdown Reset 3007
Impact Sensor – Alarm Time Duration and Deactivation 3008
Impact Sensor – View Impact Event Log 3009
Engine Mode Indicator 3010
Generation 1 (ECO-eLo ONLY) 3010
Generation 2 3011
Operator Checklist 3012
Operator Checklist Off-On Mode 3012
Edit Operator Checklist 3012
Set Operator Checklist Expiration 3013
View Checklist Log 3013
Clear Operator Checklist Log 3014
Clear Operator Checklist Fault 3014
Calibrations 3015
Set Tilt Stop Point 3015
Calibrate Loaded Weight 3015
524223770-2200YRM1130-(05-2021)-US-EN 3017
General 3021
Description 3021
Dash Display Menu Access 3021
Menu Navigation 3022
Standard Display 3022
Main Menu 3022
Passwords Menu 3023
Password Administration 3023
Add Password 3023
Delete Password 3023
Edit Password 3024
Other Password Functions 3025
Operator Passwords – Enable/Disable 3025
Password Time-Out Delay 3025
Passwords – Number Wrong to Disable 3025
Lockout Reset Password 3026
View Password Log 3026
View Versions 3027
VSM Versions 3027
Dash Display Versions 3028
Engine Controller Version 3029
Transmission (Xmsn) Controller Version 3030
Truck Serial Number 3031
Diagnostics 3032
View Fault Log 3032
Set Travel and Braking 3033
Speed Limit 3033
Acceleration Rate 3034
Auto-Deceleration Rate 3034
Set Power Reversal Rate 3035
Set Inching/Brake Overlap 3036
Setup Display Menu 3037
Set Operator Language 3037
Set Units 3038
Set Time Format (12/24 Hour) 3038
Set Daylight Saving Time 3039
Set Time 3042
Set Date Format 3042
Set Date 3043
Setup Hydraulics 3044
Return to Set Tilt Delay/On/Off 3044
Setup General Items 3045
Light Shutdown Time-Out 3045
Impact Sensor – Enable/Disable 3046
Impact Sensor – Soft Impact Settings 3047
Impact Sensor – Hard Impact Settings 3047
Adjust Impact Sensor Settings 3048
Initial Adjustment of Soft and Hard Impact Settings 3050
Readjustment of Soft and Hard Impact Settings 3050
Impact Sensor – Impact Alarm/Shutdown Reset 3051
Impact Sensor – Alarm Time Duration and Deactivation 3052
Impact Sensor – View Impact Event Log 3053
Engine Mode Indicator 3053
Generation 1 (ECO-eLo ONLY) 3053
Generation 2 3054
Operator Checklist 3055
Operator Checklist Off-On Mode 3055
Edit Operator Checklist 3055
Set Operator Checklist Expiration 3055
View Checklist Log 3056
Clear Operator Checklist Log 3057
Clear Operator Checklist Fault 3057
Calibrations 3058
Set Tilt Stop Point 3058
Calibrate Loaded Weight 3058
524223771-2200YRM1131-(03-2020)-US-EN 3061
Series Code / Model Designation Reference Table 3067
General 3069
Description 3069
Dash Display Menu Access 3069
Menu Navigation 3070
Main Menu 3070
Passwords 3071
Adding Passwords 3071
Hourmeters 3073
View Versions 3074
VSM Versions 3074
Dash Display Versions 3075
Engine Controller Version 3076
Transmission (Xmsn) Controller Version 3077
Truck Serial Number 3078
Truck Configuration 3079
Diagnostics 3080
Clear Fault Log 3080
View Fault Log 3081
No-Run Data Display 3082
Engine Accelerator and Throttle Data Display 3082
Engine Speeds and Governor Data Display 3083
Engine Fuel and Emissions Data Display 3084
Engine General Data Display 3086
XMSN/Brake Data Display 3087
Hydraulic Data Display 3090
General Truck Data Display 3092
Set Travel and Braking 3093
Speed Limit 3093
Acceleration Rate 3094
Auto-Deceleration Rate 3095
Set Power Reversal Rate 3095
Set Inching/Brake Overlap 3096
Setup Hydraulics 3096
Lift Maximum Speed 3097
Lower Maximum Speed 3097
Tilt Maximum Speed 3098
Auxiliary Function One, Direction A, Maximum Speed 3100
Auxiliary Function One, Direction B, Maximum Speed 3102
Auxiliary Function Two, Direction A, Maximum Speed 3102
Auxiliary Function Two, Direction B, Maximum Speed 3103
Auxiliary Function Three, Direction A, Maximum Speed 3104
Auxiliary Function Three, Direction B, Maximum Speed 3104
Lift/Lower Ramp Rate 3105
Hydraulic Auxiliary Ramp Rate 3105
Return to Set Tilt Delay/On/Off 3106
Hydraulic Input Device 3107
Auxiliary Solenoid 3107
Dual Function 3108
Setup Display 3109
Set Service Language 3109
Setup General Items 3109
Motion Alarm Activation Type 3110
Light Shutdown Time-Out 3111
Restore Default Settings 3111
Restore Engine Controller Default Calibration 3112
Impact Sensor – Enable/Disable 3112
Impact Sensor – Soft Impact Settings 3113
Impact Sensor – Hard Impact Settings 3114
Adjust Impact Sensor Settings 3115
Initial Adjustment of Soft and Hard Impact Settings 3117
Readjustment of Soft and Hard Impact Settings 3117
Impact Sensor – Impact Alarm/Shutdown Reset 3118
Impact Sensor – Alarm Time Duration and Deactivation 3119
Impact Sensor – View Impact Event Log 3120
Engine Mode Indicator 3120
Generation 1 (ECO-eLo ONLY) 3120
Generation 2 3121
Diesel Particulate Filter (DPF) Display 3122
General Description 3122
Passive Regeneration Only 3122
Regeneration Level 0 3122
Auto/Active Regeneration Inhibited 3123
Auto/Active Regeneration 3123
Regeneration Level 1 3123
Parked Regeneration Request 3124
Regeneration Level 2 3124
Warning Level 3124
Regeneration Level 3 3124
Service Level 3125
Regeneration Level 4 3125
Display, Diesel Particulate Filter (DPF), Revised 3125
Operator Interface 3125
Refer to Operator Manual 3125
CAN Communication Lost 3126
Passive Regeneration Only 3126
Regeneration Level 0 3126
Auto/Active Regeneration Inhibited 3126
Auto/Active Regeneration 3127
Regeneration Level 1 3127
Idle-up Auto/Active Regeneration 3127
Parked Regeneration Request 3127
Regeneration Level 2 3127
Warning Level 3129
Regeneration Level 3 3129
Service Level 3129
Regeneration Level 4 3129
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3129
Display, Diesel Particulate Filter (DPF), Stage V Engine 3129
Operator Interface 3130
Refer to Operator Manual 3130
CAN Communication Lost 3130
Passive Regeneration Only 3130
Regeneration Level 0 3130
Auto/Active Regeneration Inhibited 3131
Auto/Active Regeneration 3131
Regeneration Level 1 3131
Idle-up Auto/Active Regeneration 3132
Parked Regeneration Request 3132
Regeneration Level 2 3132
Warning Level 3133
Regeneration Level 3 3133
Service Level 3134
Regeneration Level 4 3134
Stage V Content 3134
Emissions System Malfunction 3134
Ash Load 3134
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3135
Operator Interface 3135
Refer to Operator Manual 3135
CAN Communication Lost 3136
Passive Regeneration Only 3136
Regeneration Level 0 3136
Auto/Active Regeneration Inhibited 3136
Auto/Active Regeneration 3137
Regeneration Level 1 3137
Idle-up Auto/Active Regeneration 3137
Parked Regeneration Request 3137
Regeneration Level 2 3137
Warning Level 3139
Regeneration Level 3 3139
Service Level 3139
Regeneration Level 4 3139
Calibrations 3140
Calibrate Transmission Valve 3142
Set Tilt Stop Point 3142
Calibrate Loaded Weight 3142
Calibrate Travel Speed Sensor 3143
Calibrate Mazda LP and Gas Accelerator Pedal 3143
524223771-2200YRM1131-(05-2021)-US-EN 3145
Series Code / Model Designation Reference Table 3151
General 3153
Description 3153
Dash Display Menu Access 3153
Menu Navigation 3154
Main Menu 3155
Passwords 3155
Adding Passwords 3155
Hourmeters 3157
View Versions 3158
VSM Versions 3158
Dash Display Versions 3159
Engine Controller Version 3160
Transmission (Xmsn) Controller Version 3161
Truck Serial Number 3162
Truck Configuration 3163
Diagnostics 3164
Clear Fault Log 3164
View Fault Log 3165
No-Run Data Display 3166
Engine Accelerator and Throttle Data Display 3167
Engine Speeds and Governor Data Display 3169
Engine Fuel and Emissions Data Display 3170
Engine General Data Display 3172
XMSN/Brake Data Display 3173
Hydraulic Data Display 3175
General Truck Data Display 3178
Set Travel and Braking 3180
Speed Limit 3180
Acceleration Rate 3181
Auto-Deceleration Rate 3181
Set Power Reversal Rate 3182
Set Inching/Brake Overlap 3182
Setup Hydraulics 3183
Lift Maximum Speed 3183
Lower Maximum Speed 3184
Tilt Maximum Speed 3184
Auxiliary Function One, Direction A, Maximum Speed 3186
Auxiliary Function One, Direction B, Maximum Speed 3189
Auxiliary Function Two, Direction A, Maximum Speed 3189
Auxiliary Function Two, Direction B, Maximum Speed 3190
Auxiliary Function Three, Direction A, Maximum Speed 3191
Auxiliary Function Three, Direction B, Maximum Speed 3191
Lift/Lower Ramp Rate 3192
Hydraulic Auxiliary Ramp Rate 3192
Return to Set Tilt Delay/On/Off 3193
Hydraulic Input Device 3194
Auxiliary Solenoid 3194
Dual Function 3195
Setup Display 3196
Set Service Language 3196
Setup General Items 3196
Motion Alarm Activation Type 3197
Light Shutdown Time-Out 3198
Restore Default Settings 3198
Restore Engine Controller Default Calibration 3199
Impact Sensor – Enable/Disable 3199
Impact Sensor – Soft Impact Settings 3200
Impact Sensor – Hard Impact Settings 3200
Adjust Impact Sensor Settings 3201
Initial Adjustment of Soft and Hard Impact Settings 3203
Readjustment of Soft and Hard Impact Settings 3203
Impact Sensor – Impact Alarm/Shutdown Reset 3204
Impact Sensor – Alarm Time Duration and Deactivation 3205
Impact Sensor – View Impact Event Log 3206
Engine Mode Indicator 3206
Generation 1 (ECO-eLo ONLY) 3206
Generation 2 3207
Diesel Particulate Filter (DPF) Display 3208
General Description 3208
Passive Regeneration Only 3208
Regeneration Level 0 3208
Auto/Active Regeneration Inhibited 3209
Auto/Active Regeneration 3209
Regeneration Level 1 3209
Parked Regeneration Request 3210
Regeneration Level 2 3210
Warning Level 3211
Regeneration Level 3 3211
Service Level 3211
Regeneration Level 4 3211
Display, Diesel Particulate Filter (DPF), Revised 3211
Operator Interface 3212
Refer to Operator Manual 3212
CAN Communication Lost 3212
Passive Regeneration Only 3212
Regeneration Level 0 3212
Auto/Active Regeneration Inhibited 3213
Auto/Active Regeneration 3213
Regeneration Level 1 3213
Idle-up Auto/Active Regeneration 3213
Parked Regeneration Request 3214
Regeneration Level 2 3214
Warning Level 3215
Regeneration Level 3 3215
Service Level 3215
Regeneration Level 4 3215
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3216
Display, Diesel Particulate Filter (DPF), Stage V Engine 3216
Operator Interface 3216
Refer to Operator Manual 3216
CAN Communication Lost 3217
Passive Regeneration Only 3217
Regeneration Level 0 3217
Auto/Active Regeneration Inhibited 3217
Auto/Active Regeneration 3218
Regeneration Level 1 3218
Idle-up Auto/Active Regeneration 3218
Parked Regeneration Request 3218
Regeneration Level 2 3218
Warning Level 3220
Regeneration Level 3 3220
Service Level 3220
Regeneration Level 4 3220
Stage V Content 3220
Emissions System Malfunction 3220
Ash Load 3221
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3222
Operator Interface 3222
Refer to Operator Manual 3222
CAN Communication Lost 3223
Passive Regeneration Only 3223
Regeneration Level 0 3223
Auto/Active Regeneration Inhibited 3223
Auto/Active Regeneration 3224
Regeneration Level 1 3224
Idle-up Auto/Active Regeneration 3224
Parked Regeneration Request 3224
Regeneration Level 2 3224
Warning Level 3226
Regeneration Level 3 3226
Service Level 3226
Regeneration Level 4 3226
Calibrations 3227
Calibrate Transmission Valve 3229
Set Tilt Stop Point 3229
Calibrate Loaded Weight 3230
Calibrate Travel Speed Sensor 3230
Calibrate Mazda LP and Gas Accelerator Pedal 3231
524223772-2200YRM1142-(01-2020)-US-EN 3233
General 3243
Display Switch Cluster 3246
Remove 3246
Install 3249
Direction Control and Turn Signal Levers 3249
Remove 3249
Install 3251
Key Switch 3251
Remove 3251
Install 3252
Display Switch Cluster Panel Bezel and Overlay 3252
Remove 3252
Install 3252
Steering Column Repair 3252
Remove 3252
Disassemble 3255
Assemble 3255
Install 3255
Sensors and Switches 3256
General 3256
Dash and Kick Panel, Remove and Install 3256
Remove 3256
Install 3257
Accelerator Pedal Position Sensor 3258
Remove 3258
Install 3261
Brake Fluid Level Switch 3262
Remove 3262
Install 3264
Service Brake Pedal Position Sensor 3265
Remove 3265
Install 3268
Parking Brake Sensor 3269
Remove 3269
Install 3270
Service Brake Pressure Sensor 3271
Remove 3271
Install 3273
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3274
Remove 3274
Install 3274
Sensor Microswitch (Foot Directional Control Pedal) 3275
Remove 3275
Install 3278
Low Coolant Level Sensor 3279
Remove 3279
Install 3282
Fuel Level Sensor, Gas and Diesel Engines Only 3283
Remove 3283
Install 3284
Armrest Switch 3284
Remove 3284
Install 3286
Seat Sensor (Operator Presence System) 3286
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) 3286
Remove 3286
Install 3287
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3287
Remove 3287
Install 3288
Full Suspension Seats; All Lift Truck Models 3288
Remove 3288
Install 3288
Hood Shut Off Switch 3288
Remove 3288
Install 3291
Remote Key Switch 3292
Remove 3292
Install 3292
Hydraulic Filter Pressure Switch 3293
Remove 3293
Install 3295
Transmission Speed Sensor 3295
Remove 3295
Install 3298
Transmission Pressure Sensors 3299
Remove 3299
Install 3301
Transmission Temperature Sensor 3302
Remove 3302
Install 3304
Engine Speed Sensor 3306
Remove 3306
Install 3306
Intermediate Speed Sensor 3307
Remove 3307
Install 3307
Return to Set Tilt (Tilt Angle) Sensor 3307
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) 3307
Remove 3307
Install 3308
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) 3309
Remove 3309
Install 3310
Rear Horn Button Switch 3310
Remove 3310
Install 3311
Impact Sensor 3312
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) 3312
Remove 3312
Install 3315
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) 3315
Remove 3315
Install 3316
Load Weight Sensor 3317
Remove 3317
Install 3318
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3319
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3319
Crankshaft Position (CKP) Sensor 3319
Camshaft Position (CMP) Sensor 3319
Oil Pressure Sensor 3319
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3319
Engine Coolant Temperature (ECT) Sensor 3320
Air Flow Restriction Switch 3320
Remove for GM 2 4L Gas and LPG Trucks 3320
Install for GM 2 4L Gas and LPG Trucks 3320
Oxygen Sensor 3321
Remove 3321
Install 3324
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3325
Crankshaft Position (CKP) Sensor 3325
Camshaft Position (CMP) Sensor 3325
Oil Pressure Sensor 3325
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3325
Engine Coolant Temperature (ECT) Sensor 3325
Air Flow Restriction Switch 3325
Oxygen Sensor 3325
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3325
Low LPG Pressure Switch 3325
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3326
Air Filter Restriction Switch 3326
Remove 3326
Install 3326
Oil Pressure Sensor 3326
Remove 3326
Install 3326
Engine Speed Sensor 3326
Remove 3326
Install 3326
Engine Coolant Temperature (ECT) Sensor 3326
Remove 3326
Install 3326
Throttle Position Sensor (TPS) 3329
Remove 3329
Install 3330
Fuel/Water Separator Sensor 3330
Remove 3330
Install 3330
Glow Plug Relay 3331
Remove 3331
Install 3333
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3333
Air Filter Restriction Switch 3333
Remove 3333
Install 3333
Engine Oil Pressure Sensor 3338
Remove 3338
Install 3338
Engine Speed Sensor 3338
Remove 3338
Install 3339
Engine Coolant Temperature (ECT) Sensor 3339
Remove 3339
Install 3340
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3341
Remove 3341
Install 3341
Fuel/Water Separator Sensor 3342
Remove 3342
Install 3342
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3343
Intake Air Temperature Sensor 3343
Remove 3343
Install 3344
Intake Air Pressure Sensor 3344
Remove 3344
Install 3344
Air Inlet Heater 3344
Remove 3344
Install 3345
Engine Oil Pressure Sensor 3345
Remove 3345
Install 3345
Engine Coolant Temperature (ECT) Sensor 3345
Remove 3345
Install 3345
Crankshaft Position Sensor 3346
Remove 3346
Install 3346
Adjust Shim Procedure 3347
Camshaft Position Sensor 3348
Remove 3348
Install 3348
Air Flow Restriction Sensor 3349
Remove 3349
Install 3349
Fuel/Water Separator 3349
Remove 3349
Install 3350
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3350
Intake Air Temperature Sensor 3354
Remove 3354
Install 3355
Boost Sensor 3355
Remove 3355
Install 3356
Throttle Valve Assembly and Air Intake Heater 3356
Remove 3356
Install 3356
Engine Coolant Temperature (ECT) Sensor 3357
Remove 3357
Install 3357
Engine Oil Pressure Sensor 3357
Remove 3357
Install 3358
Crankshaft Position Sensor 3358
Remove 3358
Install 3358
Adjust Shim Procedure 3359
Camshaft Position Sensor 3360
Remove 3360
Install 3361
Differential Pressure Sensor 3361
Remove 3361
Install 3361
Mass Air Flow Sensor 3362
Remove 3362
Install 3363
Fuel/Water Separator 3363
Remove 3363
Install 3364
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3364
Engine Coolant Temperature (ECT) Sensor 3365
Remove 3365
Install 3365
Throttle Position Sensor 3366
Engine Oil Pressure Sensor 3366
Remove 3366
Install 3366
Engine Speed Sensor 3366
Remove 3366
Install 3366
Fuel Shut Off Solenoid 3366
Remove 3366
Install 3366
Vehicle System Manager (VSM) 3367
General 3367
VSM Replacement 3367
Remove 3367
Install 3369
Programming a New VSM and/or Display Switch Cluster 3369
General 3369
PC Service Tool Software 3370
Data Transferring 3370
New VSM 3370
New (Blank) Display Switch Cluster 3370
Used (Non-Blank) Display Switch Cluster 3370
Power Distribution Module (PDM) and Component Parts 3372
Remove 3372
PDM as a Unit 3372
Install 3376
PDM as a Unit 3376
Remove and Install 3377
PDM Component Parts 3377
Transmission Control Unit 3377
Remove 3377
Install 3381
Battery 3383
Remove 3383
Install 3383
Lights 3384
Work Lights (Front and Rear) 3384
Remove 3384
Install 3384
Strobe Light 3385
Remove 3385
Install 3385
LED Tail, Backup, and Brake Lights 3386
Remove 3386
Install 3387
Front Marker/Turn Signal Lights 3388
Replacing Whole Front Marker/Turn Signal Light Assembly 3388
Remove 3388
Install 3388
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3389
Remove 3389
Install 3389
Diesel Particulate Filter (DPF) Display 3389
Remove 3389
Clean and Inspect 3390
Install 3390
Electronic-Hydraulic Controls – Generation 1 3391
E-Hydraulic Controls – Test 3391
Mini-Levers 3391
Full Stroke Test 3391
Function Returns to Neutral Test 3391
Push Button Switch 3391
General 3392
Mini-Lever Replacement 3392
Remove 3392
Clean and Inspect 3393
Install 3393
Push Button Switch Replacement 3394
Remove 3394
Install 3396
Mini-Lever Module (MLM) 3396
Remove 3396
Install 3396
Joystick 3397
Remove and Disassemble 3397
Inspect 3397
Assemble and Install 3397
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3398
General 3398
Mini-levers, Remove and Install 3398
Armrest Assembly 3399
Remove 3399
Install 3402
Horn Button 3402
Remove 3402
Install 3402
Direction Control Switch 3403
Remove 3403
Install 3403
push (override) buttons and Toggle Switch 3403
Remove 3404
Install 3405
Joystick 3406
Remove and Disassemble 3406
Inspect 3406
Assemble and Install 3406
Joystick Armrest Slider Assembly 3407
Remove 3407
Install 3408
Electronic-Hydraulic Controls, After January, 2020 3408
E-Hydraulic Controls – TEST 3408
Mini-Levers 3408
Full Stroke Test 3408
Function Returns to Neutral Test 3408
Push (Override) Button 3409
General 3409
Mini-levers, Remove and Install 3409
Armrest Assembly 3410
Remove 3410
Install 3413
Horn Button 3413
Remove 3413
Install 3413
Direction Control Switch 3413
Remove 3413
Install 3414
Push (Override) buttons and Toggle Switch 3414
Remove 3415
Install 3417
Special Tools 3418
524223772-2200YRM1142-(08-2021)-US-EN 3421
General 3431
Display Switch Cluster 3435
Remove 3435
Install 3437
Direction Control and Turn Signal Levers 3437
Remove 3437
Install 3438
Key Switch 3439
Remove 3439
Install 3440
Display Switch Cluster Panel Bezel and Overlay 3440
Remove 3440
Install 3440
Steering Column Repair 3441
Remove 3441
Disassemble 3444
Assemble 3444
Install 3444
Sensors and Switches 3445
General 3445
Dash and Kick Panel, Remove and Install 3445
Remove 3445
Install 3446
Accelerator Pedal Position Sensor 3446
Remove 3446
Install 3450
Brake Fluid Level Switch 3451
Remove 3451
Install 3452
Service Brake Pedal Position Sensor 3454
Remove 3454
Install 3456
Parking Brake Sensor 3457
Remove 3457
Install 3459
Service Brake Pressure Sensor 3459
Remove 3459
Install 3461
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3463
Remove 3463
Install 3463
Sensor Microswitch (Foot Directional Control Pedal) 3463
Remove 3463
Install 3466
Low Coolant Level Sensor 3467
Remove 3467
Install 3470
Fuel Level Sensor, Gas and Diesel Engines Only 3471
Remove 3471
Install 3472
Armrest Switch 3472
Remove 3472
Install 3474
Seat Sensor (Operator Presence System) 3474
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) 3474
Remove 3474
Install 3475
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3475
Remove 3475
Install 3475
Full Suspension Seats; All Lift Truck Models 3476
Remove 3476
Install 3476
Hood Shut Off Switch 3477
Remove 3477
Install 3479
Remote Key Switch 3480
Remove 3480
Install 3480
Hydraulic Filter Pressure Switch 3481
Remove 3481
Install 3483
Transmission Speed Sensor 3483
Remove 3483
Install 3486
Transmission Pressure Sensors 3487
Remove 3487
Install 3489
Transmission Temperature Sensor 3490
Remove 3490
Install 3492
Engine Speed Sensor 3494
Remove 3494
Install 3495
Intermediate Speed Sensor 3495
Remove 3495
Install 3495
Return to Set Tilt (Tilt Angle) Sensor 3496
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) 3496
Remove 3496
Install 3496
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) 3496
Remove 3497
Install 3498
Rear Horn Button Switch 3499
Remove 3499
Install 3499
Impact Sensor 3500
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) 3500
Remove 3500
Install 3502
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) 3502
Remove 3502
Install 3503
Load Weight Sensor 3503
Remove 3503
Install 3505
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3506
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3506
Crankshaft Position (CKP) Sensor 3506
Camshaft Position (CMP) Sensor 3506
Oil Pressure Sensor 3506
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3506
Engine Coolant Temperature (ECT) Sensor 3507
Air Flow Restriction Switch 3507
Remove for GM 2 4L Gas and LPG Trucks 3507
Install for GM 2 4L Gas and LPG Trucks 3507
Oxygen Sensor 3508
Remove 3508
Install 3511
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3512
Crankshaft Position (CKP) Sensor 3512
Camshaft Position (CMP) Sensor 3512
Oil Pressure Sensor 3512
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3512
Engine Coolant Temperature (ECT) Sensor 3512
Air Flow Restriction Switch 3512
Oxygen Sensor 3512
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3512
Low LPG Pressure Switch 3512
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3513
Air Filter Restriction Switch 3513
Remove 3513
Install 3513
Oil Pressure Sensor 3513
Remove 3513
Install 3513
Engine Speed Sensor 3513
Remove 3513
Install 3513
Engine Coolant Temperature (ECT) Sensor 3513
Remove 3513
Install 3513
Throttle Position Sensor (TPS) 3516
Remove 3516
Install 3517
Fuel/Water Separator Sensor 3517
Remove 3517
Install 3517
Glow Plug Relay 3518
Remove 3518
Install 3520
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3520
Air Filter Restriction Switch 3520
Remove 3520
Install 3521
Engine Oil Pressure Sensor 3525
Remove 3525
Install 3525
Engine Speed Sensor 3525
Remove 3525
Install 3526
Engine Coolant Temperature (ECT) Sensor 3526
Remove 3526
Install 3527
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3528
Remove 3528
Install 3528
Fuel/Water Separator Sensor 3529
Remove 3529
Install 3529
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3530
Intake Air Temperature Sensor 3530
Remove 3530
Install 3531
Intake Air Pressure Sensor 3531
Remove 3531
Install 3531
Air Inlet Heater 3531
Remove 3531
Install 3532
Engine Oil Pressure Sensor 3532
Remove 3532
Install 3532
Engine Coolant Temperature (ECT) Sensor 3532
Remove 3532
Install 3532
Crankshaft Position Sensor 3533
Remove 3533
Install 3533
Adjust Shim Procedure 3534
Camshaft Position Sensor 3535
Remove 3535
Install 3535
Air Flow Restriction Sensor 3535
Remove 3535
Install 3536
Fuel/Water Separator 3536
Remove 3536
Install 3537
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3537
Intake Air Temperature Sensor 3541
Remove 3541
Install 3542
Boost Sensor 3542
Remove 3542
Install 3543
Throttle Valve Assembly and Air Intake Heater 3543
Remove 3543
Install 3543
Engine Coolant Temperature (ECT) Sensor 3544
Remove 3544
Install 3544
Engine Oil Pressure Sensor 3545
Remove 3545
Install 3545
Crankshaft Position Sensor 3545
Remove 3545
Install 3545
Adjust Shim Procedure 3546
Camshaft Position Sensor 3548
Remove 3548
Install 3548
Differential Pressure Sensor 3548
Remove 3548
Install 3549
Mass Air Flow Sensor 3549
Remove 3549
Install 3550
Fuel/Water Separator 3551
Remove 3551
Install 3552
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3553
Engine Coolant Temperature (ECT) Sensor 3554
Remove 3554
Install 3554
Throttle Position Sensor 3554
Engine Oil Pressure Sensor 3554
Remove 3554
Install 3554
Engine Speed Sensor 3554
Remove 3554
Install 3554
Fuel Shut Off Solenoid 3555
Remove 3555
Install 3555
Vehicle System Manager (VSM) 3556
General 3556
VSM Replacement 3556
Remove 3556
Install 3558
Programming a New VSM and/or Display Switch Cluster 3558
General 3558
PC Service Tool Software 3559
Data Transferring 3559
New VSM 3559
New (Blank) Display Switch Cluster 3559
Used (Non-Blank) Display Switch Cluster 3559
Power Distribution Module (PDM) and Component Parts 3562
Remove 3562
PDM as a Unit 3562
Install 3565
PDM as a Unit 3565
Remove and Install 3566
PDM Component Parts 3566
Transmission Control Unit (TCU) 3567
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) 3567
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) 3567
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3568
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3568
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 3568
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 3569
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 3570
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 3572
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 3572
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 3572
Battery 3573
Remove 3573
Install 3573
Lights 3574
Work Lights (Front and Rear) 3574
Remove 3574
Install 3574
Strobe Light 3575
Remove 3575
Install 3575
LED Tail, Backup, and Brake Lights 3576
Remove 3576
Install 3577
Front Marker/Turn Signal Lights 3578
Replacing Whole Front Marker/Turn Signal Light Assembly 3578
Remove 3578
Install 3578
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3579
Remove 3579
Install 3579
Diesel Particulate Filter (DPF) Display 3580
Remove 3580
Clean and Inspect 3581
Install 3581
Electronic-Hydraulic Controls – Generation 1 3582
E-Hydraulic Controls – Test 3582
Mini-Levers 3582
Full Stroke Test 3582
Function Returns to Neutral Test 3582
Push Button Switch 3582
General 3583
Mini-Lever Replacement 3583
Remove 3583
Clean and Inspect 3584
Install 3584
Push Button Switch Replacement 3585
Remove 3585
Install 3587
Mini-Lever Module (MLM) 3587
Remove 3587
Install 3587
Joystick 3588
Remove and Disassemble 3588
Inspect 3588
Assemble and Install 3588
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3589
General 3589
Mini-levers, Remove and Install 3589
Armrest Assembly 3590
Remove 3590
Install 3593
Horn Button 3593
Remove 3593
Install 3593
Direction Control Switch 3594
Remove 3594
Install 3594
push (override) buttons and Toggle Switch 3594
Remove 3595
Install 3596
Joystick 3597
Remove and Disassemble 3597
Inspect 3597
Assemble and Install 3597
Joystick Armrest Slider Assembly 3598
Remove 3598
Install 3599
Electronic-Hydraulic Controls, After January, 2020 3600
E-Hydraulic Controls – TEST 3600
Mini-Levers 3600
Full Stroke Test 3600
Function Returns to Neutral Test 3600
Push (Override) Button 3600
General 3601
Mini-levers, Remove and Install 3601
Armrest Assembly 3602
Remove 3602
Install 3605
Horn Button 3605
Remove 3605
Install 3605
Direction Control Switch 3605
Remove 3605
Install 3606
Push (Override) buttons and Toggle Switch 3606
Remove 3607
Install 3609
Special Tools 3610
524223780-8000YRM1134-(03-2020)-US-EN 3613
Series Code / Model Designation Reference Table 3619
Description 3621
Proc_Cal_001: Service Password Entry 3623
When to Perform 3623
Why Perform 3623
How to Perform 3623
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3624
When to Perform 3624
Calibration Order 3624
Why Perform 3624
How to Perform 3625
Proc_Cal_003: Save and Exit 3626
When to Perform 3626
Why Perform 3626
How to Perform 3626
Proc_Cal_004: Lift Valve Output Threshold 3627
When to Perform 3627
Calibration Order 3627
Why Perform 3627
How to Perform 3628
Proc_Cal_005: Lower Valve Output Threshold 3630
When to Perform 3630
Calibration Order 3630
Why Perform 3630
How to Perform 3630
Proc_Cal_006: Tilt Back Valve Output Threshold 3633
When to Perform 3633
Calibration Order 3633
Why Perform 3633
How to Perform 3633
Proc_Cal_007: Tilt Forward Valve Output Threshold 3636
When to Perform 3636
Calibration Order 3636
Why Perform 3636
How to Perform 3636
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3639
When to Perform 3639
Calibration Order 3639
Why Perform 3639
How to Perform 3639
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3642
When to Perform 3642
Calibration Order 3642
Why Perform 3642
How to Perform 3642
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3645
When to Perform 3645
Calibration Order 3645
Why Perform 3645
How to Perform 3645
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3648
When to Perform 3648
Calibration Order 3648
Why Perform 3648
How to Perform 3648
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3651
When to Perform 3651
Calibration Order 3651
Why Perform 3651
How to Perform 3651
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3654
When to Perform 3654
Calibration Order 3654
Why Perform 3654
How to Perform 3654
Proc_Cal_014: Load Weight Zero Point 3658
When to Perform 3658
Calibration Order 3658
Why Perform 3658
How to Perform 3658
Proc_Cal_015: Loaded Weight Calibration 3660
When to Perform 3660
Calibration Order 3660
Why Perform 3660
How to Perform 3660
Proc_Cal_016: Transmission Valve Calibration 3663
Applicable System/Option 3663
When to Perform 3663
Calibration Order 3663
Why Perform 3663
How to Perform 3663
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3665
Applicable System/Option 3665
When to Perform 3665
Calibration Order 3665
Why Perform 3665
How to Perform 3665
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3667
Applicable System/Option 3667
When to Perform 3667
Calibration Order 3667
Why Perform 3667
How to Perform 3668
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3669
Required Tools 3669
When to Perform 3669
Calibration Order 3669
Why Perform 3670
How to Perform 3670
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3671
When to Perform 3671
Why Perform 3671
How to Perform 3671
Proc_Cal_026: Travel Speed Calibration 3673
When to Perform 3673
Calibration Order 3673
Why Perform 3673
How to Perform 3673
524223780-8000YRM1134-(05-2022)-US-EN 3677
Series Code / Model Designation Reference Table 3683
Description 3686
Proc_Cal_001: Service Password Entry 3688
When to Perform 3688
Why Perform 3688
How to Perform 3688
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3689
When to Perform 3689
Calibration Order 3689
Why Perform 3689
How to Perform 3689
Proc_Cal_003: Save and Exit 3691
When to Perform 3691
Why Perform 3691
How to Perform 3691
Proc_Cal_004: Lift Valve Output Threshold 3692
When to Perform 3692
Calibration Order 3692
Why Perform 3692
How to Perform 3692
Proc_Cal_005: Lower Valve Output Threshold 3695
When to Perform 3695
Calibration Order 3695
Why Perform 3695
How to Perform 3695
Proc_Cal_006: Tilt Back Valve Output Threshold 3698
When to Perform 3698
Calibration Order 3698
Why Perform 3698
How to Perform 3698
Proc_Cal_007: Tilt Forward Valve Output Threshold 3701
When to Perform 3701
Calibration Order 3701
Why Perform 3701
How to Perform 3701
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3704
When to Perform 3704
Calibration Order 3704
Why Perform 3704
How to Perform 3704
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3707
When to Perform 3707
Calibration Order 3707
Why Perform 3707
How to Perform 3707
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3710
When to Perform 3710
Calibration Order 3710
Why Perform 3710
How to Perform 3710
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3713
When to Perform 3713
Calibration Order 3713
Why Perform 3713
How to Perform 3713
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3716
When to Perform 3716
Calibration Order 3716
Why Perform 3716
How to Perform 3716
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3719
When to Perform 3719
Calibration Order 3719
Why Perform 3719
How to Perform 3719
Proc_Cal_014: Load Weight Zero Point 3722
When to Perform 3722
Calibration Order 3722
Why Perform 3722
How to Perform 3722
Proc_Cal_015: Loaded Weight Calibration 3724
When to Perform 3724
Calibration Order 3724
Why Perform 3724
How to Perform 3724
Proc_Cal_016: Transmission Valve Calibration 3727
Applicable System/Option 3727
When to Perform 3727
Calibration Order 3727
Why Perform 3727
How to Perform 3727
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3729
Applicable System/Option 3729
When to Perform 3729
Calibration Order 3729
Why Perform 3729
How to Perform 3729
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3732
Applicable System/Option 3732
When to Perform 3732
Calibration Order 3732
Why Perform 3732
How to Perform 3732
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3735
Required Tools 3735
When to Perform 3735
Calibration Order 3735
Why Perform 3735
How to Perform 3735
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3737
When to Perform 3737
Why Perform 3737
How to Perform 3737
Proc_Cal_026: Travel Speed Calibration 3739
When to Perform 3739
Calibration Order 3739
Why Perform 3739
How to Perform 3739
524262275-0900YRM1242-(04-2018)-US-EN 3743
General 3749
Hoses Replacement 3749
LPG Tank and Bracket Replacement 3750
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) 3750
Remove 3750
Install 3753
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) 3754
Remove 3754
Install 3754
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) 3754
Remove 3754
Install 3756
LPG Tank, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3757
Remove 3757
Install 3759
LPG Tank Bracket, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3759
Remove 3759
Install 3759
High Pressure Fuel Filter Unit Repair 3759
Fuel Filter Element 3760
Remove 3760
Clean/Inspect 3761
Install 3761
Fuel Filter Housing 3761
Remove 3761
Disassemble 3762
Assemble 3762
Install 3762
Electronic Throttle Body Repair 3763
Remove 3763
Clean/Inspect 3764
Install 3764
Fuel Injector Repair 3765
Fuel Rail 3765
Remove for Lift Trucks Built Before January, 2010 3765
Remove for Lift Trucks Built After January, 2010 3767
Install for Lift Trucks Built Before January, 2010 3768
Install for Lift Trucks Built After January, 2010 3769
Fuel Injectors and Adapters 3769
Remove for Lift Trucks Built Before January, 2010 3769
Remove for Lift Trucks Built After January, 2010 3771
Clean 3772
Install for Lift Trucks Built Before January, 2010 3772
Install for Lift Trucks Built After January, 2010 3774
LPG Regulator Repair 3774
LPG Regulator 3774
Remove for Lift Trucks Built Before January, 2010 3774
Remove for Lift Trucks Built After January, 2010 3775
Install for Lift Trucks Built Before January, 2010 3777
Install for Lift Trucks Built After January, 2010 3777
LPG Regulator Fuel Filter 3778
Remove 3778
Install 3779
Lock-Off Solenoid and Cartridge 3779
Remove 3779
Install 3780
Control System 3780
Electronic Control Unit (ECU) and Injector Driver Modules Assembly 3780
Remove 3780
Install 3781
Electronic Control Unit (ECU) 3782
Remove 3782
Install 3782
Injector Driver Modules 3783
Remove 3783
Install 3783
Fuel Pressure Sensor 3784
Remove 3784
Install 3784
Low LPG Pressure Switch 3784
Remove 3784
Install 3785
LPG Pressure Sensor 3785
Remove 3785
Install 3786
Oxygen Sensor 3786
Exhaust System Repair 3787
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 3787
Remove for Lift Trucks Built Before January, 2010 3787
Remove for Lift Trucks Built After January, 2010 3789
Inspect 3791
Install for Lift Trucks Built Before January, 2010 3791
Install for Lift Trucks Built After January, 2010 3791
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) 3792
Remove for Lift Trucks Built Before January, 2010 3792
Remove for Lift Trucks Built After January, 2010 3794
Inspect 3797
Install for Lift Trucks Built Before January, 2010 3797
Install for Lift Trucks Built After January, 2010 3798
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3799
Remove for Lift Trucks Built Before January, 2010 3799
Remove for Lift Trucks Built After January, 2010 3802
Inspect 3803
Install for Lift Trucks Built Before January, 2010 3804
Install for Lift Trucks Built After January, 2010 3804
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3805
Remove for Lift Trucks Built Before January, 2010 3805
Remove for Lift Trucks Built After January, 2010 3808
Inspect 3809
Install for Lift Trucks Built Before January, 2010 3810
Install for Lift Trucks Built After January, 2010 3810
Oxygen Sensor 3811
Remove 3811
Install 3812
LPG Fuel Testing 3812
General 3812
Available Fuel Tests 3812
Composition Test (ASTM D-2163) 3812
Ammonia Test (ASTM D-4490) 3813
Basic Nitrogen Test (ASTM UOP269-90) 3813
Residues Test (ASTM D-2158) 3813
Vapor Pressure Test (ASTM D-2598) 3813
Sulfur Compounds Test (ASTM D-5623) 3813
Methanol Test (ASTM D-4864) 3813
Copper Corrosion (ASTM D-1838) 3813
Where To Send LPG Fuel Samples For Testing 3813
524262276-0900YRM1244-(06-2012)-US-EN 3817
toc 3817
Gasoline Fuel System 3817
Safety Precautions Maintenance and Repair 3818
General 3821
Electronic Throttle Body Repair 3821
Electronic Throttle Body 3821
Remove 3821
Clean/Inspect 3821
Install 3822
Fuel System Repair 3823
Before Repair Procedure 3823
After Repair Procedure 3823
Fuel Leakage Check for Lift Trucks Built Before January, 2010 3823
Fuel Leakage Check for Lift Trucks Built After January, 2010 3824
Fuel Line Pressure Check 3826
Fuel Injector Repair 3827
Remove 3827
Install 3837
Control System 3838
Electronic Control Unit (ECU) 3838
Remove for Lift Trucks Built Before January, 2010 3838
Remove for Lift Trucks Built After January, 2010 3839
Install for Lift Trucks Built Before January, 2010 3840
Install for Lift Trucks Built After January, 2010 3841
Exhaust System Repair 3842
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; ( 3842
Remove for Lift Trucks Built Before January, 2010 3842
Remove for Lift Trucks Built After January, 2010 3844
Inspect 3844
Install for Lift Trucks Built Before January, 2010 3846
Install for Lift Trucks Built After January, 2010 3846
GM 4 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45 3847
Remove for Lift Trucks Built Before January, 2010 3847
Remove for Lift Trucks Built After January, 2010 3849
Inspect 3851
Install for Lift Trucks Built Before January, 2010 3851
Install for Lift Trucks Built After January, 2010 3852
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (G 3853
Remove for Lift Trucks Built Before January, 2010 3853
Remove for Lift Trucks Built After January, 2010 3855
Inspect 3857
Install for Lift Trucks Built Before January, 2010 3857
Install for Lift Trucks Built After January, 2010 3858
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (G 3858
Remove for Lift Trucks Built Before January, 2010 3858
Remove for Lift Trucks Built After January, 2010 3861
Inspect 3861
Install for Lift Trucks Built Before January, 2010 3863
Install for Lift Trucks Built After January, 2010 3863
Oxygen Sensor 3864
Remove 3864
Install 3864
524262279-1800YRM1247-(06-2021)-US-EN 3867
General 3871
Dry Brake System 3871
Wet Brake System 3871
Service Brakes Repair (Dry Brake) 3875
Remove and Disassemble 3875
Clean 3877
Inspect 3878
Assemble and Install 3879
Adjust 3882
Parking Brake Repair 3883
Dry Brake System 3883
Remove and Disassembly 3883
Assemble and Install 3885
Wet Brake System 3885
Remove and Install 3885
Assemble and Install 3892
Adjust 3892
Dry Brake System 3892
Wet Brake System 3893
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3893
Master Cylinder Repair 3895
Remove 3895
Disassemble 3899
Clean and Inspect 3900
Assemble 3901
Install and Adjust 3901
Accumulator 3904
Pre-Charge Check 3904
Remove 3905
Install 3907
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3908
Remove 3908
Modulating Brake Valve 3910
Disassemble 3910
Clean and Inspect 3911
Assemble 3911
Accumulator Charge Valve 3912
Disassemble 3912
Clean and Inspect 3914
Assemble 3914
Install 3915
Pressure Checks 3916
Accumulator Charge Valve Check 3916
Accumulator Check 3916
Service Brakes Adjustment (Dry Brake) 3917
Service Brakes Adjustment 3917
Brake System Air Removal 3919
Using Pressure Bleed System 3919
Using Brake Pedal Pressure 3919
Lift Truck Models with Master Cylinder 3919
Lift Truck Models with Modulating Brake Valve 3920
Brake Pedal Adjustment 3921
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) 3921
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3922
Free Pedal Adjustment 3924
Torque Specifications 3925
524262279-1800YRM1247-(09-2018)-US-EN 3927
General 3931
Dry Brake System 3931
Wet Brake System 3932
Service Brakes Repair (Dry Brake) 3936
Remove and Disassemble 3936
Clean 3938
Inspect 3939
Assemble and Install 3939
Adjust 3943
Parking Brake Repair 3943
Dry Brake System 3944
Remove and Disassembly 3944
Assemble and Install 3946
Wet Brake System 3946
Remove and Install 3947
Assemble and Install 3953
Adjust 3953
Dry Brake System 3953
Wet Brake System 3954
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3954
Master Cylinder Repair 3955
Remove 3955
Disassemble 3960
Clean and Inspect 3961
Assemble 3962
Install and Adjust 3962
Accumulator 3964
Pre-Charge Check 3965
Remove 3966
Install 3968
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3968
Remove 3969
Modulating Brake Valve 3970
Disassemble 3970
Clean and Inspect 3972
Assemble 3972
Accumulator Charge Valve 3973
Disassemble 3973
Clean and Inspect 3975
Assemble 3975
Install 3976
Pressure Checks 3977
Accumulator Charge Valve Check 3977
Accumulator Check 3977
Service Brakes Adjustment (Dry Brake) 3978
Service Brakes Adjustment 3978
Brake System Air Removal 3979
Using Pressure Bleed System 3979
Using Brake Pedal Pressure 3980
Lift Truck Models with Master Cylinder 3980
Lift Truck Models with Modulating Brake Valve 3980
Brake Pedal Adjustment 3981
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) 3981
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3982
Free Pedal Adjustment 3984
Torque Specifications 3985
524265337-0600YRM1251-(09-2015)-US-EN 3989
General 3995
Engine Removal and Installation 3995
Cylinder Head Repair 3995
Remove and Disassemble 3995
Clean and Inspect 3997
Valve Oil Seals 4000
Remove and Disassemble 4000
Cylinder Leak Down Test 4000
Clean and Inspect 4001
Assemble and Install 4001
Valve Guides and Seats, Repairs 4003
Valves, Repair 4003
Valve Seats, Repair 4004
Valve Springs 4005
Assemble and Install 4006
Engine Block Cleaning and Inspection 4009
Clean and Inspect 4010
Piston Bore Preparation 4012
Engine Mounts Installation 4012
Remove 4012
Clean and Inspect 4013
Install 4013
Lubrication System Repair 4014
Oil Pump, Remove and Disassemble 4014
Clean and Inspect 4015
Oil Pump, Assemble and Install 4016
Oil Pan, Install 4018
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4020
Timing Cover 4020
Remove 4020
Install 4022
Timing Sprockets 4022
Remove 4022
Install 4022
Camshaft 4022
Remove 4022
Inspect 4023
Install 4023
Balance Shaft 4024
Remove 4024
Install 4025
Valve Lifters 4026
Remove 4026
Clean and Inspect 4026
Install 4027
Crankshaft Repair 4027
Remove 4028
Inspect and Repair 4028
How to Check Clearance Between Main Bearings and Their Journals 4029
Install 4030
Piston and Connecting Rod Assemblies Repair 4032
Connecting Rod Bearings, Replace 4032
Piston and Connecting Rod Assemblies, Remove 4033
Disassemble 4033
Piston, Clean and Inspect 4034
Cylinder Bores, Inspect and Repair 4034
Piston Rings 4035
Assemble 4036
Piston and Connecting Rod Assemblies, Install 4036
Flywheel and Flywheel Housing Repair 4036
Flywheel, Remove 4037
Clean 4037
Inspect 4037
Flywheel, Install 4038
Coolant Pump Repair 4038
Remove 4038
Clean and Inspect 4039
Install 4039
Thermostat Replacement 4039
Remove 4040
Thermostat Operation Check 4040
Install 4040
Starter Replacement 4041
4041
Remove 4041
Install 4044
Fan Assembly Replacement 4045
Remove 4045
Inspect 4047
Install 4047
Drive Belt Installation 4048
Remove 4048
Clean 4048
Inspect 4048
Installation 4049
Compression Check 4050
Engine Specifications 4050
Engine Data 4050
Cylinder Head 4050
Hydraulic Valve Lifter 4051
Camshaft 4051
Pistons 4051
Crankshaft 4052
Connecting Rods 4052
Balance Shaft 4053
Cooling System 4053
Lubrication System 4053
Torque Specifications 4054
524265342-4000YRM1250-(06-2021)-US-EN 4059
Safety Procedures When Working Near Mast 4065
Fork Replacement 4068
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4068
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4069
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) 4071
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4072
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4073
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) 4074
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4074
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) 4075
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4076
Fixed Carriage Replacement 4078
Remove, Carriage With Hook Forks 4078
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4086
Install, Carriage With Hook Forks 4087
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4087
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4088
Connecting Attachment Hydraulic Quick Disconnect Hoses 4088
Integral Sideshift Carriage Repair 4089
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) 4089
Disassemble 4089
Clean and Inspect 4092
Assemble 4092
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) 4093
Hang On Sideshift Carriage Repair 4094
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) 4094
Disassemble 4106
Clean and Inspect 4115
Assemble 4116
Install 4117
Hang-On Sideshift Carriage Repair 4119
Remove 4119
Disassemble Carriage 4121
Clean and Inspect 4124
Assemble 4124
Install 4127
Fork Positioner 4130
Two-Stage Mast With Limited Free-Lift Repair 4131
Remove 4131
Disassemble 4134
Clean and Inspect 4137
Assemble 4155
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) 4157
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) 4159
Header Hose Alignment 4170
Two-Stage Mast With Full Free-Lift Repair 4181
Remove 4181
Disassemble 4183
Clean and Inspect 4194
Assemble 4195
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) 4197
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) 4200
Header Hose Installation and Adjustment 4204
Installation 4204
Adjustment 4205
Three-Stage Mast With Full Free-Lift Repair 4206
Remove 4206
Disassemble 4208
Clean and Inspect 4238
Assemble 4240
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) 4243
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) 4248
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) 4255
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) 4262
Mast Operation Check 4266
Tilt Cylinder Adjustment 4267
Lift Chains Adjustment 4267
Mast Adjustments 4269
Load Roller Adjustment 4269
Mast Side Kicking Adjustment 4271
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4272
Carriage Adjustments 4274
Series Code / Model Designation Reference Table 4275
524265342-4000YRM1250-(09-2018)-US-EN 4279
Safety Procedures When Working Near Mast 4285
Fork Replacement 4287
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4287
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4289
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) 4290
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4291
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4292
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) 4293
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4293
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) 4295
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4295
Fixed Carriage Replacement 4297
Remove, Carriage With Hook Forks 4297
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4306
Install, Carriage With Hook Forks 4307
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4307
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4308
Connecting Attachment Hydraulic Quick Disconnect Hoses 4308
Integral Sideshift Carriage Repair 4309
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) 4309
Disassemble 4309
Clean and Inspect 4312
Assemble 4312
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) 4313
Hang On Sideshift Carriage Repair 4313
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) 4313
Disassemble 4325
Clean and Inspect 4334
Assemble 4335
Install 4336
Bolzoni Hang-On Sideshift Carriage Repair 4338
Remove 4338
Disassemble Carriage 4340
Clean and Inspect 4343
Assemble 4343
Install 4346
Fork Positioner 4348
Two-Stage Mast With Limited Free-Lift Repair 4349
Remove 4349
Disassemble 4353
Clean and Inspect 4356
Assemble 4373
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) 4375
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) 4376
Header Hose Alignment 4388
Two-Stage Mast With Full Free-Lift Repair 4398
Remove 4398
Disassemble 4400
Clean and Inspect 4412
Assemble 4413
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) 4415
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) 4418
Header Hose Installation and Adjustment 4422
Installation 4422
Adjustment 4422
Three-Stage Mast With Full Free-Lift Repair 4423
Remove 4423
Disassemble 4425
Clean and Inspect 4455
Assemble 4456
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) 4460
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) 4465
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) 4472
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) 4478
Mast Operation Check 4482
Tilt Cylinder Adjustment 4482
Lift Chains Adjustment 4483
Mast Adjustments 4484
Load Roller Adjustment 4484
Mast Side Kicking Adjustment 4486
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4487
Carriage Adjustments 4490
524288189-0100YRM1316-(01-2022)-US-EN 4493
General 4497
Description 4498
Hood, Seat, Dash, and Side Covers Replacement 4500
Remove 4500
Install 4506
Steering Column 4510
Description 4510
Steering Column Repair 4510
Remove 4510
Disassemble 4511
Clean 4513
Inspect 4513
Assemble 4513
Install 4513
LPG Tank and Bracket Replacement 4513
Counterweight Replacement 4514
Remove 4514
Install 4515
Tow Pin, Remove and Install 4517
Overhead Guard Replacement 4518
Remove 4518
Install 4519
LED Tail, Backup, and Brake Lights, Replace 4520
Operator Restraint System Replacement 4521
Description 4521
Engine Replacement 4523
Remove Engine Only 4523
Install Engine only 4549
Remove Engine and Transmission 4552
Install Engine and Transmission 4554
Electronic Throttle Replacement 4558
Cummins 4 5L Diesel Engine With Electronic Throttle 4558
Remove 4558
Install 4562
Pull Actuator Linkage Adjustment 4564
Low Idle Adjustment 4564
Throttle Pedal and Cable Adjustment 4565
Cummins 4 5L Diesel Engine 4565
Exhaust System Repair 4567
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4567
PSI 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4567
Cummins QSB 3 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4567
Remove 4567
Inspect 4567
Install 4570
Cummins 4 5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4570
Remove 4570
Inspect 4572
Install 4572
Kubota 3 8L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 4572
Remove 4572
Inspect 4575
Install 4575
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) 4575
Remove 4575
Inspect 4578
Install 4578
Kubota 3 8L Diesel Engine w/DOC for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) 4578
Remove 4578
Inspect 4581
Install 4581
Cooling System 4582
Description 4582
Hydraulic Filter Assembly Repair 4583
Remove 4583
Disassemble 4583
Clean 4584
Inspect 4584
Assemble 4584
Install 4584
Fuel and Hydraulic Tanks Repair 4585
Inspect 4585
Clean 4585
Steam Method of Cleaning 4585
Chemical Solution Method of Cleaning 4586
Additional Preparations for Repair 4587
Small Leaks, Repair 4587
Large Leaks, Repair 4587
Preparations for Use After Repair 4587
Safety Labels 4588
524288189-0100YRM1316-(11-2017)-US-EN 4595
General 4599
Description 4599
Hood, Seat, Dash, and Side Covers Replacement 4600
Remove 4601
Install 4606
Steering Column 4609
Description 4609
Steering Column Repair 4609
Remove 4609
Disassemble 4611
Clean 4612
Inspect 4612
Assemble 4612
Install 4612
LPG Tank and Bracket Replacement 4612
Counterweight Replacement 4612
Remove 4613
Install 4614
Tow Pin, Remove and Install 4616
Overhead Guard Replacement 4616
Remove 4616
Install 4617
LED Tail, Backup, and Brake Lights, Replace 4618
Operator Restraint System Replacement 4618
Description 4619
Engine Replacement 4620
Remove Engine Only 4620
Install Engine only 4642
Remove Engine and Transmission 4646
Install Engine and Transmission 4649
Electronic Throttle Replacement 4651
Cummins 4 5L Diesel Engine With Electronic Throttle 4651
Remove 4651
Install 4655
Pull Actuator Linkage Adjustment 4657
Low Idle Adjustment 4657
Throttle Pedal and Cable Adjustment 4657
Cummins 4 5L Diesel Engine 4658
Exhaust System Repair 4659
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4660
PSI 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4660
Cummins QSB 3 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4660
Remove 4660
Inspect 4660
Install 4662
Cummins 4 5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4662
Remove 4662
Inspect 4663
Install 4663
Kubota 3 8L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 4665
Remove 4665
Inspect 4665
Install 4666
Kubota 3 8L Diesel Engine w/DPF for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4667
Remove 4667
Inspect 4669
Install 4669
Kubota 3 8L Diesel Engine w/DOC for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4669
Remove 4669
Inspect 4670
Install 4670
Cooling System 4673
Description 4674
Hydraulic Filter Assembly Repair 4674
Remove 4674
Disassemble 4674
Clean 4674
Inspect 4675
Assemble 4675
Install 4675
Fuel and Hydraulic Tanks Repair 4675
Inspect 4676
Clean 4676
Steam Method of Cleaning 4676
Chemical Solution Method of Cleaning 4677
Additional Preparations for Repair 4678
Small Leaks, Repair 4678
Large Leaks, Repair 4678
Preparations for Use After Repair 4678
Safety Labels 4678
524288194-1300YRM1317-(03-2020)-US-EN 4685
Transmission Repair 4689
Remove 4689
Torque Converter, Remove 4689
Disassemble 4690
Clean and Inspect 4739
Housings 4739
Oil Seals and Gaskets 4739
Bearings 4739
Gears and Shafts 4740
Assemble 4740
Torque Converter, Install 4781
Install 4782
Control Valve Repair 4783
Remove 4783
Disassemble 4783
Clean 4785
Inspect 4785
Assemble 4785
Install 4786
Torque Specification 4787
524288194-1300YRM1317-(06-2021)-US-EN 4789
Transmission Repair 4793
Remove 4793
Torque Converter, Remove 4793
Disassemble 4794
Clean and Inspect 4845
Housings 4845
Oil Seals and Gaskets 4845
Bearings 4845
Gears and Shafts 4846
Assemble 4846
Torque Converter, Install 4888
Install 4889
Control Valve Repair 4890
Remove 4890
Disassemble 4890
Clean 4892
Inspect 4892
Assemble 4892
Install 4893
Torque Specification 4894
524288199-1400YRM1318-(06-2021)-US-EN 4897
General 4901
Identification Plate 4901
Drive Axle Removal 4901
Planetary Reduction Gear Repair 4909
Clean and Inspect 4916
Brake Repair 4924
Clean and Inspect 4931
Wet Brake Noise Reduction 4942
General 4942
Adding Additive To Transmission 4942
Differential Repair 4944
Clean and Inspect 4953
Bevel Pinion 4965
Clean and Inspect 4969
Drive Axle Installation 4980
Special Tools 4988
Torque Specifications 4989
524288199-1400YRM1318-(09-2018)-US-EN 4991
General 4995
Identification Plate 4995
Drive Axle Removal 4995
Planetary Reduction Gear Repair 5002
Clean and Inspect 5010
Brake Repair 5017
Clean and Inspect 5025
Wet Brake Noise Reduction 5035
General 5035
Adding Additive To Transmission 5035
Differential Repair 5036
Clean and Inspect 5046
Bevel Pinion 5058
Clean and Inspect 5062
Drive Axle Installation 5072
Special Tools 5079
Torque Specifications 5079
524288204-8000YRM1319-(12-2018)-US-EN 5083
General 5089
Serial Number Data 5089
How to Move Disabled Lift Truck 5090
How to Tow Lift Truck 5090
How to Put Lift Truck on Blocks 5091
How to Raise Drive Tires 5091
How to Raise Steering Tires 5091
How to Clean a Lift Truck 5092
Maintenance Schedule 5093
Maintenance Procedures Every 8 Hours or Daily 5112
How to Make Checks With Engine Stopped 5113
Tires and Wheels 5113
Safety Labels 5113
Mast, Carriage, Lift Chains, Header Hoses, Attachment 5114
Operator Restraint System 5114
Emergency Locking Retractor (ELR) 5114
Adjust Seat – Full Suspension 5115
Adjust Seat – Internal Suspension 5117
Hood and Seat Latches 5117
Engine Compartment 5118
Paper Application 5118
Fuel, Oil, and Coolant Leaks, Check 5118
Hydraulic Hoses 5119
Coolant Hoses 5119
Steering Column Gas Cylinder 5119
Transmission 5119
Hydraulic System Oil 5119
Engine Oil 5121
Air Filter 5125
Forks 5125
Remove 5125
Inspect 5126
Install 5126
Adjust 5127
Hang On Sideshift Carriage 5127
How to Make Checks With Engine Running 5128
Indicator Lights, Horn, Fuses, and Relays 5128
Service Brakes 5130
Brake Oil Level 5130
Operation, Check 5131
Parking Brake 5131
Engine Oil Pressure 5131
Cooling System 5131
Steering System 5132
Control Levers and Pedals 5132
Lift System, Operate 5133
Air Filter 5133
Fuel/Water Separator Filter, Cummins 4 5L and QSB 3 3L Diesel Engine 5133
First Service After First 100 Hours of Operation 5133
GM 4 3L Engine Oil and Oil Filter 5134
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 5134
Maintenance Procedures Every 250 Hours or 6 Months 5134
GM 4 3L Engine Oil and Oil Filter Change 5134
Drive Belt 5135
GM 4 3L Engine 5135
Fan and Alternator Drive Belt 5135
Drain Tar From LPG Regulator 5136
Drain Tar From LPG Converter 5137
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine 5138
Maintenance Procedures Every 500 Hours or 6 Months 5139
Hydraulic System Oil 5140
Hydraulic Tank Breather 5142
Inspect 5142
Battery 5143
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 5143
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 5144
Remove 5144
Install 5144
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 5146
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 5147
Controlled Venting 5147
Manual Bleeding 5147
Low Idle Speed Adjustment, Cummins 4 5L Engine Only 5147
Drive Belt 5148
Cummins 4 5L and QSB 3 3L Diesel Engine 5148
Fan and Alternator Drive Belt 5148
Clean Debris From Radiator Core 5149
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 5149
Wet Brake Center Body Oil Level Check 5150
Forks 5154
Mast Lubrication 5154
Header Hose Checks 5159
Lift Chain Lubrication 5159
Tilt Cylinder Lubrication 5159
Master Brake Cylinder Rod End Pin Lubrication 5160
Manual Hydraulic Levers Lubrication 5161
Brake Oil 5161
Tie Rod Lubrication 5162
Parking Brake Adjustment 5162
Maintenance Procedures Every 1000 Hours or 6 Months 5163
Valve Clearance, Check and Adjust 5163
Ignition System 5163
GM 4 3L Engine 5163
LPG Fuel Filter Element Replace, GM 4 3L Engine 5163
Remove 5163
Install 5164
In-Line Filter Replacement, Cummins 4 5L Engine 5164
Remove 5164
Install 5165
Lift Chains Wear Check 5166
Lift Chain Lubrication 5166
Hang On Sideshift Carriage, Check Sliding Surfaces 5167
Steering Axle Spindle Bearings 5170
Control Levers and Pedals 5171
Inspect Engine Electrical System, Connectors 5171
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 5172
Parking Brake Lever Lubrication, Wet Brake Axle 5176
Normal Operating Environment 5176
Heavy Duty or Contaminated Environment 5177
Remove 5177
Clean and Inspect 5178
Install 5178
Maintenance Procedures Every 2000 Hours or Annually 5178
Hydraulic System 5179
Hydraulic Filter Assembly, Replace 5179
Hydraulic Tank Breather, Replace 5180
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 5180
Cooling System Check 5180
Air Filter 5182
Oxygen Sensor, GM 4 3L Engine Equipped With GFI Installed 5184
LPG Regulator Fuel Filter, GM 4 3L Engines with GFI Installed 5185
Remove 5185
Install 5186
Gasoline Fuel Filter 5186
Remove and Replace 5186
LPG Fuel Injector, GM 4 3L Engines with GFI Installed 5187
Gasoline Fuel Injector, GM Engines 5187
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 5187
Forks 5187
Brake Oil (Master Cylinder), Change 5187
Test Regulator PressureLPG/GAS 5188
Check Throttle Shaft for Sticking 5188
Inspect Exhaust Manifold and Piping for Leaks 5188
Transmission Automatic Clutch Calibration 5188
Brake System Accumulator 5188
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 5188
Wheel Bearings 5189
Steer Wheels, Lubrication 5189
Maintenance Procedures Every 4000 Hours or 2 Years 5189
Hydraulic Oil, Replace 5190
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 5192
Safety Procedures When Working Near Mast 5194
Fuel Filter Water Removal 5197
Hood Latch Check 5197
Lift Chain Adjustments 5198
Jump-Starting the Lift Truck 5200
Jump-Starting Using a Battery Charger 5200
Jump-Starting a Lift Truck Using Another Lift Truck 5200
Welding Repairs 5201
Overhead Guard Changes 5201
Wheel and Tire Replacement 5202
General 5202
Solid Rubber Tire, Change 5202
Remove and Install Tire on Wheel 5202
Adhesives and Sealants 5204
524288212-8000YRM1320-(06-2019)-US-EN 5207
Lift Truck Lifting Capacity 5211
Counterweight Weights 5211
Tire Sizes 5211
Capacities 5212
Electrical System 5219
Transmission Oil Pressures 5220
Hydraulic System Relief Pressures 5224
Steering System 5225
Stall Speeds (in RPM ±100 rpm) 5226
GM 4 3L Gas GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 5226
GM 4 3L LPG GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 5226
GM 4 3L Gas GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 5226
GM 4 3L LPG GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 5226
Cummins 4 5L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879) 5227
Cummins QSB 3 3L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879) 5227
Cummins 4 5L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878) 5227
Cummins QSB 3 3L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 5227
Mast Speeds 5228
Tilt Angles 5229
Front End Equipment – Mast Creep 5230
Mast Creep 5230
Engine Specifications 5230
Torque Specifications 5232
Frame 5232
Mast, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 5232
Mast, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 5233
Hang On Sideshift Carriage With Fork Positioner, Lift Truck Models Manufactured After August, 2012GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 5233
Steering System 5233
Transmission 5234
Engine – GM 4 3L 5234
Engine – Cummins 4 5L and QSB 3 3L Diesel 5235
524294873-1300YRM1343-(06-2021)-US-EN 5237
Transmission Repair 5241
Remove 5241
Torque Converter, Remove 5241
Disassemble 5243
Clean and Inspect 5284
Housings 5284
Oil Seals and Gaskets 5284
Bearings 5284
Gears and Shafts 5285
Assemble 5285
Torque Converter, Install 5323
Install 5324
Control Valve Repair 5325
Remove 5325
Disassemble 5325
Control Valve Assembly 5325
Control Valve Body 5325
Clean 5328
Inspect 5328
Assemble 5328
Control Valve Body 5328
Control Valve Assembly 5329
Install 5329
Torque Specification 5331
524294873-1300YRM1343-(11-2019)-US-EN 5333
Transmission Repair 5337
Remove 5337
Torque Converter, Remove 5337
Disassemble 5338
Clean and Inspect 5378
Housings 5378
Oil Seals and Gaskets 5378
Bearings 5379
Gears and Shafts 5379
Assemble 5379
Torque Converter, Install 5417
Install 5418
Control Valve Repair 5419
Remove 5419
Disassemble 5419
Control Valve Assembly 5419
Control Valve Body 5419
Clean 5422
Inspect 5422
Assemble 5422
Control Valve Body 5422
Control Valve Assembly 5422
Install 5423
Torque Specification 5425
524294878-2100YRM1328-(06-2021)-US-EN 5427
General 5431
Safety Procedures When Working Near Mast 5431
Tilt Cylinder Repair 5434
Remove 5434
Disassemble 5438
Clean 5440
Inspect 5440
Assemble 5440
Install 5442
Tilt Cylinders, Adjust 5444
Tilt Cylinder Leak Check 5446
Lift Cylinder Repair 5447
Remove 5447
Disassemble 5456
Clean 5459
Inspect 5459
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) 5459
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5459
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) 5460
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5460
Free-Lift Cylinder Repair 5462
Remove 5462
Disassemble 5468
Clean 5470
Inspect 5470
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) 5471
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5471
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) 5471
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5472
Sideshift Cylinder Repair 5473
Remove 5473
Disassemble 5474
Clean 5477
Inspect 5477
Assemble 5478
Install 5479
Bolzoni Sideshift Cylinder Repair 5480
Remove 5480
Disassemble 5480
Clean 5481
Inspect 5481
Assemble 5482
Install 5482
Fork Positioner Cylinder Repair 5483
Remove 5483
Disassemble 5486
Clean 5490
Inspect 5490
Assemble 5491
Install 5492
Lift Cylinder Leak Check 5494
Seal Kit Installation 5495
External Installation (Seal and Back-Up Ring) 5495
Internal Installation (Piston Rod Assembly) 5495
Special Tools 5496
Torque Specifications 5497
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) 5497
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5497
524294878-2100YRM1328-(09-2018)-US-EN 5499
General 5503
Safety Procedures When Working Near Mast 5503
Tilt Cylinder Repair 5505
Remove 5505
Disassemble 5510
Clean 5512
Inspect 5512
Assemble 5512
Install 5514
Tilt Cylinders, Adjust 5516
Tilt Cylinder Leak Check 5517
Lift Cylinder Repair 5518
Remove 5518
Disassemble 5528
Clean 5531
Inspect 5531
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) 5531
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5531
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) 5532
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5532
Free-Lift Cylinder Repair 5533
Remove 5533
Disassemble 5539
Clean 5541
Inspect 5541
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) 5542
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5542
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) 5542
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5543
Sideshift Cylinder Repair 5544
Remove 5544
Disassemble 5545
Clean 5548
Inspect 5548
Assemble 5549
Install 5550
Bolzoni Sideshift Cylinder Repair 5551
Remove 5551
Disassemble 5551
Clean 5552
Inspect 5552
Assemble 5553
Install 5553
Fork Positioner Cylinder Repair 5553
Remove 5554
Disassemble 5557
Clean 5561
Inspect 5561
Assemble 5562
Install 5563
Lift Cylinder Leak Check 5564
Seal Kit Installation 5564
External Installation (Seal and Back-Up Ring) 5564
Internal Installation (Piston Rod Assembly) 5565
Special Tools 5566
Torque Specifications 5567
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) 5567
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5567
524329117-8000YRM1387-(03-2020)-US-EN 5571
General Information About Diagrams and Schematics 5575
Symbol Definitions 5575
Diagrams Manual Applications 5576
Diagrams and Schematics 5578
524329117-8000YRM1387-(06-2021)-US-EN 5643
General Information About Diagrams and Schematics 5647
Symbol Definitions 5647
Diagrams Manual Applications 5648
Diagrams and Schematics 5650
550001092-8000YRM1409-(03-2020)-US-EN 5713
General Information About Diagrams and Schematics 5717
Symbol Definitions 5717
Diagrams Manual Applications 5718
Diagrams and Schematics 5720
550001092-8000YRM1409-(06-2021)-US-EN 5801
General Information About Diagrams and Schematics 5805
Symbol Definitions 5805
Diagrams Manual Applications 5806
Diagrams and Schematics 5808
550043871-0900YRM1556-(04-2018)-US-EN 5883
General 5887
LPG Tank and Bracket 5887
LPG Tank, Lift Truck Models GLC40-55VX; GLC55SVX; GLC080-120VX; GLC080-100VXBCS; GLC120SVX; GLC120VXPRS) (E818, F818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080-120VX) (G813, H813, J813, K813), and GLC60-70VX (GLC135-155VX) (D879, E879, F879) 5887
Remove 5887
Install 5895
LPG Tank Bracket, Lift Truck Models GLC40-55VX; GLC55SVX (GLC080-120VX; GLC080-100VXBCS, GLC120SVX; GLC120VXPRS) (E818, F818), GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (G813, H813, J813, K813), and GLC60-70VX (GLC135-155VX) (D879, E879, F879) 5896
Remove 5896
Install 5898
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 5898
Remove 5898
Install 5900
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 5900
Remove 5900
Install 5900
LPG Tank Bracket Alignment Pin, Lift Truck Models GLC40-55VX; GLC55SVX (GLC080-120VX; GLC080-100VXBCS, GLC120SVX; GLC120VXPRS) (E818, F818), GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (F813, G813, H813, J813, K813), and GLC60-70VX (GLC135-155VX) (D879, E879, F879) 5901
Remove 5901
Install 5903
Fuel Filter Unit 5903
Fuel Filter Element 5904
Remove 5904
Clean and Inspect 5904
Install 5905
Fuel Filter Housing with LP Vapor Sensor 5905
Remove 5905
Disassemble 5907
Clean and Inspect 5908
Assemble 5908
Install 5909
Throttle Body 5910
Remove 5910
Clean 5914
Install 5914
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 5915
Remove 5915
Install 5916
Control System 5916
Engine Control Unit (ECU) 5917
Remove 5917
Install 5918
Low Pressure Switch 5918
Remove 5918
Install 5918
Low Fuel Sensor 5919
Remove 5919
Install 5919
LP Converter 5920
Remove and Disassemble 5920
Assemble and Install 5921
LPG Lock-Off 5921
Remove 5922
Install 5923
Exhaust System 5924
Counterweight Exhaust 5924
Remove and Disassemble 5924
Inspect 5926
Assemble and Install 5926
Overhead Exhaust 5927
Remove and Disassemble 5927
Inspect 5929
Assemble and Install 5929
Exhaust Manifold 5929
Remove 5929
Install 5931
Oxygen (HEGO) Sensor 5931
Remove 5931
Install 5931
LPG Fuel Testing 5932
General 5932
Available Fuel Tests 5932
Composition Test (ASTM D-2163) 5932
Ammonia Test (ASTM D-4490) 5932
Basic Nitrogen Test (ASTM UOP269-90) 5932
Residues Test (ASTM D-2158) 5932
Vapor Pressure Test (ASTM D-2598) 5932
Sulfur Compounds Test (ASTM D-5623) 5932
Methanol Test (ASTM D-4864) 5933
Copper Corrosion (ASTM D-1838) 5933
Where To Send LPG Fuel Samples For Testing 5933
550073240-1900YRM1620-(01-2023)-US-EN 5937
Proper Flushing after Major Hydraulic Repairs 5943
Introduction 5943
The Phases of Wear 5943
Causes of Hydraulic System Failure 5943
Progression of Contaminant Caused Hydraulic System Failure 5944
Hydraulic System Flushing Techniques 5944
Double Oil and Filter Change 5944
Mechanical Cleaning 5945
Cleaning of Components 5945
How to Clean Tubes and Hoses 5945
Filter Caddy 5945
Start-Up Procedure for Cleaned System 5946
Contaminated Oil Coolers 5946
Additional Filter Caddy Functions 5947
How to Handle Different Fluids 5947
Water Removal Filters 5947
Fluid Conditioning and System Flushing Procedures 5948
Operation of the Filter Caddy 5948
Filter Caddy operation 5948
Fluid Conditioning Procedure 5948
Filter Caddy Start-Up 5949
System Flushing Procedure 5949
Component Cleaning Procedure 5950
Reservoir Cleaning Procedure 5950
Cylinder Cleaning Procedure 5950
Hose and Tube Cleaning Procedure 5950
Valve Cleaning Procedure 5951
Front-End Attachment Cleaning Procedure 5952
System Flushing Procedure 5952
Filter Caddy Start-Up 5953
System Start-Up and Flushing 5953
Reservoir Fluid Cleaning Times 5954
Dealing With Different Fluid Types 5955
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5955
Filter Caddy Maintenance 5955
Servicing the Strainer 5955
DC Motor 5955
Hydraulic Oil Sampling Method and Procedure 5956
Hydraulic Oil Sampling Method 5956
Objective 5956
General Guidelines 5956
Synopsis 5957
Hydraulic Oil Analysis Report Guidelines 5958
Sampling Conditions 5958
Equipment 5958
Sampling Procedure 5959
Hydraulic Oil Sampling 5959
Sample Labeling 5959
Results Documentation 5959
550073240-1900YRM1620-(03-2020)-US-EN 5961
Proper Flushing after Major Hydraulic Repairs 5965
Introduction 5965
The Phases of Wear 5965
Causes of Hydraulic System Failure 5965
Progression of Contaminant Caused Hydraulic System Failure 5966
Hydraulic System Flushing Techniques 5966
Double Oil and Filter Change 5966
Mechanical Cleaning 5967
Cleaning of Components 5967
How to Clean Tubes and Hoses 5967
Filter Caddy 5967
Start-Up Procedure for Cleaned System 5968
Contaminated Oil Coolers 5968
Additional Filter Caddy Functions 5968
How to Handle Different Fluids 5968
Water Removal Filters 5969
Fluid Conditioning and System Flushing Procedures 5969
Operation of the Filter Caddy 5969
Filter Caddy operation 5969
Fluid Conditioning Procedure 5970
Filter Caddy Start-Up 5970
System Flushing Procedure 5971
Component Cleaning Procedure 5971
Reservoir Cleaning Procedure 5971
Cylinder Cleaning Procedure 5971
Hose and Tube Cleaning Procedure 5972
Valve Cleaning Procedure 5972
Front-End Attachment Cleaning Procedure 5973
System Flushing Procedure 5973
Filter Caddy Start-Up 5974
System Start-Up and Flushing 5974
Reservoir Fluid Cleaning Times 5975
Dealing With Different Fluid Types 5975
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5975
Filter Caddy Maintenance 5976
Servicing the Strainer 5976
DC Motor 5976
Hydraulic Oil Sampling Method and Procedure 5976
Hydraulic Oil Sampling Method 5976
Objective 5976
General Guidelines 5976
Synopsis 5977
Hydraulic Oil Analysis Report Guidelines 5978
Sampling Conditions 5979
Equipment 5979
Sampling Procedure 5979
Hydraulic Oil Sampling 5979
Sample Labeling 5980
Results Documentation 5980

S.V 06/24