Yale Forklift D879 (GLC_GDC60VX, GLC_GDC70VX) Service Manual PDF

Description

Yale Forklift D879 (GLC_GDC60VX, GLC_GDC70VX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift D879 (GLC_GDC60VX, GLC_GDC70VX) Service Manual – PDF DOWNLOAD

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

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift D879 (GLC_GDC60VX, GLC_GDC70VX) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-UK-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524208014-2200YRM1097-(03-2020)-US-EN 43
Series Code / Model Designation Reference Table 47
Description 48
Distributor Ignition (DI) System 48
Crankshaft Position (CKP) Sensor 48
Camshaft Position (CMP) Sensor 48
Ignition Coil and Ignition Control Module (ICM) 48
Secondary Ignition Components 48
Spark Plugs and Wires 49
Spark Plug Wire Inspection 49
Spark Plug Wire Replacement 49
Remove 49
Install 50
Spark Plug Inspection 50
Usage 50
Inspection 50
Visual Inspection 52
Spark Plug Replacement 52
Remove 52
Install 52
Distributor Repair 53
Inspect 53
Overhaul 53
Disassemble 53
Assemble 56
Replace 57
Remove 57
Install Procedure 1 59
Install Procedure 2 60
Ignition Coil Replacement 61
Remove 61
Install 61
Ignition Control Module Replacement 62
Remove 62
Install 62
Starter Replacement 63
Remove 63
Install 66
Sensors and Switches 67
Gas and LPG Trucks 67
Crankshaft Position (CKP) Sensor 67
Remove 67
Install 67
Camshaft Position (CMP) Sensor 68
Remove 68
Install 70
Oil Pressure Sensor 70
Remove 70
Install 71
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 72
Remove 72
Install 72
Engine Coolant Temperature (ECT) Sensor 73
Remove 73
Install 74
Air Flow Restriction Switch 74
Remove 74
Install 75
Specifications and Special Tools 76
524221866-9000YRM1112-(10-2020)-US-EN 81
SECTION 9010 Operational Diagnostic Procedures 97
Group 05 – Operational Checkout 99
SECTION 9020 Engine 117
Group 10 – Principles of Operation 127
Group 30 – Observed Symptoms 325
Group 40 – Tests and Adjustments 427
SECTION 9030 Electrical System 459
Group 03 – General Maintenance and Diagnostic Data 483
Group 10 – Principles of Operation 577
Group 20 – Diagnostic Trouble Codes 601
Group 30 – Observed Symptoms 1573
SECTION 9040 Drive Train 1629
Group 10 – Principles of Operation 1633
Group 30 – Observed Symptoms 1689
Group 40 – Tests and Adjustments 1739
SECTION 9050 Hydraulic Systems 1749
Group 10 – Principles of Operation 1753
Group 30 – Observed Symptoms 1811
Group 33 – Observed Symptoms-Gear Pump 1813
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1901
Group 40 – Tests and Adjustments 1945
Group 43 – Tests and Adjustments-Gear Pump 1947
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1971
SECTION 9060 Operators Station 1989
Group 10 – Principles of Operation 1991
SECTION 9070 Front End (Mast) and Chassis 2027
Group 10 – Principles of Operation 2029
Group 30 – Observed Symptoms 2051
SECTION 9080 Supplementary Data 2109
Group 50 – Abbreviations and Acronyms 2111
Group 60 – Special Tools List 2119
Group 70 – Fault Mode Indicator Reference 2129
Group 80 – Supplier Specification Data 2131
524223757-0700YRM1123-(06-2016)-UK-EN 2135
General 2139
Cooling System Checks 2139
Exhaust Leaks Into Cooling System 2139
Water Flow Restrictions in Radiator 2139
Radiator Hoses 2139
Water Pump 2140
Flushing the Cooling System 2140
Cooling System, Clean 2140
Radiator Replacement 2141
Radiator, Remove GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2142
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2157
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2160
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 2163
Radiator, Install for Lift Truck Models GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2170
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2175
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2177
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2180
Fan Assembly Replacement 2192
Fan Removal 2192
Inspect 2207
Fan Installation 2207
524223757-0700YRM1123-(06-2021)-US-EN 2213
General 2217
Cooling System Checks 2217
Exhaust Leaks Into Cooling System 2217
Water Flow Restrictions in Radiator 2217
Radiator Hoses 2217
Water Pump 2217
Flushing the Cooling System 2219
Cooling System, Clean 2219
Radiator Replacement 2221
Radiator, Remove GC/GLC030VX,GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX (GP/GLP/GDP030VX,GP/GLP/GDP035VX, GP/GLP/GDP040SVX)(C810); GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910); GLC050LX(A967); GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875);GLP/GDP20-25LX (GLP/GDP050LX)(A974); GLC40, 45, 55VX, GLC55SVX,(GC/GLC080, 100, 120VX, GC/GLC080,100VXBCS, GC/GLC120SVX,GC/GLC120VXPRS) (E818, F818) ANDGLP/GDP40VX5/VX6, GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) 2221
Radiator, Remove for Lift Trucks Models Equipped with Oil CoolerGC/GLC030VX, GC/GLC035VX,GC/GLC040SVX (C809); GLP/GDP16VX,GLP/GDP18VX, GLP/GDP20SVX(GP/GLP/GDP030VX, GP/GLP/GDP035VX,GP/GLP/GDP040SVX) (C810); GLC050LX(A967) AND GLP/GDP20-25LX(GLP/GDP050LX) (A974) 2236
Radiator, Remove for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2239
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX(GP/GLP/GDP135VX, GP/GLP/GDP155VX)(C878, D878, E878) and GLP/GDP80VX,GLP/GDP80VX9, GLP/GDP90VX(GLP/GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (A909, B909) 2242
Radiator, Install for Lift Truck Models GC/GLC030VX,GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX (GP/GLP/GDP030VX,GP/GLP/GDP035VX, GP/GLP/GDP040SVX)(C810); GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910); GLC050LX(A967); GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875);GLP/GDP20-25LX (GLP/GDP050LX)(A974); GLC40, 45, 55VX; GLC55SVX;(GC/GLC080, 100, 120VX; GC/GLC080,100VXBCS; GC/GLC120SVX;GC/GLC120VXPRS) (E818, F818) andGLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) 2248
Radiator, Install for Lift Truck Models Equipped with Oil CoolerGC/GLC030VX, GC/GLC035VX,GC/GLC040SVX (C809); GLP/GDP16VX,GLP/GDP18VX, GLP/GDP20SVX(GP/GLP/GDP030VX, GP/GLP/GDP035VX,GP/GLP/GDP040SVX) (C810); GLC050LX(A967) and GLP/GDP20-25LX(GLP/GDP050LX) (A974) 2252
Radiator, Install for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2253
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2256
Fan Assembly Replacement 2267
Fan Removal 2267
Inspect 2281
Fan Installation 2282
524223764-1600YRM1133-(07-2013)-UK-EN 2287
toc 2287
Steering Axle 2287
Safety Precautions Maintenance and Repair 2288
General 2291
Steering Axle Assembly Repair 2293
Remove 2293
Disassemble 2294
Clean 2302
Inspect 2302
Assemble 2302
Install 2308
Spindles, Bearings, and Tie Rods Repair 2310
Spindles and Bearings 2310
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2310
Remove 2310
Disassemble 2312
Clean 2313
Inspect 2313
Assemble 2313
Install 2314
Spindles and Bearings 2317
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2317
Remove and Disassemble 2317
Assemble and Install 2318
Tie Rods 2318
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2318
Remove 2318
Install 2319
Tie Rods 2320
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2320
Remove 2320
Install 2326
Steering Cylinder Repair 2326
Remove and Disassemble 2326
Clean and Inspect 2327
Assemble and Install 2327
Torque Specifications 2328
524223764-1600YRM1133-(07-2013)-US-EN 2333
toc 2333
Steering Axle 2333
Safety Precautions Maintenance and Repair 2334
General 2337
Steering Axle Assembly Repair 2339
Remove 2339
Disassemble 2340
Clean 2348
Inspect 2348
Assemble 2348
Install 2354
Spindles, Bearings, and Tie Rods Repair 2356
Spindles and Bearings 2356
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2356
Remove 2356
Disassemble 2358
Clean 2359
Inspect 2359
Assemble 2359
Install 2360
Spindles and Bearings 2363
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2363
Remove and Disassemble 2363
Assemble and Install 2364
Tie Rods 2364
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2364
Remove 2364
Install 2365
Tie Rods 2366
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2366
Remove 2366
Install 2372
Steering Cylinder Repair 2372
Remove and Disassemble 2372
Clean and Inspect 2373
Assemble and Install 2373
Torque Specifications 2374
524223766-1900YRM1136-(01-2022)-US-EN 2379
General 2383
Hydraulic Gear Pump Assembly 2384
Variable Displacement Pump Assembly 2385
Single Gear Pump Assembly Repair 2386
Remove 2386
Disassemble 2392
Clean 2394
Inspect 2394
Assemble 2394
Install 2394
Tandem Gear Pump Assembly 2399
Remove 2399
Disassemble 2400
Clean 2403
Inspect 2403
Assemble 2403
Install 2404
Gear Pump Specifications 2405
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2411
Remove 2411
Disassemble 2421
Clean 2424
Inspect 2425
Assemble 2425
Install 2425
63 0 cc/rev – Variable Displacement Pump Repair 2430
Remove 2430
Disassemble 2433
Clean 2435
Inspect 2435
Assemble 2435
Install 2435
Variable Displacement Pump Checks and Adjustments (Single Pump) 2439
Margin Pressure Check 2439
Flow Compensator Adjustment 2440
Pressure Compensator Adjustment 2440
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2442
Variable Displacement Pump Specifications 2445
Torque Specifications 2447
Hydraulic Gear Pump 2447
Variable Displacement Pump 2448
Special Tools 2449
524223766-1900YRM1136-(11-2017)-UK-EN 2451
General 2455
Hydraulic Gear Pump Assembly 2456
Variable Displacement Pump Assembly 2457
Single Gear Pump Assembly Repair 2457
Remove 2457
Disassemble 2464
Clean 2464
Inspect 2466
Assemble 2466
Install 2466
Tandem Gear Pump Assembly 2470
Remove 2471
Disassemble 2473
Clean 2475
Inspect 2475
Assemble 2475
Install 2476
Gear Pump Specifications 2476
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2482
Remove 2482
Disassemble 2492
Clean 2495
Inspect 2495
Assemble 2495
Install 2496
63 0 cc/rev – Variable Displacement Pump Repair 2499
Remove 2499
Disassemble 2502
Clean 2502
Inspect 2502
Assemble 2504
Install 2504
Variable Displacement Pump Checks and Adjustments (Single Pump) 2506
Margin Pressure Check 2506
Flow Compensator Adjustment 2507
Pressure Compensator Adjustment 2507
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2508
Variable Displacement Pump Specifications 2511
Torque Specifications 2512
Hydraulic Gear Pump 2513
Variable Displacement Pump 2514
Special Tools 2514
524223767-2000YRM1137-(01-2017)-UK-EN 2519
General 2525
Electro-Hydraulic Main Control Valve 2526
Description 2526
Remove 2534
Electro-Hydraulic Control Valve Sections 2539
General 2539
Outlet Control Valve Section 2539
Remove 2539
Disassemble 2540
Clean 2542
Inspect 2542
Assemble 2542
Install 2543
Auxiliary Control Valve Sections 2543
Remove 2543
Disassemble 2550
Clean 2551
Inspect 2552
Assemble 2552
Install 2554
Tilt Control Valve Section 2555
Remove 2555
Disassemble 2555
Clean 2561
Inspect 2561
Assemble 2561
Install 2562
Lift/Lower Control Valve Section 2563
Remove 2563
Disassemble 2563
Clean 2572
Inspect 2572
Assemble 2572
Install 2573
Mid-Inlet Section 2573
Remove 2573
Clean 2574
Inspect 2574
Install 2574
Install 2574
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2579
Lift Pilot Pin 2579
Lower Pilot Pin 2583
Abnormal/Erroneous EHPV Adjustment 2585
Manual Main Control Valve 2586
Description 2586
Remove 2590
OPS Solenoid Assembly 2598
General 2598
Remove 2599
Clean and Inspect 2602
Install 2602
Manual Control Valve Sections 2603
General 2603
Outlet Control Valve Section 2603
Remove 2603
Disassemble 2603
Clean 2606
Inspect 2606
Assemble 2606
Install 2607
Auxiliary Control Valve Sections 2607
Remove 2607
Disassemble 2607
Clean 2610
Inspect 2610
Assemble 2610
Install 2611
Lift/Tilt Control Valve Section 2611
Remove 2611
Disassemble 2611
Clean 2618
Inspect 2618
Assemble 2619
Install 2620
Mid-Inlet Section 2621
Remove 2621
Clean 2621
Inspect 2621
Install 2621
Install 2622
Pressure Relief Valve Check and Adjustment 2628
Primary Relief Valve 2629
Secondary Relief Valve 2633
Steering Control Unit Repair 2640
Steering Control Unit, Remove 2640
Steering Control Unit, Disassemble 2644
Steering Control Unit, Clean 2646
Steering Control Unit, Inspect 2646
Steering Control Unit, Assemble 2646
Relief Valve, Disassemble 2647
Relief Valve, Clean 2647
Relief Valve, Inspect 2648
Relief Valve, Assemble 2648
Steering Control Unit, Install 2648
524223767-2000YRM1137-(06-2021)-US-EN 2653
General 2657
Electro-Hydraulic Main Control Valve 2658
Description 2658
Remove 2666
Electro-Hydraulic Control Valve Sections 2671
General 2671
Outlet Control Valve Section 2671
Remove 2671
Disassemble 2671
Clean 2674
Inspect 2674
Assemble 2675
Install 2675
Auxiliary Control Valve Sections 2675
Remove 2676
Disassemble 2681
Clean 2683
Inspect 2683
Assemble 2683
Install 2685
Tilt Control Valve Section 2686
Remove 2686
Disassemble 2687
Clean 2691
Inspect 2691
Assemble 2692
Install 2693
Lift/Lower Control Valve Section 2693
Remove 2693
Disassemble 2693
Clean 2699
Inspect 2699
Assemble 2699
Install 2700
Mid-Inlet Section 2700
Remove 2700
Clean 2701
Inspect 2701
Install 2701
Install 2701
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2706
Lift Pilot Pin 2706
Lower Pilot Pin 2709
Abnormal/Erroneous EHPV Adjustment 2711
Manual Main Control Valve 2712
Description 2712
Remove 2716
OPS Solenoid Assembly 2724
General 2724
Remove 2725
Clean and Inspect 2727
Install 2727
Manual Control Valve Sections 2728
General 2728
Outlet Control Valve Section 2728
Remove 2728
Disassemble 2728
Clean 2731
Inspect 2731
Assemble 2731
Install 2731
Auxiliary Control Valve Sections 2732
Remove 2732
Disassemble 2732
Clean 2735
Inspect 2735
Assemble 2735
Install 2735
Lift/Tilt Control Valve Section 2736
Remove 2736
Disassemble 2736
Clean 2742
Inspect 2742
Assemble 2742
Install 2744
Mid-Inlet Section 2744
Remove 2744
Clean 2745
Inspect 2745
Install 2745
Install 2745
Pressure Relief Valve Check and Adjustment 2753
Primary Relief Valve 2753
Secondary Relief Valve 2756
Steering Control Unit Repair 2761
Steering Control Unit, Remove 2761
Steering Control Unit, Disassemble 2765
Steering Control Unit, Clean 2767
Steering Control Unit, Inspect 2767
Steering Control Unit, Assemble 2767
Relief Valve, Disassemble 2768
Relief Valve, Clean 2768
Relief Valve, Inspect 2769
Relief Valve, Assemble 2769
Steering Control Unit, Install 2769
524223769-2200YRM1128-(01-2023)-US-EN 2773
Series Code / Model Designation Reference Table 2781
General 2783
Deutsch Crimping Tool 2784
How to Strip a Wire for Use With Deutsch Crimping Tool 2784
How to Crimp With the Deutsch Crimping Tool 2785
Calibration Test for the Deutsch Crimping Tool 2787
Deutsch Connectors 2789
DT, DTM, and DTP Series Connectors 2789
HD Series Connectors 2832
Metri-Pack Connectors 2854
Remove and Install 2854
Micro-Pack Connectors 2857
Weather-Pack Connectors 2858
AMPSEAL Crimping Tools 2860
AMP Hand Crimping Tool With Certi-Crimp 2860
Description 2860
Stripping Wire for Use with AMP Hand Crimping Tool 2861
Insulation Crimp Adjustment 2862
Maintenance and Inspection for AMP Hand Crimping Tool 2862
AMP Hand Crimping Tool 2862
Crimp Height Inspection 2862
How to use AMP Hand Crimping Tool 2863
AMP Pro-Crimper II Tool 2863
Description 2863
Remove and Install Die Set and Locator Assembly 2864
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2864
Contact Support Adjustment 2865
Crimp Height Adjustment 2866
Maintenance and Inspection Procedures 2866
PRO-CRIMPER II Tool 2866
Crimp Height Inspection 2866
How to Use AMP PRO-CRIMPER II Tool 2867
AMPSEAL Connector Assemblies 2868
Description for Plug Connector Assembly 2868
Seal Plug 2869
Contact Crimping 2869
Description for Plug Connector and Header Assembly 2874
Voltage Reading 2877
Seal Plug 2877
Contact Crimping 2877
AMP Superseal 1 5 Crimping Tools 2884
Mini Mic Receptacle and Tab Contacts 2884
Description 2884
Crimping Conditions and Measurements 2884
Insertion of Rubber Seal on Cable 2886
AMP Hand Application Tool 2891
Description 2891
Maintenance and Inspection 2891
Crimp Height Inspection 2891
Crimp Height Adjustment 2892
How to Use AMP Hand Application Tool 2892
AMP Pro-Crimper II Tool 2893
Description 2893
Remove and Install Die Set and Locator Assembly 2893
Adjustments 2894
Contact Support 2894
Crimp Height 2895
Inspections and Maintenance 2896
Crimp Height Inspection 2896
Visual Inspection 2896
Maintenance 2897
How to Use Pro-Crimper II Tool 2897
AMP Superseal 1 5 Connector Assemblies 2898
Description 2898
Repair and Maintenance 2905
Panel Mount Option 2905
AMP Fastin-Faston Hand Tools 2906
Description – AMP Double Action Hand Tool 2906
Maintenance and Inspection Procedures 2906
Daily Maintenance 2906
Periodic Tool Inspection 2907
Lubrication 2907
Visual Inspection 2907
Crimp Height Inspection 2907
Certi-Crimp Ratchet Inspection 2908
How to Use AMP Double Action Hand Tool 2909
Description – AMP Extraction Tool 2910
Maintenance and Inspection 2911
How to Use AMP Extraction Tool 2911
AMP Fastin-Faston Receptacles and Housings 2913
Description 2913
Wire Repair 2921
Wire Splicing Requirements 2921
Deutsch Jiffy Splice 2922
Twisted/Shielded Cable and Leads Repair 2928
Special Tools 2930
524223769-2200YRM1128-(07-2020)-UK-EN 2939
Series Code / Model Designation Reference Table 2945
General 2948
Deutsch Crimping Tool 2948
How to Strip a Wire for Use With Deutsch Crimping Tool 2948
How to Crimp With the Deutsch Crimping Tool 2949
Calibration Test for the Deutsch Crimping Tool 2951
Deutsch Connectors 2953
DT, DTM, and DTP Series Connectors 2953
HD Series Connectors 2995
Metri-Pack Connectors 3018
Remove and Install 3018
Micro-Pack Connectors 3020
Weather-Pack Connectors 3021
AMPSEAL Crimping Tools 3023
AMP Hand Crimping Tool With Certi-Crimp 3023
Description 3023
Stripping Wire for Use with AMP Hand Crimping Tool 3023
Insulation Crimp Adjustment 3024
Maintenance and Inspection for AMP Hand Crimping Tool 3024
AMP Hand Crimping Tool 3024
Crimp Height Inspection 3024
How to use AMP Hand Crimping Tool 3025
AMP Pro-Crimper II Tool 3025
Description 3025
Remove and Install Die Set and Locator Assembly 3026
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3027
Contact Support Adjustment 3027
Crimp Height Adjustment 3028
Maintenance and Inspection Procedures 3028
PRO-CRIMPER II Tool 3028
Crimp Height Inspection 3028
How to Use AMP PRO-CRIMPER II Tool 3029
AMPSEAL Connector Assemblies 3030
Description for Plug Connector Assembly 3030
Seal Plug 3031
Contact Crimping 3031
Description for Plug Connector and Header Assembly 3036
Voltage Reading 3038
Seal Plug 3038
Contact Crimping 3038
AMP Superseal 1 5 Crimping Tools 3045
Mini Mic Receptacle and Tab Contacts 3045
Description 3045
Crimping Conditions and Measurements 3045
Insertion of Rubber Seal on Cable 3047
AMP Hand Application Tool 3052
Description 3052
Maintenance and Inspection 3052
Crimp Height Inspection 3052
Crimp Height Adjustment 3053
How to Use AMP Hand Application Tool 3053
AMP Pro-Crimper II Tool 3054
Description 3054
Remove and Install Die Set and Locator Assembly 3055
Adjustments 3055
Contact Support 3055
Crimp Height 3056
Inspections and Maintenance 3057
Crimp Height Inspection 3057
Visual Inspection 3057
Maintenance 3058
How to Use Pro-Crimper II Tool 3058
AMP Superseal 1 5 Connector Assemblies 3059
Description 3059
Repair and Maintenance 3066
Panel Mount Option 3066
AMP Fastin-Faston Hand Tools 3067
Description – AMP Double Action Hand Tool 3067
Maintenance and Inspection Procedures 3067
Daily Maintenance 3067
Periodic Tool Inspection 3068
Lubrication 3068
Visual Inspection 3068
Crimp Height Inspection 3068
Certi-Crimp Ratchet Inspection 3069
How to Use AMP Double Action Hand Tool 3070
Description – AMP Extraction Tool 3071
Maintenance and Inspection 3071
How to Use AMP Extraction Tool 3072
AMP Fastin-Faston Receptacles and Housings 3073
Description 3073
Wire Repair 3080
Wire Splicing Requirements 3080
Deutsch Jiffy Splice 3081
Twisted/Shielded Cable and Leads Repair 3086
Special Tools 3089
524223770-2200YRM1130-(03-2020)-UK-EN 3097
General 3101
Description 3101
Dash Display Menu Access 3101
Menu Navigation 3102
Standard Display 3102
Main Menu 3102
Passwords Menu 3103
Password Administration 3103
Add Password 3103
Delete Password 3104
Edit Password 3104
Other Password Functions 3105
Operator Passwords – Enable/Disable 3105
Password Time-Out Delay 3105
Passwords – Number Wrong to Disable 3106
Lockout Reset Password 3106
View Password Log 3107
View Versions 3108
VSM Versions 3108
Dash Display Versions 3109
Engine Controller Version 3110
Transmission (Xmsn) Controller Version 3111
Truck Serial Number 3112
Diagnostics 3113
View Fault Log 3113
Set Travel and Braking 3114
Speed Limit 3114
Acceleration Rate 3115
Auto-Deceleration Rate 3115
Set Power Reversal Rate 3116
Set Inching/Brake Overlap 3117
Setup Display Menu 3118
Set Operator Language 3118
Set Units 3119
Set Time Format (12/24 Hour) 3119
Set Daylight Saving Time 3119
Set Time 3122
Set Date Format 3123
Set Date 3123
Setup Hydraulics 3124
Return to Set Tilt Delay/On/Off 3124
Setup General Items 3125
Light Shutdown Time-Out 3125
Impact Sensor – Enable/Disable 3126
Impact Sensor – Soft Impact Settings 3127
Impact Sensor – Hard Impact Settings 3128
Adjust Impact Sensor Settings 3128
Initial Adjustment of Soft and Hard Impact Settings 3130
Readjustment of Soft and Hard Impact Settings 3130
Impact Sensor – Impact Alarm/Shutdown Reset 3131
Impact Sensor – Alarm Time Duration and Deactivation 3132
Impact Sensor – View Impact Event Log 3133
Engine Mode Indicator 3134
Generation 1 (ECO-eLo ONLY) 3134
Generation 2 3135
Operator Checklist 3136
Operator Checklist Off-On Mode 3136
Edit Operator Checklist 3136
Set Operator Checklist Expiration 3137
View Checklist Log 3137
Clear Operator Checklist Log 3138
Clear Operator Checklist Fault 3138
Calibrations 3139
Set Tilt Stop Point 3139
Calibrate Loaded Weight 3139
524223770-2200YRM1130-(05-2021)-US-EN 3141
General 3145
Description 3145
Dash Display Menu Access 3145
Menu Navigation 3146
Standard Display 3146
Main Menu 3146
Passwords Menu 3147
Password Administration 3147
Add Password 3147
Delete Password 3147
Edit Password 3148
Other Password Functions 3149
Operator Passwords – Enable/Disable 3149
Password Time-Out Delay 3149
Passwords – Number Wrong to Disable 3149
Lockout Reset Password 3150
View Password Log 3150
View Versions 3151
VSM Versions 3151
Dash Display Versions 3152
Engine Controller Version 3153
Transmission (Xmsn) Controller Version 3154
Truck Serial Number 3155
Diagnostics 3156
View Fault Log 3156
Set Travel and Braking 3157
Speed Limit 3157
Acceleration Rate 3158
Auto-Deceleration Rate 3158
Set Power Reversal Rate 3159
Set Inching/Brake Overlap 3160
Setup Display Menu 3161
Set Operator Language 3161
Set Units 3162
Set Time Format (12/24 Hour) 3162
Set Daylight Saving Time 3163
Set Time 3166
Set Date Format 3166
Set Date 3167
Setup Hydraulics 3168
Return to Set Tilt Delay/On/Off 3168
Setup General Items 3169
Light Shutdown Time-Out 3169
Impact Sensor – Enable/Disable 3170
Impact Sensor – Soft Impact Settings 3171
Impact Sensor – Hard Impact Settings 3171
Adjust Impact Sensor Settings 3172
Initial Adjustment of Soft and Hard Impact Settings 3174
Readjustment of Soft and Hard Impact Settings 3174
Impact Sensor – Impact Alarm/Shutdown Reset 3175
Impact Sensor – Alarm Time Duration and Deactivation 3176
Impact Sensor – View Impact Event Log 3177
Engine Mode Indicator 3177
Generation 1 (ECO-eLo ONLY) 3177
Generation 2 3178
Operator Checklist 3179
Operator Checklist Off-On Mode 3179
Edit Operator Checklist 3179
Set Operator Checklist Expiration 3179
View Checklist Log 3180
Clear Operator Checklist Log 3181
Clear Operator Checklist Fault 3181
Calibrations 3182
Set Tilt Stop Point 3182
Calibrate Loaded Weight 3182
524223771-2200YRM1131-(03-2020)-UK-EN 3185
Series Code / Model Designation Reference Table 3191
General 3193
Description 3193
Dash Display Menu Access 3193
Menu Navigation 3194
Main Menu 3194
Passwords 3195
Adding Passwords 3195
Hourmeters 3197
View Versions 3198
VSM Versions 3198
Dash Display Versions 3199
Engine Controller Version 3200
Transmission (Xmsn) Controller Version 3201
Truck Serial Number 3202
Truck Configuration 3203
Diagnostics 3204
Clear Fault Log 3204
View Fault Log 3205
No-Run Data Display 3206
Engine Accelerator and Throttle Data Display 3206
Engine Speeds and Governor Data Display 3207
Engine Fuel and Emissions Data Display 3208
Engine General Data Display 3210
XMSN/Brake Data Display 3211
Hydraulic Data Display 3214
General Truck Data Display 3216
Set Travel and Braking 3217
Speed Limit 3217
Acceleration Rate 3218
Auto-Deceleration Rate 3219
Set Power Reversal Rate 3219
Set Inching/Brake Overlap 3220
Setup Hydraulics 3220
Lift Maximum Speed 3221
Lower Maximum Speed 3221
Tilt Maximum Speed 3222
Auxiliary Function One, Direction A, Maximum Speed 3224
Auxiliary Function One, Direction B, Maximum Speed 3226
Auxiliary Function Two, Direction A, Maximum Speed 3226
Auxiliary Function Two, Direction B, Maximum Speed 3227
Auxiliary Function Three, Direction A, Maximum Speed 3228
Auxiliary Function Three, Direction B, Maximum Speed 3228
Lift/Lower Ramp Rate 3229
Hydraulic Auxiliary Ramp Rate 3229
Return to Set Tilt Delay/On/Off 3230
Hydraulic Input Device 3231
Auxiliary Solenoid 3231
Dual Function 3232
Setup Display 3233
Set Service Language 3233
Setup General Items 3233
Motion Alarm Activation Type 3234
Light Shutdown Time-Out 3235
Restore Default Settings 3235
Restore Engine Controller Default Calibration 3236
Impact Sensor – Enable/Disable 3236
Impact Sensor – Soft Impact Settings 3237
Impact Sensor – Hard Impact Settings 3238
Adjust Impact Sensor Settings 3239
Initial Adjustment of Soft and Hard Impact Settings 3241
Readjustment of Soft and Hard Impact Settings 3241
Impact Sensor – Impact Alarm/Shutdown Reset 3242
Impact Sensor – Alarm Time Duration and Deactivation 3243
Impact Sensor – View Impact Event Log 3244
Engine Mode Indicator 3244
Generation 1 (ECO-eLo ONLY) 3244
Generation 2 3245
Diesel Particulate Filter (DPF) Display 3246
General Description 3246
Passive Regeneration Only 3246
Regeneration Level 0 3246
Auto/Active Regeneration Inhibited 3247
Auto/Active Regeneration 3247
Regeneration Level 1 3247
Parked Regeneration Request 3248
Regeneration Level 2 3248
Warning Level 3248
Regeneration Level 3 3248
Service Level 3249
Regeneration Level 4 3249
Display, Diesel Particulate Filter (DPF), Revised 3249
Operator Interface 3249
Refer to Operator Manual 3249
CAN Communication Lost 3250
Passive Regeneration Only 3250
Regeneration Level 0 3250
Auto/Active Regeneration Inhibited 3250
Auto/Active Regeneration 3251
Regeneration Level 1 3251
Idle-up Auto/Active Regeneration 3251
Parked Regeneration Request 3251
Regeneration Level 2 3251
Warning Level 3253
Regeneration Level 3 3253
Service Level 3253
Regeneration Level 4 3253
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3253
Display, Diesel Particulate Filter (DPF), Stage V Engine 3253
Operator Interface 3254
Refer to Operator Manual 3254
CAN Communication Lost 3254
Passive Regeneration Only 3254
Regeneration Level 0 3254
Auto/Active Regeneration Inhibited 3255
Auto/Active Regeneration 3255
Regeneration Level 1 3255
Idle-up Auto/Active Regeneration 3256
Parked Regeneration Request 3256
Regeneration Level 2 3256
Warning Level 3257
Regeneration Level 3 3257
Service Level 3258
Regeneration Level 4 3258
Stage V Content 3258
Emissions System Malfunction 3258
Ash Load 3258
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3259
Operator Interface 3259
Refer to Operator Manual 3259
CAN Communication Lost 3260
Passive Regeneration Only 3260
Regeneration Level 0 3260
Auto/Active Regeneration Inhibited 3260
Auto/Active Regeneration 3261
Regeneration Level 1 3261
Idle-up Auto/Active Regeneration 3261
Parked Regeneration Request 3261
Regeneration Level 2 3261
Warning Level 3263
Regeneration Level 3 3263
Service Level 3263
Regeneration Level 4 3263
Calibrations 3264
Calibrate Transmission Valve 3266
Set Tilt Stop Point 3266
Calibrate Loaded Weight 3266
Calibrate Travel Speed Sensor 3267
Calibrate Mazda LP and Gas Accelerator Pedal 3267
524223771-2200YRM1131-(05-2021)-US-EN 3269
Series Code / Model Designation Reference Table 3275
General 3277
Description 3277
Dash Display Menu Access 3277
Menu Navigation 3278
Main Menu 3279
Passwords 3279
Adding Passwords 3279
Hourmeters 3281
View Versions 3282
VSM Versions 3282
Dash Display Versions 3283
Engine Controller Version 3284
Transmission (Xmsn) Controller Version 3285
Truck Serial Number 3286
Truck Configuration 3287
Diagnostics 3288
Clear Fault Log 3288
View Fault Log 3289
No-Run Data Display 3290
Engine Accelerator and Throttle Data Display 3291
Engine Speeds and Governor Data Display 3293
Engine Fuel and Emissions Data Display 3294
Engine General Data Display 3296
XMSN/Brake Data Display 3297
Hydraulic Data Display 3299
General Truck Data Display 3302
Set Travel and Braking 3304
Speed Limit 3304
Acceleration Rate 3305
Auto-Deceleration Rate 3305
Set Power Reversal Rate 3306
Set Inching/Brake Overlap 3306
Setup Hydraulics 3307
Lift Maximum Speed 3307
Lower Maximum Speed 3308
Tilt Maximum Speed 3308
Auxiliary Function One, Direction A, Maximum Speed 3310
Auxiliary Function One, Direction B, Maximum Speed 3313
Auxiliary Function Two, Direction A, Maximum Speed 3313
Auxiliary Function Two, Direction B, Maximum Speed 3314
Auxiliary Function Three, Direction A, Maximum Speed 3315
Auxiliary Function Three, Direction B, Maximum Speed 3315
Lift/Lower Ramp Rate 3316
Hydraulic Auxiliary Ramp Rate 3316
Return to Set Tilt Delay/On/Off 3317
Hydraulic Input Device 3318
Auxiliary Solenoid 3318
Dual Function 3319
Setup Display 3320
Set Service Language 3320
Setup General Items 3320
Motion Alarm Activation Type 3321
Light Shutdown Time-Out 3322
Restore Default Settings 3322
Restore Engine Controller Default Calibration 3323
Impact Sensor – Enable/Disable 3323
Impact Sensor – Soft Impact Settings 3324
Impact Sensor – Hard Impact Settings 3324
Adjust Impact Sensor Settings 3325
Initial Adjustment of Soft and Hard Impact Settings 3327
Readjustment of Soft and Hard Impact Settings 3327
Impact Sensor – Impact Alarm/Shutdown Reset 3328
Impact Sensor – Alarm Time Duration and Deactivation 3329
Impact Sensor – View Impact Event Log 3330
Engine Mode Indicator 3330
Generation 1 (ECO-eLo ONLY) 3330
Generation 2 3331
Diesel Particulate Filter (DPF) Display 3332
General Description 3332
Passive Regeneration Only 3332
Regeneration Level 0 3332
Auto/Active Regeneration Inhibited 3333
Auto/Active Regeneration 3333
Regeneration Level 1 3333
Parked Regeneration Request 3334
Regeneration Level 2 3334
Warning Level 3335
Regeneration Level 3 3335
Service Level 3335
Regeneration Level 4 3335
Display, Diesel Particulate Filter (DPF), Revised 3335
Operator Interface 3336
Refer to Operator Manual 3336
CAN Communication Lost 3336
Passive Regeneration Only 3336
Regeneration Level 0 3336
Auto/Active Regeneration Inhibited 3337
Auto/Active Regeneration 3337
Regeneration Level 1 3337
Idle-up Auto/Active Regeneration 3337
Parked Regeneration Request 3338
Regeneration Level 2 3338
Warning Level 3339
Regeneration Level 3 3339
Service Level 3339
Regeneration Level 4 3339
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3340
Display, Diesel Particulate Filter (DPF), Stage V Engine 3340
Operator Interface 3340
Refer to Operator Manual 3340
CAN Communication Lost 3341
Passive Regeneration Only 3341
Regeneration Level 0 3341
Auto/Active Regeneration Inhibited 3341
Auto/Active Regeneration 3342
Regeneration Level 1 3342
Idle-up Auto/Active Regeneration 3342
Parked Regeneration Request 3342
Regeneration Level 2 3342
Warning Level 3344
Regeneration Level 3 3344
Service Level 3344
Regeneration Level 4 3344
Stage V Content 3344
Emissions System Malfunction 3344
Ash Load 3345
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3346
Operator Interface 3346
Refer to Operator Manual 3346
CAN Communication Lost 3347
Passive Regeneration Only 3347
Regeneration Level 0 3347
Auto/Active Regeneration Inhibited 3347
Auto/Active Regeneration 3348
Regeneration Level 1 3348
Idle-up Auto/Active Regeneration 3348
Parked Regeneration Request 3348
Regeneration Level 2 3348
Warning Level 3350
Regeneration Level 3 3350
Service Level 3350
Regeneration Level 4 3350
Calibrations 3351
Calibrate Transmission Valve 3353
Set Tilt Stop Point 3353
Calibrate Loaded Weight 3354
Calibrate Travel Speed Sensor 3354
Calibrate Mazda LP and Gas Accelerator Pedal 3355
524223772-2200YRM1142-(01-2020)-UK-EN 3357
General 3367
Display Switch Cluster 3370
Remove 3370
Install 3373
Direction Control and Turn Signal Levers 3373
Remove 3373
Install 3375
Key Switch 3375
Remove 3375
Install 3376
Display Switch Cluster Panel Bezel and Overlay 3376
Remove 3376
Install 3376
Steering Column Repair 3376
Remove 3376
Disassemble 3379
Assemble 3379
Install 3379
Sensors and Switches 3380
General 3380
Dash and Kick Panel, Remove and Install 3380
Remove 3380
Install 3381
Accelerator Pedal Position Sensor 3382
Remove 3382
Install 3385
Brake Fluid Level Switch 3386
Remove 3386
Install 3388
Service Brake Pedal Position Sensor 3389
Remove 3389
Install 3392
Parking Brake Sensor 3393
Remove 3393
Install 3394
Service Brake Pressure Sensor 3395
Remove 3395
Install 3397
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3398
Remove 3398
Install 3398
Sensor Microswitch (Foot Directional Control Pedal) 3399
Remove 3399
Install 3402
Low Coolant Level Sensor 3403
Remove 3403
Install 3406
Fuel Level Sensor, Gas and Diesel Engines Only 3407
Remove 3407
Install 3408
Armrest Switch 3408
Remove 3408
Install 3410
Seat Sensor (Operator Presence System) 3410
Non-Suspension and Semi-Suspension Seats; For Lift truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-8VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (C879, D879, E879, F879) 3410
Remove 3410
Install 3411
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3411
Remove 3411
Install 3412
Full Suspension Seats; All Lift Truck Models 3412
Remove 3412
Install 3412
Hood Shut Off Switch 3412
Remove 3412
Install 3415
Remote Key Switch 3416
Remove 3416
Install 3416
Hydraulic Filter Pressure Switch 3417
Remove 3417
Install 3419
Transmission Speed Sensor 3419
Remove 3419
Install 3422
Transmission Pressure Sensors 3423
Remove 3423
Install 3425
Transmission Temperature Sensor 3426
Remove 3426
Install 3428
Engine Speed Sensor 3430
Remove 3430
Install 3430
Intermediate Speed Sensor 3431
Remove 3431
Install 3431
Return to Set Tilt (Tilt Angle) Sensor 3431
Lift Truck Models GLC20-35VX (GC/GCL040-070VX, GC/GLC055SVX) (A910); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP30VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) 3431
Remove 3431
Install 3432
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3433
Remove 3433
Install 3434
Rear Horn Button Switch 3434
Remove 3434
Install 3435
Impact Sensor 3436
Lift Truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX,) (C879, D879, E879, F879) 3436
Remove 3436
Install 3439
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3439
Remove 3439
Install 3440
Load Weight Sensor 3441
Remove 3441
Install 3442
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3443
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3443
Crankshaft Position (CKP) Sensor 3443
Camshaft Position (CMP) Sensor 3443
Oil Pressure Sensor 3443
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3443
Engine Coolant Temperature (ECT) Sensor 3444
Air Flow Restriction Switch 3444
Remove for GM 2 4L Gas and LPG Trucks 3444
Install for GM 2 4L Gas and LPG Trucks 3444
Oxygen Sensor 3445
Remove 3445
Install 3448
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3449
Crankshaft Position (CKP) Sensor 3449
Camshaft Position (CMP) Sensor 3449
Oil Pressure Sensor 3449
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3449
Engine Coolant Temperature (ECT) Sensor 3449
Air Flow Restriction Switch 3449
Oxygen Sensor 3449
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3449
Low LPG Pressure Switch 3449
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3450
Air Filter Restriction Switch 3450
Remove 3450
Install 3450
Oil Pressure Sensor 3450
Remove 3450
Install 3450
Engine Speed Sensor 3450
Remove 3450
Install 3450
Engine Coolant Temperature (ECT) Sensor 3450
Remove 3450
Install 3450
Throttle Position Sensor (TPS) 3453
Remove 3453
Install 3454
Fuel/Water Separator Sensor 3454
Remove 3454
Install 3454
Glow Plug Relay 3455
Remove 3455
Install 3457
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3457
Air Filter Restriction Switch 3457
Remove 3457
Install 3457
Engine Oil Pressure Sensor 3462
Remove 3462
Install 3462
Engine Speed Sensor 3462
Remove 3462
Install 3463
Engine Coolant Temperature (ECT) Sensor 3463
Remove 3463
Install 3464
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3465
Remove 3465
Install 3465
Fuel/Water Separator Sensor 3466
Remove 3466
Install 3466
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3467
Intake Air Temperature Sensor 3467
Remove 3467
Install 3468
Intake Air Pressure Sensor 3468
Remove 3468
Install 3468
Air Inlet Heater 3468
Remove 3468
Install 3469
Engine Oil Pressure Sensor 3469
Remove 3469
Install 3469
Engine Coolant Temperature (ECT) Sensor 3469
Remove 3469
Install 3469
Crankshaft Position Sensor 3470
Remove 3470
Install 3470
Adjust Shim Procedure 3471
Camshaft Position Sensor 3472
Remove 3472
Install 3472
Air Flow Restriction Sensor 3473
Remove 3473
Install 3473
Fuel/Water Separator 3473
Remove 3473
Install 3474
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3474
Intake Air Temperature Sensor 3478
Remove 3478
Install 3479
Boost Sensor 3479
Remove 3479
Install 3480
Throttle Valve Assembly and Air Intake Heater 3480
Remove 3480
Install 3480
Engine Coolant Temperature (ECT) Sensor 3481
Remove 3481
Install 3481
Engine Oil Pressure Sensor 3481
Remove 3481
Install 3482
Crankshaft Position Sensor 3482
Remove 3482
Install 3482
Adjust Shim Procedure 3483
Camshaft Position Sensor 3484
Remove 3484
Install 3485
Differential Pressure Sensor 3485
Remove 3485
Install 3485
Mass Air Flow Sensor 3486
Remove 3486
Install 3487
Fuel/Water Separator 3487
Remove 3487
Install 3488
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3488
Engine Coolant Temperature (ECT) Sensor 3489
Remove 3489
Install 3489
Throttle Position Sensor 3490
Engine Oil Pressure Sensor 3490
Remove 3490
Install 3490
Engine Speed Sensor 3490
Remove 3490
Install 3490
Fuel Shut Off Solenoid 3490
Remove 3490
Install 3490
Vehicle System Manager (VSM) 3491
General 3491
VSM Replacement 3491
Remove 3491
Install 3493
Programming a New VSM and/or Display Switch Cluster 3493
General 3493
PC Service Tool Software 3494
Data Transferring 3494
New VSM 3494
New (Blank) Display Switch Cluster 3494
Used (Non-Blank) Display Switch Cluster 3494
Power Distribution Module (PDM) and Component Parts 3496
Remove 3496
PDM as a Unit 3496
Install 3500
PDM as a Unit 3500
Remove and Install 3501
PDM Component Parts 3501
Transmission Control Unit 3501
Remove 3501
Install 3505
Battery 3507
Remove 3507
Install 3507
Lights 3508
Work Lights (Front and Rear) 3508
Remove 3508
Install 3508
Strobe Light 3509
Remove 3509
Install 3509
LED Tail, Backup, and Brake Lights 3510
Remove 3510
Install 3511
Front Marker/Turn Signal Lights 3512
Replacing Whole Front Marker/Turn Signal Light Assembly 3512
Remove 3512
Install 3512
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3513
Remove 3513
Install 3513
Diesel Particulate Filter (DPF) Display 3513
Remove 3513
Clean and Inspect 3514
Install 3514
Electronic-Hydraulic Controls – Generation 1 3515
E-Hydraulic Controls – Test 3515
Mini-Levers 3515
Full Stroke Test 3515
Function Returns to Neutral Test 3515
Push Button Switch 3515
General 3516
Mini-Lever Replacement 3516
Remove 3516
Clean and Inspect 3517
Install 3517
Push Button Switch Replacement 3518
Remove 3518
Install 3520
Mini-Lever Module (MLM) 3520
Remove 3520
Install 3520
Joystick 3521
Remove and Disassemble 3521
Inspect 3521
Assemble and Install 3521
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3522
General 3522
Mini-levers, Remove and Install 3522
Armrest Assembly 3523
Remove 3523
Install 3526
Horn Button 3526
Remove 3526
Install 3526
Direction Control Switch 3527
Remove 3527
Install 3527
push (override) buttons and Toggle Switch 3527
Remove 3528
Install 3529
Joystick 3530
Remove and Disassemble 3530
Inspect 3530
Assemble and Install 3530
Joystick Armrest Slider Assembly 3531
Remove 3531
Install 3532
Electronic-Hydraulic Controls, After January, 2020 3532
E-Hydraulic Controls – TEST 3532
Mini-Levers 3532
Full Stroke Test 3532
Function Returns to Neutral Test 3532
Push (Override) Button 3533
General 3533
Mini-levers, Remove and Install 3533
Armrest Assembly 3534
Remove 3534
Install 3537
Horn Button 3537
Remove 3537
Install 3537
Direction Control Switch 3537
Remove 3537
Install 3538
Push (Override) buttons and Toggle Switch 3538
Remove 3539
Install 3541
Special Tools 3542
524223772-2200YRM1142-(08-2021)-US-EN 3545
General 3555
Display Switch Cluster 3559
Remove 3559
Install 3561
Direction Control and Turn Signal Levers 3561
Remove 3561
Install 3562
Key Switch 3563
Remove 3563
Install 3564
Display Switch Cluster Panel Bezel and Overlay 3564
Remove 3564
Install 3564
Steering Column Repair 3565
Remove 3565
Disassemble 3568
Assemble 3568
Install 3568
Sensors and Switches 3569
General 3569
Dash and Kick Panel, Remove and Install 3569
Remove 3569
Install 3570
Accelerator Pedal Position Sensor 3570
Remove 3570
Install 3574
Brake Fluid Level Switch 3575
Remove 3575
Install 3576
Service Brake Pedal Position Sensor 3578
Remove 3578
Install 3580
Parking Brake Sensor 3581
Remove 3581
Install 3583
Service Brake Pressure Sensor 3583
Remove 3583
Install 3585
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3587
Remove 3587
Install 3587
Sensor Microswitch (Foot Directional Control Pedal) 3587
Remove 3587
Install 3590
Low Coolant Level Sensor 3591
Remove 3591
Install 3594
Fuel Level Sensor, Gas and Diesel Engines Only 3595
Remove 3595
Install 3596
Armrest Switch 3596
Remove 3596
Install 3598
Seat Sensor (Operator Presence System) 3598
Non-Suspension and Semi-Suspension Seats; For Lift truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-8VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (C879, D879, E879, F879) 3598
Remove 3598
Install 3599
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3599
Remove 3599
Install 3599
Full Suspension Seats; All Lift Truck Models 3600
Remove 3600
Install 3600
Hood Shut Off Switch 3601
Remove 3601
Install 3603
Remote Key Switch 3604
Remove 3604
Install 3604
Hydraulic Filter Pressure Switch 3605
Remove 3605
Install 3607
Transmission Speed Sensor 3607
Remove 3607
Install 3610
Transmission Pressure Sensors 3611
Remove 3611
Install 3613
Transmission Temperature Sensor 3614
Remove 3614
Install 3616
Engine Speed Sensor 3618
Remove 3618
Install 3619
Intermediate Speed Sensor 3619
Remove 3619
Install 3619
Return to Set Tilt (Tilt Angle) Sensor 3620
Lift Truck Models GLC20-35VX (GC/GCL040-070VX, GC/GLC055SVX) (A910); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP30VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) 3620
Remove 3620
Install 3620
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3620
Remove 3621
Install 3622
Rear Horn Button Switch 3623
Remove 3623
Install 3623
Impact Sensor 3624
Lift Truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX,) (C879, D879, E879, F879) 3624
Remove 3624
Install 3626
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3626
Remove 3626
Install 3627
Load Weight Sensor 3627
Remove 3627
Install 3629
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3630
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3630
Crankshaft Position (CKP) Sensor 3630
Camshaft Position (CMP) Sensor 3630
Oil Pressure Sensor 3630
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3630
Engine Coolant Temperature (ECT) Sensor 3631
Air Flow Restriction Switch 3631
Remove for GM 2 4L Gas and LPG Trucks 3631
Install for GM 2 4L Gas and LPG Trucks 3631
Oxygen Sensor 3632
Remove 3632
Install 3635
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3636
Crankshaft Position (CKP) Sensor 3636
Camshaft Position (CMP) Sensor 3636
Oil Pressure Sensor 3636
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3636
Engine Coolant Temperature (ECT) Sensor 3636
Air Flow Restriction Switch 3636
Oxygen Sensor 3636
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3636
Low LPG Pressure Switch 3636
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3637
Air Filter Restriction Switch 3637
Remove 3637
Install 3637
Oil Pressure Sensor 3637
Remove 3637
Install 3637
Engine Speed Sensor 3637
Remove 3637
Install 3637
Engine Coolant Temperature (ECT) Sensor 3637
Remove 3637
Install 3637
Throttle Position Sensor (TPS) 3640
Remove 3640
Install 3641
Fuel/Water Separator Sensor 3641
Remove 3641
Install 3641
Glow Plug Relay 3642
Remove 3642
Install 3644
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3644
Air Filter Restriction Switch 3644
Remove 3644
Install 3645
Engine Oil Pressure Sensor 3649
Remove 3649
Install 3649
Engine Speed Sensor 3649
Remove 3649
Install 3650
Engine Coolant Temperature (ECT) Sensor 3650
Remove 3650
Install 3651
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3652
Remove 3652
Install 3652
Fuel/Water Separator Sensor 3653
Remove 3653
Install 3653
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3654
Intake Air Temperature Sensor 3654
Remove 3654
Install 3655
Intake Air Pressure Sensor 3655
Remove 3655
Install 3655
Air Inlet Heater 3655
Remove 3655
Install 3656
Engine Oil Pressure Sensor 3656
Remove 3656
Install 3656
Engine Coolant Temperature (ECT) Sensor 3656
Remove 3656
Install 3656
Crankshaft Position Sensor 3657
Remove 3657
Install 3657
Adjust Shim Procedure 3658
Camshaft Position Sensor 3659
Remove 3659
Install 3659
Air Flow Restriction Sensor 3659
Remove 3659
Install 3660
Fuel/Water Separator 3660
Remove 3660
Install 3661
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3661
Intake Air Temperature Sensor 3665
Remove 3665
Install 3666
Boost Sensor 3666
Remove 3666
Install 3667
Throttle Valve Assembly and Air Intake Heater 3667
Remove 3667
Install 3667
Engine Coolant Temperature (ECT) Sensor 3668
Remove 3668
Install 3668
Engine Oil Pressure Sensor 3669
Remove 3669
Install 3669
Crankshaft Position Sensor 3669
Remove 3669
Install 3669
Adjust Shim Procedure 3670
Camshaft Position Sensor 3672
Remove 3672
Install 3672
Differential Pressure Sensor 3672
Remove 3672
Install 3673
Mass Air Flow Sensor 3673
Remove 3673
Install 3674
Fuel/Water Separator 3675
Remove 3675
Install 3676
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3677
Engine Coolant Temperature (ECT) Sensor 3678
Remove 3678
Install 3678
Throttle Position Sensor 3678
Engine Oil Pressure Sensor 3678
Remove 3678
Install 3678
Engine Speed Sensor 3678
Remove 3678
Install 3678
Fuel Shut Off Solenoid 3679
Remove 3679
Install 3679
Vehicle System Manager (VSM) 3680
General 3680
VSM Replacement 3680
Remove 3680
Install 3682
Programming a New VSM and/or Display Switch Cluster 3682
General 3682
PC Service Tool Software 3683
Data Transferring 3683
New VSM 3683
New (Blank) Display Switch Cluster 3683
Used (Non-Blank) Display Switch Cluster 3683
Power Distribution Module (PDM) and Component Parts 3686
Remove 3686
PDM as a Unit 3686
Install 3689
PDM as a Unit 3689
Remove and Install 3690
PDM Component Parts 3690
Transmission Control Unit (TCU) 3691
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3691
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3691
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3692
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3692
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) Equipped with 3-Speed Transmission and Manufactured Before December, 2018 3692
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) Equipped With 3-Speed Transmission and Manufactured Before December, 2018 3693
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) Equipped with 3-Speed Transmission and Manufactured Between December, 2018 and July, 2021 3694
Install, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) Equipped with 3-Speed Transmission and Manufactured Between December, 2018 and July, 2021 3696
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) Equipped with 3-Speed Transmission and Manufactured After July, 2021 3696
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) Equipped With 3-Speed Transmission and Manufactured After July, 2021 3696
Battery 3697
Remove 3697
Install 3697
Lights 3698
Work Lights (Front and Rear) 3698
Remove 3698
Install 3698
Strobe Light 3699
Remove 3699
Install 3699
LED Tail, Backup, and Brake Lights 3700
Remove 3700
Install 3701
Front Marker/Turn Signal Lights 3702
Replacing Whole Front Marker/Turn Signal Light Assembly 3702
Remove 3702
Install 3702
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3703
Remove 3703
Install 3703
Diesel Particulate Filter (DPF) Display 3704
Remove 3704
Clean and Inspect 3705
Install 3705
Electronic-Hydraulic Controls – Generation 1 3706
E-Hydraulic Controls – Test 3706
Mini-Levers 3706
Full Stroke Test 3706
Function Returns to Neutral Test 3706
Push Button Switch 3706
General 3707
Mini-Lever Replacement 3707
Remove 3707
Clean and Inspect 3708
Install 3708
Push Button Switch Replacement 3709
Remove 3709
Install 3711
Mini-Lever Module (MLM) 3711
Remove 3711
Install 3711
Joystick 3712
Remove and Disassemble 3712
Inspect 3712
Assemble and Install 3712
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3713
General 3713
Mini-levers, Remove and Install 3713
Armrest Assembly 3714
Remove 3714
Install 3717
Horn Button 3717
Remove 3717
Install 3717
Direction Control Switch 3718
Remove 3718
Install 3718
push (override) buttons and Toggle Switch 3718
Remove 3719
Install 3720
Joystick 3721
Remove and Disassemble 3721
Inspect 3721
Assemble and Install 3721
Joystick Armrest Slider Assembly 3722
Remove 3722
Install 3723
Electronic-Hydraulic Controls, After January, 2020 3724
E-Hydraulic Controls – TEST 3724
Mini-Levers 3724
Full Stroke Test 3724
Function Returns to Neutral Test 3724
Push (Override) Button 3724
General 3725
Mini-levers, Remove and Install 3725
Armrest Assembly 3726
Remove 3726
Install 3729
Horn Button 3729
Remove 3729
Install 3729
Direction Control Switch 3729
Remove 3729
Install 3730
Push (Override) buttons and Toggle Switch 3730
Remove 3731
Install 3733
Special Tools 3734
524223780-8000YRM1134-(03-2020)-UK-EN 3737
Series Code / Model Designation Reference Table 3743
Description 3745
Proc_Cal_001: Service Password Entry 3747
When to Perform 3747
Why Perform 3747
How to Perform 3747
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3748
When to Perform 3748
Calibration Order 3748
Why Perform 3748
How to Perform 3749
Proc_Cal_003: Save and Exit 3750
When to Perform 3750
Why Perform 3750
How to Perform 3750
Proc_Cal_004: Lift Valve Output Threshold 3751
When to Perform 3751
Calibration Order 3751
Why Perform 3751
How to Perform 3752
Proc_Cal_005: Lower Valve Output Threshold 3754
When to Perform 3754
Calibration Order 3754
Why Perform 3754
How to Perform 3754
Proc_Cal_006: Tilt Back Valve Output Threshold 3757
When to Perform 3757
Calibration Order 3757
Why Perform 3757
How to Perform 3757
Proc_Cal_007: Tilt Forward Valve Output Threshold 3760
When to Perform 3760
Calibration Order 3760
Why Perform 3760
How to Perform 3760
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3763
When to Perform 3763
Calibration Order 3763
Why Perform 3763
How to Perform 3763
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3766
When to Perform 3766
Calibration Order 3766
Why Perform 3766
How to Perform 3766
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3769
When to Perform 3769
Calibration Order 3769
Why Perform 3769
How to Perform 3769
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3772
When to Perform 3772
Calibration Order 3772
Why Perform 3772
How to Perform 3772
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3775
When to Perform 3775
Calibration Order 3775
Why Perform 3775
How to Perform 3775
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3778
When to Perform 3778
Calibration Order 3778
Why Perform 3778
How to Perform 3778
Proc_Cal_014: Load Weight Zero Point 3782
When to Perform 3782
Calibration Order 3782
Why Perform 3782
How to Perform 3782
Proc_Cal_015: Loaded Weight Calibration 3784
When to Perform 3784
Calibration Order 3784
Why Perform 3784
How to Perform 3784
Proc_Cal_016: Transmission Valve Calibration 3787
Applicable System/Option 3787
When to Perform 3787
Calibration Order 3787
Why Perform 3787
How to Perform 3787
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3789
Applicable System/Option 3789
When to Perform 3789
Calibration Order 3789
Why Perform 3789
How to Perform 3789
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3791
Applicable System/Option 3791
When to Perform 3791
Calibration Order 3791
Why Perform 3791
How to Perform 3792
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3793
Required Tools 3793
When to Perform 3793
Calibration Order 3793
Why Perform 3794
How to Perform 3794
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3795
When to Perform 3795
Why Perform 3795
How to Perform 3795
Proc_Cal_026: Travel Speed Calibration 3797
When to Perform 3797
Calibration Order 3797
Why Perform 3797
How to Perform 3797
524223780-8000YRM1134-(05-2022)-US-EN 3801
Series Code / Model Designation Reference Table 3807
Description 3810
Proc_Cal_001: Service Password Entry 3812
When to Perform 3812
Why Perform 3812
How to Perform 3812
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3813
When to Perform 3813
Calibration Order 3813
Why Perform 3813
How to Perform 3813
Proc_Cal_003: Save and Exit 3815
When to Perform 3815
Why Perform 3815
How to Perform 3815
Proc_Cal_004: Lift Valve Output Threshold 3816
When to Perform 3816
Calibration Order 3816
Why Perform 3816
How to Perform 3816
Proc_Cal_005: Lower Valve Output Threshold 3819
When to Perform 3819
Calibration Order 3819
Why Perform 3819
How to Perform 3819
Proc_Cal_006: Tilt Back Valve Output Threshold 3822
When to Perform 3822
Calibration Order 3822
Why Perform 3822
How to Perform 3822
Proc_Cal_007: Tilt Forward Valve Output Threshold 3825
When to Perform 3825
Calibration Order 3825
Why Perform 3825
How to Perform 3825
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3828
When to Perform 3828
Calibration Order 3828
Why Perform 3828
How to Perform 3828
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3831
When to Perform 3831
Calibration Order 3831
Why Perform 3831
How to Perform 3831
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3834
When to Perform 3834
Calibration Order 3834
Why Perform 3834
How to Perform 3834
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3837
When to Perform 3837
Calibration Order 3837
Why Perform 3837
How to Perform 3837
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3840
When to Perform 3840
Calibration Order 3840
Why Perform 3840
How to Perform 3840
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3843
When to Perform 3843
Calibration Order 3843
Why Perform 3843
How to Perform 3843
Proc_Cal_014: Load Weight Zero Point 3846
When to Perform 3846
Calibration Order 3846
Why Perform 3846
How to Perform 3846
Proc_Cal_015: Loaded Weight Calibration 3848
When to Perform 3848
Calibration Order 3848
Why Perform 3848
How to Perform 3848
Proc_Cal_016: Transmission Valve Calibration 3851
Applicable System/Option 3851
When to Perform 3851
Calibration Order 3851
Why Perform 3851
How to Perform 3851
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3853
Applicable System/Option 3853
When to Perform 3853
Calibration Order 3853
Why Perform 3853
How to Perform 3853
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3856
Applicable System/Option 3856
When to Perform 3856
Calibration Order 3856
Why Perform 3856
How to Perform 3856
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3859
Required Tools 3859
When to Perform 3859
Calibration Order 3859
Why Perform 3859
How to Perform 3859
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3861
When to Perform 3861
Why Perform 3861
How to Perform 3861
Proc_Cal_026: Travel Speed Calibration 3863
When to Perform 3863
Calibration Order 3863
Why Perform 3863
How to Perform 3863
524262275-0900YRM1242-(04-2018)-US-EN 3867
General 3873
Hoses Replacement 3873
LPG Tank and Bracket Replacement 3874
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) 3874
Remove 3874
Install 3877
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) 3878
Remove 3878
Install 3878
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) 3878
Remove 3878
Install 3880
LPG Tank, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3881
Remove 3881
Install 3883
LPG Tank Bracket, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3883
Remove 3883
Install 3883
High Pressure Fuel Filter Unit Repair 3883
Fuel Filter Element 3884
Remove 3884
Clean/Inspect 3885
Install 3885
Fuel Filter Housing 3885
Remove 3885
Disassemble 3886
Assemble 3886
Install 3886
Electronic Throttle Body Repair 3887
Remove 3887
Clean/Inspect 3888
Install 3888
Fuel Injector Repair 3889
Fuel Rail 3889
Remove for Lift Trucks Built Before January, 2010 3889
Remove for Lift Trucks Built After January, 2010 3891
Install for Lift Trucks Built Before January, 2010 3892
Install for Lift Trucks Built After January, 2010 3893
Fuel Injectors and Adapters 3893
Remove for Lift Trucks Built Before January, 2010 3893
Remove for Lift Trucks Built After January, 2010 3895
Clean 3896
Install for Lift Trucks Built Before January, 2010 3896
Install for Lift Trucks Built After January, 2010 3898
LPG Regulator Repair 3898
LPG Regulator 3898
Remove for Lift Trucks Built Before January, 2010 3898
Remove for Lift Trucks Built After January, 2010 3899
Install for Lift Trucks Built Before January, 2010 3901
Install for Lift Trucks Built After January, 2010 3901
LPG Regulator Fuel Filter 3902
Remove 3902
Install 3903
Lock-Off Solenoid and Cartridge 3903
Remove 3903
Install 3904
Control System 3904
Electronic Control Unit (ECU) and Injector Driver Modules Assembly 3904
Remove 3904
Install 3905
Electronic Control Unit (ECU) 3906
Remove 3906
Install 3906
Injector Driver Modules 3907
Remove 3907
Install 3907
Fuel Pressure Sensor 3908
Remove 3908
Install 3908
Low LPG Pressure Switch 3908
Remove 3908
Install 3909
LPG Pressure Sensor 3909
Remove 3909
Install 3910
Oxygen Sensor 3910
Exhaust System Repair 3911
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 3911
Remove for Lift Trucks Built Before January, 2010 3911
Remove for Lift Trucks Built After January, 2010 3913
Inspect 3915
Install for Lift Trucks Built Before January, 2010 3915
Install for Lift Trucks Built After January, 2010 3915
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) 3916
Remove for Lift Trucks Built Before January, 2010 3916
Remove for Lift Trucks Built After January, 2010 3918
Inspect 3921
Install for Lift Trucks Built Before January, 2010 3921
Install for Lift Trucks Built After January, 2010 3922
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3923
Remove for Lift Trucks Built Before January, 2010 3923
Remove for Lift Trucks Built After January, 2010 3926
Inspect 3927
Install for Lift Trucks Built Before January, 2010 3928
Install for Lift Trucks Built After January, 2010 3928
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3929
Remove for Lift Trucks Built Before January, 2010 3929
Remove for Lift Trucks Built After January, 2010 3932
Inspect 3933
Install for Lift Trucks Built Before January, 2010 3934
Install for Lift Trucks Built After January, 2010 3934
Oxygen Sensor 3935
Remove 3935
Install 3936
LPG Fuel Testing 3936
General 3936
Available Fuel Tests 3936
Composition Test (ASTM D-2163) 3936
Ammonia Test (ASTM D-4490) 3937
Basic Nitrogen Test (ASTM UOP269-90) 3937
Residues Test (ASTM D-2158) 3937
Vapor Pressure Test (ASTM D-2598) 3937
Sulfur Compounds Test (ASTM D-5623) 3937
Methanol Test (ASTM D-4864) 3937
Copper Corrosion (ASTM D-1838) 3937
Where To Send LPG Fuel Samples For Testing 3937
524262276-0900YRM1244-(06-2012)-US-EN 3941
toc 3941
Gasoline Fuel System 3941
Safety Precautions Maintenance and Repair 3942
General 3945
Electronic Throttle Body Repair 3945
Electronic Throttle Body 3945
Remove 3945
Clean/Inspect 3945
Install 3946
Fuel System Repair 3947
Before Repair Procedure 3947
After Repair Procedure 3947
Fuel Leakage Check for Lift Trucks Built Before January, 2010 3947
Fuel Leakage Check for Lift Trucks Built After January, 2010 3948
Fuel Line Pressure Check 3950
Fuel Injector Repair 3951
Remove 3951
Install 3961
Control System 3962
Electronic Control Unit (ECU) 3962
Remove for Lift Trucks Built Before January, 2010 3962
Remove for Lift Trucks Built After January, 2010 3963
Install for Lift Trucks Built Before January, 2010 3964
Install for Lift Trucks Built After January, 2010 3965
Exhaust System Repair 3966
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; ( 3966
Remove for Lift Trucks Built Before January, 2010 3966
Remove for Lift Trucks Built After January, 2010 3968
Inspect 3968
Install for Lift Trucks Built Before January, 2010 3970
Install for Lift Trucks Built After January, 2010 3970
GM 4 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45 3971
Remove for Lift Trucks Built Before January, 2010 3971
Remove for Lift Trucks Built After January, 2010 3973
Inspect 3975
Install for Lift Trucks Built Before January, 2010 3975
Install for Lift Trucks Built After January, 2010 3976
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (G 3977
Remove for Lift Trucks Built Before January, 2010 3977
Remove for Lift Trucks Built After January, 2010 3979
Inspect 3981
Install for Lift Trucks Built Before January, 2010 3981
Install for Lift Trucks Built After January, 2010 3982
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (G 3982
Remove for Lift Trucks Built Before January, 2010 3982
Remove for Lift Trucks Built After January, 2010 3985
Inspect 3985
Install for Lift Trucks Built Before January, 2010 3987
Install for Lift Trucks Built After January, 2010 3987
Oxygen Sensor 3988
Remove 3988
Install 3988
524262279-1800YRM1247-(06-2021)-US-EN 3991
General 3995
Dry Brake System 3995
Wet Brake System 3995
Service Brakes Repair (Dry Brake) 3999
Remove and Disassemble 3999
Clean 4001
Inspect 4002
Assemble and Install 4003
Adjust 4006
Parking Brake Repair 4007
Dry Brake System 4007
Remove and Disassembly 4007
Assemble and Install 4009
Wet Brake System 4009
Remove and Install 4009
Assemble and Install 4016
Adjust 4016
Dry Brake System 4016
Wet Brake System 4017
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 4017
Master Cylinder Repair 4019
Remove 4019
Disassemble 4023
Clean and Inspect 4024
Assemble 4025
Install and Adjust 4025
Accumulator 4028
Pre-Charge Check 4028
Remove 4029
Install 4031
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 4032
Remove 4032
Modulating Brake Valve 4034
Disassemble 4034
Clean and Inspect 4035
Assemble 4035
Accumulator Charge Valve 4036
Disassemble 4036
Clean and Inspect 4038
Assemble 4038
Install 4039
Pressure Checks 4040
Accumulator Charge Valve Check 4040
Accumulator Check 4040
Service Brakes Adjustment (Dry Brake) 4041
Service Brakes Adjustment 4041
Brake System Air Removal 4043
Using Pressure Bleed System 4043
Using Brake Pedal Pressure 4043
Lift Truck Models with Master Cylinder 4043
Lift Truck Models with Modulating Brake Valve 4044
Brake Pedal Adjustment 4045
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) 4045
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4046
Free Pedal Adjustment 4048
Torque Specifications 4049
524262279-1800YRM1247-(09-2018)-UK-EN 4051
General 4055
Dry Brake System 4055
Wet Brake System 4056
Service Brakes Repair (Dry Brake) 4060
Remove and Disassemble 4060
Clean 4062
Inspect 4063
Assemble and Install 4063
Adjust 4067
Parking Brake Repair 4067
Dry Brake System 4068
Remove and Disassembly 4068
Assemble and Install 4070
Wet Brake System 4070
Remove and Install 4071
Assemble and Install 4077
Adjust 4077
Dry Brake System 4077
Wet Brake System 4078
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 4078
Master Cylinder Repair 4079
Remove 4079
Disassemble 4084
Clean and Inspect 4085
Assemble 4086
Install and Adjust 4086
Accumulator 4088
Pre-Charge Check 4089
Remove 4090
Install 4092
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 4092
Remove 4093
Modulating Brake Valve 4094
Disassemble 4094
Clean and Inspect 4096
Assemble 4096
Accumulator Charge Valve 4097
Disassemble 4097
Clean and Inspect 4099
Assemble 4099
Install 4100
Pressure Checks 4101
Accumulator Charge Valve Check 4101
Accumulator Check 4101
Service Brakes Adjustment (Dry Brake) 4102
Service Brakes Adjustment 4102
Brake System Air Removal 4103
Using Pressure Bleed System 4103
Using Brake Pedal Pressure 4104
Lift Truck Models with Master Cylinder 4104
Lift Truck Models with Modulating Brake Valve 4104
Brake Pedal Adjustment 4105
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) 4105
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4106
Free Pedal Adjustment 4108
Torque Specifications 4109
524265337-0600YRM1251-(09-2015)-US-EN 4113
General 4119
Engine Removal and Installation 4119
Cylinder Head Repair 4119
Remove and Disassemble 4119
Clean and Inspect 4121
Valve Oil Seals 4124
Remove and Disassemble 4124
Cylinder Leak Down Test 4124
Clean and Inspect 4125
Assemble and Install 4125
Valve Guides and Seats, Repairs 4127
Valves, Repair 4127
Valve Seats, Repair 4128
Valve Springs 4129
Assemble and Install 4130
Engine Block Cleaning and Inspection 4133
Clean and Inspect 4134
Piston Bore Preparation 4136
Engine Mounts Installation 4136
Remove 4136
Clean and Inspect 4137
Install 4137
Lubrication System Repair 4138
Oil Pump, Remove and Disassemble 4138
Clean and Inspect 4139
Oil Pump, Assemble and Install 4140
Oil Pan, Install 4142
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4144
Timing Cover 4144
Remove 4144
Install 4146
Timing Sprockets 4146
Remove 4146
Install 4146
Camshaft 4146
Remove 4146
Inspect 4147
Install 4147
Balance Shaft 4148
Remove 4148
Install 4149
Valve Lifters 4150
Remove 4150
Clean and Inspect 4150
Install 4151
Crankshaft Repair 4151
Remove 4152
Inspect and Repair 4152
How to Check Clearance Between Main Bearings and Their Journals 4153
Install 4154
Piston and Connecting Rod Assemblies Repair 4156
Connecting Rod Bearings, Replace 4156
Piston and Connecting Rod Assemblies, Remove 4157
Disassemble 4157
Piston, Clean and Inspect 4158
Cylinder Bores, Inspect and Repair 4158
Piston Rings 4159
Assemble 4160
Piston and Connecting Rod Assemblies, Install 4160
Flywheel and Flywheel Housing Repair 4160
Flywheel, Remove 4161
Clean 4161
Inspect 4161
Flywheel, Install 4162
Coolant Pump Repair 4162
Remove 4162
Clean and Inspect 4163
Install 4163
Thermostat Replacement 4163
Remove 4164
Thermostat Operation Check 4164
Install 4164
Starter Replacement 4165
4165
Remove 4165
Install 4168
Fan Assembly Replacement 4169
Remove 4169
Inspect 4171
Install 4171
Drive Belt Installation 4172
Remove 4172
Clean 4172
Inspect 4172
Installation 4173
Compression Check 4174
Engine Specifications 4174
Engine Data 4174
Cylinder Head 4174
Hydraulic Valve Lifter 4175
Camshaft 4175
Pistons 4175
Crankshaft 4176
Connecting Rods 4176
Balance Shaft 4177
Cooling System 4177
Lubrication System 4177
Torque Specifications 4178
524265342-4000YRM1250-(06-2021)-US-EN 4183
Safety Procedures When Working Near Mast 4189
Fork Replacement 4192
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4192
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4193
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) 4195
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4196
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4197
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) 4198
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4198
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) 4199
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4200
Fixed Carriage Replacement 4202
Remove, Carriage With Hook Forks 4202
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4210
Install, Carriage With Hook Forks 4211
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4211
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4212
Connecting Attachment Hydraulic Quick Disconnect Hoses 4212
Integral Sideshift Carriage Repair 4213
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) 4213
Disassemble 4213
Clean and Inspect 4216
Assemble 4216
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) 4217
Hang On Sideshift Carriage Repair 4218
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) 4218
Disassemble 4230
Clean and Inspect 4239
Assemble 4240
Install 4241
Hang-On Sideshift Carriage Repair 4243
Remove 4243
Disassemble Carriage 4245
Clean and Inspect 4248
Assemble 4248
Install 4251
Fork Positioner 4254
Two-Stage Mast With Limited Free-Lift Repair 4255
Remove 4255
Disassemble 4258
Clean and Inspect 4261
Assemble 4279
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) 4281
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) 4283
Header Hose Alignment 4294
Two-Stage Mast With Full Free-Lift Repair 4305
Remove 4305
Disassemble 4307
Clean and Inspect 4318
Assemble 4319
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) 4321
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) 4324
Header Hose Installation and Adjustment 4328
Installation 4328
Adjustment 4329
Three-Stage Mast With Full Free-Lift Repair 4330
Remove 4330
Disassemble 4332
Clean and Inspect 4362
Assemble 4364
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) 4367
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) 4372
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) 4379
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) 4386
Mast Operation Check 4390
Tilt Cylinder Adjustment 4391
Lift Chains Adjustment 4391
Mast Adjustments 4393
Load Roller Adjustment 4393
Mast Side Kicking Adjustment 4395
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4396
Carriage Adjustments 4398
Series Code / Model Designation Reference Table 4399
524265342-4000YRM1250-(09-2018)-UK-EN 4403
Safety Procedures When Working Near Mast 4409
Fork Replacement 4411
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4411
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4413
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) 4414
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4415
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4416
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) 4417
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4417
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) 4419
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4419
Fixed Carriage Replacement 4421
Remove, Carriage With Hook Forks 4421
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4430
Install, Carriage With Hook Forks 4431
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4431
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4432
Connecting Attachment Hydraulic Quick Disconnect Hoses 4432
Integral Sideshift Carriage Repair 4433
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) 4433
Disassemble 4433
Clean and Inspect 4436
Assemble 4436
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) 4437
Hang On Sideshift Carriage Repair 4437
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) 4437
Disassemble 4449
Clean and Inspect 4458
Assemble 4459
Install 4460
Bolzoni Hang-On Sideshift Carriage Repair 4462
Remove 4462
Disassemble Carriage 4464
Clean and Inspect 4467
Assemble 4467
Install 4470
Fork Positioner 4472
Two-Stage Mast With Limited Free-Lift Repair 4473
Remove 4473
Disassemble 4477
Clean and Inspect 4480
Assemble 4497
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) 4499
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) 4500
Header Hose Alignment 4512
Two-Stage Mast With Full Free-Lift Repair 4522
Remove 4522
Disassemble 4524
Clean and Inspect 4536
Assemble 4537
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) 4539
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) 4542
Header Hose Installation and Adjustment 4546
Installation 4546
Adjustment 4546
Three-Stage Mast With Full Free-Lift Repair 4547
Remove 4547
Disassemble 4549
Clean and Inspect 4579
Assemble 4580
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) 4584
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) 4589
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) 4596
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) 4602
Mast Operation Check 4606
Tilt Cylinder Adjustment 4606
Lift Chains Adjustment 4607
Mast Adjustments 4608
Load Roller Adjustment 4608
Mast Side Kicking Adjustment 4610
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4611
Carriage Adjustments 4614
524288189-0100YRM1316-(01-2022)-US-EN 4617
General 4621
Description 4622
Hood, Seat, Dash, and Side Covers Replacement 4624
Remove 4624
Install 4630
Steering Column 4634
Description 4634
Steering Column Repair 4634
Remove 4634
Disassemble 4635
Clean 4637
Inspect 4637
Assemble 4637
Install 4637
LPG Tank and Bracket Replacement 4637
Counterweight Replacement 4638
Remove 4638
Install 4639
Tow Pin, Remove and Install 4641
Overhead Guard Replacement 4642
Remove 4642
Install 4643
LED Tail, Backup, and Brake Lights, Replace 4644
Operator Restraint System Replacement 4645
Description 4645
Engine Replacement 4647
Remove Engine Only 4647
Install Engine only 4673
Remove Engine and Transmission 4676
Install Engine and Transmission 4678
Electronic Throttle Replacement 4682
Cummins 4 5L Diesel Engine With Electronic Throttle 4682
Remove 4682
Install 4686
Pull Actuator Linkage Adjustment 4688
Low Idle Adjustment 4688
Throttle Pedal and Cable Adjustment 4689
Cummins 4 5L Diesel Engine 4689
Exhaust System Repair 4691
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4691
PSI 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4691
Cummins QSB 3 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4691
Remove 4691
Inspect 4691
Install 4694
Cummins 4 5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4694
Remove 4694
Inspect 4696
Install 4696
Kubota 3 8L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 4696
Remove 4696
Inspect 4699
Install 4699
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) 4699
Remove 4699
Inspect 4702
Install 4702
Kubota 3 8L Diesel Engine w/DOC for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) 4702
Remove 4702
Inspect 4705
Install 4705
Cooling System 4706
Description 4706
Hydraulic Filter Assembly Repair 4707
Remove 4707
Disassemble 4707
Clean 4708
Inspect 4708
Assemble 4708
Install 4708
Fuel and Hydraulic Tanks Repair 4709
Inspect 4709
Clean 4709
Steam Method of Cleaning 4709
Chemical Solution Method of Cleaning 4710
Additional Preparations for Repair 4711
Small Leaks, Repair 4711
Large Leaks, Repair 4711
Preparations for Use After Repair 4711
Safety Labels 4712
524288189-0100YRM1316-(11-2017)-UK-EN 4719
General 4723
Description 4723
Hood, Seat, Dash, and Side Covers Replacement 4724
Remove 4725
Install 4730
Steering Column 4733
Description 4733
Steering Column Repair 4733
Remove 4733
Disassemble 4735
Clean 4736
Inspect 4736
Assemble 4736
Install 4736
LPG Tank and Bracket Replacement 4736
Counterweight Replacement 4736
Remove 4737
Install 4738
Tow Pin, Remove and Install 4740
Overhead Guard Replacement 4740
Remove 4740
Install 4741
LED Tail, Backup, and Brake Lights, Replace 4742
Operator Restraint System Replacement 4742
Description 4743
Engine Replacement 4744
Remove Engine Only 4744
Install Engine only 4766
Remove Engine and Transmission 4770
Install Engine and Transmission 4773
Electronic Throttle Replacement 4775
Cummins 4 5L Diesel Engine With Electronic Throttle 4775
Remove 4775
Install 4779
Pull Actuator Linkage Adjustment 4781
Low Idle Adjustment 4781
Throttle Pedal and Cable Adjustment 4781
Cummins 4 5L Diesel Engine 4782
Exhaust System Repair 4783
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4784
PSI 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4784
Cummins QSB 3 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4784
Remove 4784
Inspect 4784
Install 4786
Cummins 4 5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4786
Remove 4786
Inspect 4787
Install 4787
Kubota 3 8L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 4789
Remove 4789
Inspect 4789
Install 4790
Kubota 3 8L Diesel Engine w/DPF for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4791
Remove 4791
Inspect 4793
Install 4793
Kubota 3 8L Diesel Engine w/DOC for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4793
Remove 4793
Inspect 4794
Install 4794
Cooling System 4797
Description 4798
Hydraulic Filter Assembly Repair 4798
Remove 4798
Disassemble 4798
Clean 4798
Inspect 4799
Assemble 4799
Install 4799
Fuel and Hydraulic Tanks Repair 4799
Inspect 4800
Clean 4800
Steam Method of Cleaning 4800
Chemical Solution Method of Cleaning 4801
Additional Preparations for Repair 4802
Small Leaks, Repair 4802
Large Leaks, Repair 4802
Preparations for Use After Repair 4802
Safety Labels 4802
524288194-1300YRM1317-(03-2020)-UK-EN 4809
Transmission Repair 4813
Remove 4813
Torque Converter, Remove 4813
Disassemble 4814
Clean and Inspect 4863
Housings 4863
Oil Seals and Gaskets 4863
Bearings 4863
Gears and Shafts 4864
Assemble 4864
Torque Converter, Install 4905
Install 4906
Control Valve Repair 4907
Remove 4907
Disassemble 4907
Clean 4909
Inspect 4909
Assemble 4909
Install 4910
Torque Specification 4911
524288194-1300YRM1317-(06-2021)-US-EN 4913
Transmission Repair 4917
Remove 4917
Torque Converter, Remove 4917
Disassemble 4918
Clean and Inspect 4969
Housings 4969
Oil Seals and Gaskets 4969
Bearings 4969
Gears and Shafts 4970
Assemble 4970
Torque Converter, Install 5012
Install 5013
Control Valve Repair 5014
Remove 5014
Disassemble 5014
Clean 5016
Inspect 5016
Assemble 5016
Install 5017
Torque Specification 5018
524288199-1400YRM1318-(06-2021)-US-EN 5021
General 5025
Identification Plate 5025
Drive Axle Removal 5025
Planetary Reduction Gear Repair 5033
Clean and Inspect 5040
Brake Repair 5048
Clean and Inspect 5055
Wet Brake Noise Reduction 5066
General 5066
Adding Additive To Transmission 5066
Differential Repair 5068
Clean and Inspect 5077
Bevel Pinion 5089
Clean and Inspect 5093
Drive Axle Installation 5104
Special Tools 5112
Torque Specifications 5113
524288199-1400YRM1318-(09-2018)-UK-EN 5115
General 5119
Identification Plate 5119
Drive Axle Removal 5119
Planetary Reduction Gear Repair 5126
Clean and Inspect 5134
Brake Repair 5141
Clean and Inspect 5149
Wet Brake Noise Reduction 5159
General 5159
Adding Additive To Transmission 5159
Differential Repair 5160
Clean and Inspect 5170
Bevel Pinion 5182
Clean and Inspect 5186
Drive Axle Installation 5196
Special Tools 5203
Torque Specifications 5203
524288204-8000YRM1319-(12-2018)-US-EN 5207
General 5213
Serial Number Data 5213
How to Move Disabled Lift Truck 5214
How to Tow Lift Truck 5214
How to Put Lift Truck on Blocks 5215
How to Raise Drive Tires 5215
How to Raise Steering Tires 5215
How to Clean a Lift Truck 5216
Maintenance Schedule 5217
Maintenance Procedures Every 8 Hours or Daily 5236
How to Make Checks With Engine Stopped 5237
Tires and Wheels 5237
Safety Labels 5237
Mast, Carriage, Lift Chains, Header Hoses, Attachment 5238
Operator Restraint System 5238
Emergency Locking Retractor (ELR) 5238
Adjust Seat – Full Suspension 5239
Adjust Seat – Internal Suspension 5241
Hood and Seat Latches 5241
Engine Compartment 5242
Paper Application 5242
Fuel, Oil, and Coolant Leaks, Check 5242
Hydraulic Hoses 5243
Coolant Hoses 5243
Steering Column Gas Cylinder 5243
Transmission 5243
Hydraulic System Oil 5243
Engine Oil 5245
Air Filter 5249
Forks 5249
Remove 5249
Inspect 5250
Install 5250
Adjust 5251
Hang On Sideshift Carriage 5251
How to Make Checks With Engine Running 5252
Indicator Lights, Horn, Fuses, and Relays 5252
Service Brakes 5254
Brake Oil Level 5254
Operation, Check 5255
Parking Brake 5255
Engine Oil Pressure 5255
Cooling System 5255
Steering System 5256
Control Levers and Pedals 5256
Lift System, Operate 5257
Air Filter 5257
Fuel/Water Separator Filter, Cummins 4 5L and QSB 3 3L Diesel Engine 5257
First Service After First 100 Hours of Operation 5257
GM 4 3L Engine Oil and Oil Filter 5258
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 5258
Maintenance Procedures Every 250 Hours or 6 Months 5258
GM 4 3L Engine Oil and Oil Filter Change 5258
Drive Belt 5259
GM 4 3L Engine 5259
Fan and Alternator Drive Belt 5259
Drain Tar From LPG Regulator 5260
Drain Tar From LPG Converter 5261
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine 5262
Maintenance Procedures Every 500 Hours or 6 Months 5263
Hydraulic System Oil 5264
Hydraulic Tank Breather 5266
Inspect 5266
Battery 5267
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 5267
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 5268
Remove 5268
Install 5268
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 5270
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 5271
Controlled Venting 5271
Manual Bleeding 5271
Low Idle Speed Adjustment, Cummins 4 5L Engine Only 5271
Drive Belt 5272
Cummins 4 5L and QSB 3 3L Diesel Engine 5272
Fan and Alternator Drive Belt 5272
Clean Debris From Radiator Core 5273
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 5273
Wet Brake Center Body Oil Level Check 5274
Forks 5278
Mast Lubrication 5278
Header Hose Checks 5283
Lift Chain Lubrication 5283
Tilt Cylinder Lubrication 5283
Master Brake Cylinder Rod End Pin Lubrication 5284
Manual Hydraulic Levers Lubrication 5285
Brake Oil 5285
Tie Rod Lubrication 5286
Parking Brake Adjustment 5286
Maintenance Procedures Every 1000 Hours or 6 Months 5287
Valve Clearance, Check and Adjust 5287
Ignition System 5287
GM 4 3L Engine 5287
LPG Fuel Filter Element Replace, GM 4 3L Engine 5287
Remove 5287
Install 5288
In-Line Filter Replacement, Cummins 4 5L Engine 5288
Remove 5288
Install 5289
Lift Chains Wear Check 5290
Lift Chain Lubrication 5290
Hang On Sideshift Carriage, Check Sliding Surfaces 5291
Steering Axle Spindle Bearings 5294
Control Levers and Pedals 5295
Inspect Engine Electrical System, Connectors 5295
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 5296
Parking Brake Lever Lubrication, Wet Brake Axle 5300
Normal Operating Environment 5300
Heavy Duty or Contaminated Environment 5301
Remove 5301
Clean and Inspect 5302
Install 5302
Maintenance Procedures Every 2000 Hours or Annually 5302
Hydraulic System 5303
Hydraulic Filter Assembly, Replace 5303
Hydraulic Tank Breather, Replace 5304
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 5304
Cooling System Check 5304
Air Filter 5306
Oxygen Sensor, GM 4 3L Engine Equipped With GFI Installed 5308
LPG Regulator Fuel Filter, GM 4 3L Engines with GFI Installed 5309
Remove 5309
Install 5310
Gasoline Fuel Filter 5310
Remove and Replace 5310
LPG Fuel Injector, GM 4 3L Engines with GFI Installed 5311
Gasoline Fuel Injector, GM Engines 5311
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 5311
Forks 5311
Brake Oil (Master Cylinder), Change 5311
Test Regulator PressureLPG/GAS 5312
Check Throttle Shaft for Sticking 5312
Inspect Exhaust Manifold and Piping for Leaks 5312
Transmission Automatic Clutch Calibration 5312
Brake System Accumulator 5312
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 5312
Wheel Bearings 5313
Steer Wheels, Lubrication 5313
Maintenance Procedures Every 4000 Hours or 2 Years 5313
Hydraulic Oil, Replace 5314
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 5316
Safety Procedures When Working Near Mast 5318
Fuel Filter Water Removal 5321
Hood Latch Check 5321
Lift Chain Adjustments 5322
Jump-Starting the Lift Truck 5324
Jump-Starting Using a Battery Charger 5324
Jump-Starting a Lift Truck Using Another Lift Truck 5324
Welding Repairs 5325
Overhead Guard Changes 5325
Wheel and Tire Replacement 5326
General 5326
Solid Rubber Tire, Change 5326
Remove and Install Tire on Wheel 5326
Adhesives and Sealants 5328
524288207-8000YRM1319-(05-2019)-UK-EN 5331
General 5337
Serial Number Data 5337
How to Move Disabled Lift Truck 5337
How to Tow Lift Truck 5337
How to Put Lift Truck on Blocks 5339
How to Raise Drive Tires 5339
How to Raise Steering Tires 5339
How to Clean a Lift Truck 5340
Maintenance Schedule 5341
Maintenance Procedures Every 8 Hours or Daily 5358
How to Make Checks With Engine Stopped 5359
Tires and Wheels 5359
Safety Labels 5359
Mast, Carriage, Lift Chains, Header Hoses, Attachment 5360
Operator Restraint System 5360
Emergency Locking Retractor (ELR) 5360
Adjust Seat – Full Suspension 5361
Adjust Seat – Internal Suspension 5363
Hood and Seat Latches 5363
Engine Compartment 5363
Paper Application 5364
Fuel, Oil, and Coolant Leaks, Check 5364
Hydraulic Hoses 5365
Coolant Hoses 5365
Steering Column Gas Cylinder 5365
Transmission 5365
Hydraulic System Oil 5365
Engine Oil 5367
Air Filter 5370
Forks 5370
Remove 5370
Inspect 5371
Install 5371
Adjust 5372
Hang On Sideshift Carriage 5372
How to Make Checks With Engine Running 5373
Indicator Lights, Horn, Fuses, and Relays 5373
Service Brakes 5375
Brake Oil Level 5375
Operation, Check 5376
Parking Brake 5376
Engine Oil Pressure 5376
Cooling System 5376
Steering System 5377
Control Levers and Pedals 5377
Lift System, Operate 5378
Air Filter 5378
Fuel/Water Separator Filter, Cummins 4 5L and QSB 3 3L Diesel Engine 5378
First Service After First 100 Hours of Operation 5378
GM 4 3L Engine Oil and Oil Filter 5379
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 5379
Maintenance Procedures Every 500 Hours or 1 Year 5379
Hydraulic System Oil 5380
Hydraulic Tank Breather 5382
Inspect 5382
Battery 5383
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 5383
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 5384
Remove 5384
Install 5384
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 5386
Priming The Fuel System, Cummins 4 5L and QSB 3 3L Engines 5386
Controlled Venting 5386
Manual Bleeding 5386
Low Idle Speed Adjustment, Cummins 4 5L Engine Only 5387
GM 4 3L Engine Oil and Oil Filter 5387
Drain Tar From LPG Regulator 5388
Drain Tar From LPG Converter 5388
Drive Belt 5389
Cummins 4 5L and QSB 3 3L Diesel Engine and GM 4 3L Engine 5389
Fan and Alternator Drive Belt 5389
Clean Debris From Radiator Core 5391
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 5391
Wet Brake Center Body Oil Level Check 5392
Forks 5395
Mast Lubrication 5396
Header Hose Checks 5398
Lift Chain Lubrication 5398
Tilt Cylinder Lubrication 5398
Master Brake Cylinder Rod End Pin Lubrication 5399
Manual Hydraulic Levers Lubrication 5400
Brake Oil 5400
Tie Rod Lubrication 5401
Parking Brake Adjustment 5401
Maintenance Procedures Every 1000 Hours or 1 Year 5402
Valve Clearance, Check and Adjust 5402
Ignition System 5402
GM 4 3L Engine 5402
LPG Fuel Filter Element Replace, GM 4 3L Engine 5402
Remove 5402
Install 5403
In-Line Filter Replacement, Cummins 4 5L Engine 5403
Remove 5403
Install 5404
Lift Chains Wear Check 5405
Lift Chain Lubrication 5405
Hang On Sideshift Carriage, Check Sliding Surfaces 5405
Steering Axle Spindle Bearings 5408
Control Levers and Pedals 5409
Inspect Engine Electrical System, Connectors 5409
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 5409
Parking Brake Lever Lubrication, Wet Brake Axle 5414
Normal Operating Environment 5414
Heavy Duty or Contaminated Environment 5415
Remove 5415
Clean and Inspect 5415
Install 5416
Maintenance Procedures Every 2000 Hours or Annually 5416
Hydraulic System 5416
Hydraulic Filter Assembly, Replace 5416
Hydraulic Tank Breather, Replace 5418
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 5418
Cooling System Check 5418
Air Filter 5419
Oxygen Sensor, GM 4 3L Engine Equipped With GFI Installed 5421
LPG Regulator Fuel Filter, GM 4 3L Engines with GFI Installed 5422
Remove 5422
Install 5423
LPG Fuel Injector, GM 4 3L Engines with GFI Installed 5423
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 5423
Forks 5423
Brake Oil (Master Cylinder), Change 5424
Test Regulator PressureLPG 5424
Check Throttle Shaft for Sticking 5424
Inspect Exhaust Manifold and Piping for Leaks 5425
Transmission Automatic Clutch Calibration 5425
Brake System Accumulator 5425
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 5425
Wheel Bearings 5426
Steer Wheels, Lubrication 5426
Maintenance Procedures Every 4000 Hours or 2 Years 5426
Hydraulic Oil, Replace 5426
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 5429
Safety Procedures When Working Near Mast 5432
Fuel Filter Water Removal 5434
Hood Latch Check 5434
Lift Chain Adjustments 5435
Jump-Starting the Lift Truck 5437
Jump-Starting Using a Battery Charger 5437
Jump-Starting a Lift Truck Using Another Lift Truck 5437
Welding Repairs 5438
Overhead Guard Changes 5438
Wheel and Tire Replacement 5438
General 5438
Solid Rubber Tire, Change 5438
Remove and Install Tire on Wheel 5439
Adhesives and Sealants 5439
524288212-8000YRM1320-(06-2019)-US-EN 5443
Lift Truck Lifting Capacity 5447
Counterweight Weights 5447
Tire Sizes 5447
Capacities 5448
Electrical System 5455
Transmission Oil Pressures 5456
Hydraulic System Relief Pressures 5460
Steering System 5461
Stall Speeds (in RPM ±100 rpm) 5462
GM 4 3L Gas GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 5462
GM 4 3L LPG GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 5462
GM 4 3L Gas GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 5462
GM 4 3L LPG GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 5462
Cummins 4 5L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879) 5463
Cummins QSB 3 3L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879) 5463
Cummins 4 5L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878) 5463
Cummins QSB 3 3L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 5463
Mast Speeds 5464
Tilt Angles 5465
Front End Equipment – Mast Creep 5466
Mast Creep 5466
Engine Specifications 5466
Torque Specifications 5468
Frame 5468
Mast, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 5468
Mast, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 5469
Hang On Sideshift Carriage With Fork Positioner, Lift Truck Models Manufactured After August, 2012GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 5469
Steering System 5469
Transmission 5470
Engine – GM 4 3L 5470
Engine – Cummins 4 5L and QSB 3 3L Diesel 5471
524294873-1300YRM1343-(06-2021)-US-EN 5473
Transmission Repair 5477
Remove 5477
Torque Converter, Remove 5477
Disassemble 5479
Clean and Inspect 5520
Housings 5520
Oil Seals and Gaskets 5520
Bearings 5520
Gears and Shafts 5521
Assemble 5521
Torque Converter, Install 5559
Install 5560
Control Valve Repair 5561
Remove 5561
Disassemble 5561
Control Valve Assembly 5561
Control Valve Body 5561
Clean 5564
Inspect 5564
Assemble 5564
Control Valve Body 5564
Control Valve Assembly 5565
Install 5565
Torque Specification 5567
524294873-1300YRM1343-(11-2019)-UK-EN 5569
Transmission Repair 5573
Remove 5573
Torque Converter, Remove 5573
Disassemble 5574
Clean and Inspect 5614
Housings 5614
Oil Seals and Gaskets 5614
Bearings 5615
Gears and Shafts 5615
Assemble 5615
Torque Converter, Install 5653
Install 5654
Control Valve Repair 5655
Remove 5655
Disassemble 5655
Control Valve Assembly 5655
Control Valve Body 5655
Clean 5658
Inspect 5658
Assemble 5658
Control Valve Body 5658
Control Valve Assembly 5658
Install 5659
Torque Specification 5661
524294878-2100YRM1328-(06-2021)-US-EN 5663
General 5667
Safety Procedures When Working Near Mast 5667
Tilt Cylinder Repair 5670
Remove 5670
Disassemble 5674
Clean 5676
Inspect 5676
Assemble 5676
Install 5678
Tilt Cylinders, Adjust 5680
Tilt Cylinder Leak Check 5682
Lift Cylinder Repair 5683
Remove 5683
Disassemble 5692
Clean 5695
Inspect 5695
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) 5695
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5695
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) 5696
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5696
Free-Lift Cylinder Repair 5698
Remove 5698
Disassemble 5704
Clean 5706
Inspect 5706
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) 5707
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5707
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) 5707
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5708
Sideshift Cylinder Repair 5709
Remove 5709
Disassemble 5710
Clean 5713
Inspect 5713
Assemble 5714
Install 5715
Bolzoni Sideshift Cylinder Repair 5716
Remove 5716
Disassemble 5716
Clean 5717
Inspect 5717
Assemble 5718
Install 5718
Fork Positioner Cylinder Repair 5719
Remove 5719
Disassemble 5722
Clean 5726
Inspect 5726
Assemble 5727
Install 5728
Lift Cylinder Leak Check 5730
Seal Kit Installation 5731
External Installation (Seal and Back-Up Ring) 5731
Internal Installation (Piston Rod Assembly) 5731
Special Tools 5732
Torque Specifications 5733
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) 5733
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5733
524294878-2100YRM1328-(09-2018)-UK-EN 5735
General 5739
Safety Procedures When Working Near Mast 5739
Tilt Cylinder Repair 5741
Remove 5741
Disassemble 5746
Clean 5748
Inspect 5748
Assemble 5748
Install 5750
Tilt Cylinders, Adjust 5752
Tilt Cylinder Leak Check 5753
Lift Cylinder Repair 5754
Remove 5754
Disassemble 5764
Clean 5767
Inspect 5767
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) 5767
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5767
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) 5768
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5768
Free-Lift Cylinder Repair 5769
Remove 5769
Disassemble 5775
Clean 5777
Inspect 5777
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) 5778
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5778
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) 5778
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5779
Sideshift Cylinder Repair 5780
Remove 5780
Disassemble 5781
Clean 5784
Inspect 5784
Assemble 5785
Install 5786
Bolzoni Sideshift Cylinder Repair 5787
Remove 5787
Disassemble 5787
Clean 5788
Inspect 5788
Assemble 5789
Install 5789
Fork Positioner Cylinder Repair 5789
Remove 5790
Disassemble 5793
Clean 5797
Inspect 5797
Assemble 5798
Install 5799
Lift Cylinder Leak Check 5800
Seal Kit Installation 5800
External Installation (Seal and Back-Up Ring) 5800
Internal Installation (Piston Rod Assembly) 5801
Special Tools 5802
Torque Specifications 5803
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) 5803
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5803
524329117-8000YRM1387-(03-2020)-UK-EN 5807
General Information About Diagrams and Schematics 5811
Symbol Definitions 5811
Diagrams Manual Applications 5812
Diagrams and Schematics 5814
524329117-8000YRM1387-(06-2021)-US-EN 5879
General Information About Diagrams and Schematics 5883
Symbol Definitions 5883
Diagrams Manual Applications 5884
Diagrams and Schematics 5886
550001092-8000YRM1409-(03-2020)-UK-EN 5949
General Information About Diagrams and Schematics 5953
Symbol Definitions 5953
Diagrams Manual Applications 5954
Diagrams and Schematics 5956
550001092-8000YRM1409-(06-2021)-US-EN 6037
General Information About Diagrams and Schematics 6041
Symbol Definitions 6041
Diagrams Manual Applications 6042
Diagrams and Schematics 6044
550043871-0900YRM1556-(04-2018)-US-EN 6119
General 6123
LPG Tank and Bracket 6123
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) 6123
Remove 6123
Install 6131
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) 6132
Remove 6132
Install 6134
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 6134
Remove 6134
Install 6136
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 6136
Remove 6136
Install 6136
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) 6137
Remove 6137
Install 6139
Fuel Filter Unit 6139
Fuel Filter Element 6140
Remove 6140
Clean and Inspect 6140
Install 6141
Fuel Filter Housing with LP Vapor Sensor 6141
Remove 6141
Disassemble 6143
Clean and Inspect 6144
Assemble 6144
Install 6145
Throttle Body 6146
Remove 6146
Clean 6150
Install 6150
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 6151
Remove 6151
Install 6152
Control System 6152
Engine Control Unit (ECU) 6153
Remove 6153
Install 6154
Low Pressure Switch 6154
Remove 6154
Install 6154
Low Fuel Sensor 6155
Remove 6155
Install 6155
LP Converter 6156
Remove and Disassemble 6156
Assemble and Install 6157
LPG Lock-Off 6157
Remove 6158
Install 6159
Exhaust System 6160
Counterweight Exhaust 6160
Remove and Disassemble 6160
Inspect 6162
Assemble and Install 6162
Overhead Exhaust 6163
Remove and Disassemble 6163
Inspect 6165
Assemble and Install 6165
Exhaust Manifold 6165
Remove 6165
Install 6167
Oxygen (HEGO) Sensor 6167
Remove 6167
Install 6167
LPG Fuel Testing 6168
General 6168
Available Fuel Tests 6168
Composition Test (ASTM D-2163) 6168
Ammonia Test (ASTM D-4490) 6168
Basic Nitrogen Test (ASTM UOP269-90) 6168
Residues Test (ASTM D-2158) 6168
Vapor Pressure Test (ASTM D-2598) 6168
Sulfur Compounds Test (ASTM D-5623) 6168
Methanol Test (ASTM D-4864) 6169
Copper Corrosion (ASTM D-1838) 6169
Where To Send LPG Fuel Samples For Testing 6169
550073240-1900YRM1620-(01-2023)-US-EN 6173
Proper Flushing after Major Hydraulic Repairs 6179
Introduction 6179
The Phases of Wear 6179
Causes of Hydraulic System Failure 6179
Progression of Contaminant Caused Hydraulic System Failure 6180
Hydraulic System Flushing Techniques 6180
Double Oil and Filter Change 6180
Mechanical Cleaning 6181
Cleaning of Components 6181
How to Clean Tubes and Hoses 6181
Filter Caddy 6181
Start-Up Procedure for Cleaned System 6182
Contaminated Oil Coolers 6182
Additional Filter Caddy Functions 6183
How to Handle Different Fluids 6183
Water Removal Filters 6183
Fluid Conditioning and System Flushing Procedures 6184
Operation of the Filter Caddy 6184
Filter Caddy operation 6184
Fluid Conditioning Procedure 6184
Filter Caddy Start-Up 6185
System Flushing Procedure 6185
Component Cleaning Procedure 6186
Reservoir Cleaning Procedure 6186
Cylinder Cleaning Procedure 6186
Hose and Tube Cleaning Procedure 6186
Valve Cleaning Procedure 6187
Front-End Attachment Cleaning Procedure 6188
System Flushing Procedure 6188
Filter Caddy Start-Up 6189
System Start-Up and Flushing 6189
Reservoir Fluid Cleaning Times 6190
Dealing With Different Fluid Types 6191
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 6191
Filter Caddy Maintenance 6191
Servicing the Strainer 6191
DC Motor 6191
Hydraulic Oil Sampling Method and Procedure 6192
Hydraulic Oil Sampling Method 6192
Objective 6192
General Guidelines 6192
Synopsis 6193
Hydraulic Oil Analysis Report Guidelines 6194
Sampling Conditions 6194
Equipment 6194
Sampling Procedure 6195
Hydraulic Oil Sampling 6195
Sample Labeling 6195
Results Documentation 6195
550073240-1900YRM1620-(03-2020)-UK-EN 6197
Proper Flushing after Major Hydraulic Repairs 6201
Introduction 6201
The Phases of Wear 6201
Causes of Hydraulic System Failure 6201
Progression of Contaminant Caused Hydraulic System Failure 6202
Hydraulic System Flushing Techniques 6202
Double Oil and Filter Change 6202
Mechanical Cleaning 6203
Cleaning of Components 6203
How to Clean Tubes and Hoses 6203
Filter Caddy 6203
Start-Up Procedure for Cleaned System 6204
Contaminated Oil Coolers 6204
Additional Filter Caddy Functions 6204
How to Handle Different Fluids 6204
Water Removal Filters 6205
Fluid Conditioning and System Flushing Procedures 6205
Operation of the Filter Caddy 6205
Filter Caddy operation 6205
Fluid Conditioning Procedure 6206
Filter Caddy Start-Up 6206
System Flushing Procedure 6207
Component Cleaning Procedure 6207
Reservoir Cleaning Procedure 6207
Cylinder Cleaning Procedure 6207
Hose and Tube Cleaning Procedure 6208
Valve Cleaning Procedure 6208
Front-End Attachment Cleaning Procedure 6209
System Flushing Procedure 6209
Filter Caddy Start-Up 6210
System Start-Up and Flushing 6210
Reservoir Fluid Cleaning Times 6211
Dealing With Different Fluid Types 6211
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 6211
Filter Caddy Maintenance 6212
Servicing the Strainer 6212
DC Motor 6212
Hydraulic Oil Sampling Method and Procedure 6212
Hydraulic Oil Sampling Method 6212
Objective 6212
General Guidelines 6212
Synopsis 6213
Hydraulic Oil Analysis Report Guidelines 6214
Sampling Conditions 6215
Equipment 6215
Sampling Procedure 6215
Hydraulic Oil Sampling 6215
Sample Labeling 6216
Results Documentation 6216

S.V 06/24