Yale Forklift E818 (GC_GLC080-100-120VX, GC_GLC080-100VXBCS, GC120SVX, GC_GLC120V) Service Manual PDF

Description

Yale Forklift E818 (GC_GLC080-100-120VX, GC_GLC080-100VXBCS, GC120SVX, GC_GLC120V) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift E818 (GC_GLC080-100-120VX, GC_GLC080-100VXBCS, GC120SVX, GC_GLC120V) Service Manual – PDF DOWNLOAD

Language : English
Pages : 6040
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift E818 (GC_GLC080-100-120VX, GC_GLC080-100VXBCS, GC120SVX, GC_GLC120V) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524208014-2200YRM1097-(03-2020)-US-EN 43
Series Code / Model Designation Reference Table 47
Description 48
Distributor Ignition (DI) System 48
Crankshaft Position (CKP) Sensor 48
Camshaft Position (CMP) Sensor 48
Ignition Coil and Ignition Control Module (ICM) 48
Secondary Ignition Components 48
Spark Plugs and Wires 49
Spark Plug Wire Inspection 49
Spark Plug Wire Replacement 49
Remove 49
Install 50
Spark Plug Inspection 50
Usage 50
Inspection 50
Visual Inspection 52
Spark Plug Replacement 52
Remove 52
Install 52
Distributor Repair 53
Inspect 53
Overhaul 53
Disassemble 53
Assemble 56
Replace 57
Remove 57
Install Procedure 1 59
Install Procedure 2 60
Ignition Coil Replacement 61
Remove 61
Install 61
Ignition Control Module Replacement 62
Remove 62
Install 62
Starter Replacement 63
Remove 63
Install 66
Sensors and Switches 67
Gas and LPG Trucks 67
Crankshaft Position (CKP) Sensor 67
Remove 67
Install 67
Camshaft Position (CMP) Sensor 68
Remove 68
Install 70
Oil Pressure Sensor 70
Remove 70
Install 71
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 72
Remove 72
Install 72
Engine Coolant Temperature (ECT) Sensor 73
Remove 73
Install 74
Air Flow Restriction Switch 74
Remove 74
Install 75
Specifications and Special Tools 76
524221866-9000YRM1112-(10-2020)-US-EN 81
SECTION 9010 Operational Diagnostic Procedures 97
Group 05 – Operational Checkout 99
SECTION 9020 Engine 117
Group 10 – Principles of Operation 127
Group 30 – Observed Symptoms 325
Group 40 – Tests and Adjustments 427
SECTION 9030 Electrical System 459
Group 03 – General Maintenance and Diagnostic Data 483
Group 10 – Principles of Operation 577
Group 20 – Diagnostic Trouble Codes 601
Group 30 – Observed Symptoms 1573
SECTION 9040 Drive Train 1629
Group 10 – Principles of Operation 1633
Group 30 – Observed Symptoms 1689
Group 40 – Tests and Adjustments 1739
SECTION 9050 Hydraulic Systems 1749
Group 10 – Principles of Operation 1753
Group 30 – Observed Symptoms 1811
Group 33 – Observed Symptoms-Gear Pump 1813
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1901
Group 40 – Tests and Adjustments 1945
Group 43 – Tests and Adjustments-Gear Pump 1947
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1971
SECTION 9060 Operators Station 1989
Group 10 – Principles of Operation 1991
SECTION 9070 Front End (Mast) and Chassis 2027
Group 10 – Principles of Operation 2029
Group 30 – Observed Symptoms 2051
SECTION 9080 Supplementary Data 2109
Group 50 – Abbreviations and Acronyms 2111
Group 60 – Special Tools List 2119
Group 70 – Fault Mode Indicator Reference 2129
Group 80 – Supplier Specification Data 2131
524223757-0700YRM1123-(06-2016)-US-EN 2135
General 2139
Cooling System Checks 2139
Exhaust Leaks Into Cooling System 2139
Water Flow Restrictions in Radiator 2139
Radiator Hoses 2139
Water Pump 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
524223762-1300YRM1129-(11-2018)-US-EN 2287
General 2291
Serial Number 2291
Charge Pump Repair 2291
Remove 2291
Inspect 2292
Install 2292
Torque Converter Replace 2292
Remove 2292
Install 2300
Front Cover Housing and Chain Drive Repair 2306
Remove 2306
Clean 2315
Inspect 2315
Install 2315
Clutch Packs Repair 2324
Remove and Disassemble 2324
Transmission, Remove and Disassemble 2324
Clean 2343
Inspect 2343
Assemble and Install 2344
Transmission, Assemble and Install 2352
Control Valve Repair 2358
Remove and Disassemble 2358
Clean 2362
Inspect 2362
Assemble and Install 2362
Foot Directional Control Pedal Repair 2363
Remove and Disassemble 2363
Assemble and Install 2367
Direction Control Lever 2368
Remove 2368
Install 2368
524223764-1600YRM1133-(07-2013)-US-EN 2373
toc 2373
Steering Axle 2373
Safety Precautions Maintenance and Repair 2374
General 2377
Steering Axle Assembly Repair 2379
Remove 2379
Disassemble 2380
Clean 2388
Inspect 2388
Assemble 2388
Install 2394
Spindles, Bearings, and Tie Rods Repair 2396
Spindles and Bearings 2396
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2396
Remove 2396
Disassemble 2398
Clean 2399
Inspect 2399
Assemble 2399
Install 2400
Spindles and Bearings 2403
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2403
Remove and Disassemble 2403
Assemble and Install 2404
Tie Rods 2404
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2404
Remove 2404
Install 2405
Tie Rods 2406
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2406
Remove 2406
Install 2412
Steering Cylinder Repair 2412
Remove and Disassemble 2412
Clean and Inspect 2413
Assemble and Install 2413
Torque Specifications 2414
524223766-1900YRM1136-(01-2022)-US-EN 2419
General 2423
Hydraulic Gear Pump Assembly 2424
Variable Displacement Pump Assembly 2425
Single Gear Pump Assembly Repair 2426
Remove 2426
Disassemble 2432
Clean 2434
Inspect 2434
Assemble 2434
Install 2434
Tandem Gear Pump Assembly 2439
Remove 2439
Disassemble 2440
Clean 2443
Inspect 2443
Assemble 2443
Install 2444
Gear Pump Specifications 2445
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2451
Remove 2451
Disassemble 2461
Clean 2464
Inspect 2465
Assemble 2465
Install 2465
63 0 cc/rev – Variable Displacement Pump Repair 2470
Remove 2470
Disassemble 2473
Clean 2475
Inspect 2475
Assemble 2475
Install 2475
Variable Displacement Pump Checks and Adjustments (Single Pump) 2479
Margin Pressure Check 2479
Flow Compensator Adjustment 2480
Pressure Compensator Adjustment 2480
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2482
Variable Displacement Pump Specifications 2485
Torque Specifications 2487
Hydraulic Gear Pump 2487
Variable Displacement Pump 2488
Special Tools 2489
524223766-1900YRM1136-(11-2017)-US-EN 2491
General 2495
Hydraulic Gear Pump Assembly 2496
Variable Displacement Pump Assembly 2497
Single Gear Pump Assembly Repair 2497
Remove 2497
Disassemble 2504
Clean 2504
Inspect 2506
Assemble 2506
Install 2506
Tandem Gear Pump Assembly 2510
Remove 2511
Disassemble 2513
Clean 2515
Inspect 2515
Assemble 2515
Install 2516
Gear Pump Specifications 2516
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2522
Remove 2522
Disassemble 2532
Clean 2535
Inspect 2535
Assemble 2535
Install 2536
63 0 cc/rev – Variable Displacement Pump Repair 2539
Remove 2539
Disassemble 2542
Clean 2542
Inspect 2542
Assemble 2544
Install 2544
Variable Displacement Pump Checks and Adjustments (Single Pump) 2546
Margin Pressure Check 2546
Flow Compensator Adjustment 2547
Pressure Compensator Adjustment 2547
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2548
Variable Displacement Pump Specifications 2551
Torque Specifications 2552
Hydraulic Gear Pump 2553
Variable Displacement Pump 2554
Special Tools 2554
524223767-2000YRM1137-(01-2017)-US-EN 2559
General 2565
Electro-Hydraulic Main Control Valve 2566
Description 2566
Remove 2574
Electro-Hydraulic Control Valve Sections 2579
General 2579
Outlet Control Valve Section 2579
Remove 2579
Disassemble 2580
Clean 2582
Inspect 2582
Assemble 2582
Install 2583
Auxiliary Control Valve Sections 2583
Remove 2583
Disassemble 2590
Clean 2591
Inspect 2592
Assemble 2592
Install 2594
Tilt Control Valve Section 2595
Remove 2595
Disassemble 2595
Clean 2601
Inspect 2601
Assemble 2601
Install 2602
Lift/Lower Control Valve Section 2603
Remove 2603
Disassemble 2603
Clean 2612
Inspect 2612
Assemble 2612
Install 2613
Mid-Inlet Section 2613
Remove 2613
Clean 2614
Inspect 2614
Install 2614
Install 2614
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2619
Lift Pilot Pin 2619
Lower Pilot Pin 2623
Abnormal/Erroneous EHPV Adjustment 2625
Manual Main Control Valve 2626
Description 2626
Remove 2630
OPS Solenoid Assembly 2638
General 2638
Remove 2639
Clean and Inspect 2642
Install 2642
Manual Control Valve Sections 2643
General 2643
Outlet Control Valve Section 2643
Remove 2643
Disassemble 2643
Clean 2646
Inspect 2646
Assemble 2646
Install 2647
Auxiliary Control Valve Sections 2647
Remove 2647
Disassemble 2647
Clean 2650
Inspect 2650
Assemble 2650
Install 2651
Lift/Tilt Control Valve Section 2651
Remove 2651
Disassemble 2651
Clean 2658
Inspect 2658
Assemble 2659
Install 2660
Mid-Inlet Section 2661
Remove 2661
Clean 2661
Inspect 2661
Install 2661
Install 2662
Pressure Relief Valve Check and Adjustment 2668
Primary Relief Valve 2669
Secondary Relief Valve 2673
Steering Control Unit Repair 2680
Steering Control Unit, Remove 2680
Steering Control Unit, Disassemble 2684
Steering Control Unit, Clean 2686
Steering Control Unit, Inspect 2686
Steering Control Unit, Assemble 2686
Relief Valve, Disassemble 2687
Relief Valve, Clean 2687
Relief Valve, Inspect 2688
Relief Valve, Assemble 2688
Steering Control Unit, Install 2688
524223767-2000YRM1137-(06-2021)-US-EN 2693
General 2697
Electro-Hydraulic Main Control Valve 2698
Description 2698
Remove 2706
Electro-Hydraulic Control Valve Sections 2711
General 2711
Outlet Control Valve Section 2711
Remove 2711
Disassemble 2711
Clean 2714
Inspect 2714
Assemble 2715
Install 2715
Auxiliary Control Valve Sections 2715
Remove 2716
Disassemble 2721
Clean 2723
Inspect 2723
Assemble 2723
Install 2725
Tilt Control Valve Section 2726
Remove 2726
Disassemble 2727
Clean 2731
Inspect 2731
Assemble 2732
Install 2733
Lift/Lower Control Valve Section 2733
Remove 2733
Disassemble 2733
Clean 2739
Inspect 2739
Assemble 2739
Install 2740
Mid-Inlet Section 2740
Remove 2740
Clean 2741
Inspect 2741
Install 2741
Install 2741
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2746
Lift Pilot Pin 2746
Lower Pilot Pin 2749
Abnormal/Erroneous EHPV Adjustment 2751
Manual Main Control Valve 2752
Description 2752
Remove 2756
OPS Solenoid Assembly 2764
General 2764
Remove 2765
Clean and Inspect 2767
Install 2767
Manual Control Valve Sections 2768
General 2768
Outlet Control Valve Section 2768
Remove 2768
Disassemble 2768
Clean 2771
Inspect 2771
Assemble 2771
Install 2771
Auxiliary Control Valve Sections 2772
Remove 2772
Disassemble 2772
Clean 2775
Inspect 2775
Assemble 2775
Install 2775
Lift/Tilt Control Valve Section 2776
Remove 2776
Disassemble 2776
Clean 2782
Inspect 2782
Assemble 2782
Install 2784
Mid-Inlet Section 2784
Remove 2784
Clean 2785
Inspect 2785
Install 2785
Install 2785
Pressure Relief Valve Check and Adjustment 2793
Primary Relief Valve 2793
Secondary Relief Valve 2796
Steering Control Unit Repair 2801
Steering Control Unit, Remove 2801
Steering Control Unit, Disassemble 2805
Steering Control Unit, Clean 2807
Steering Control Unit, Inspect 2807
Steering Control Unit, Assemble 2807
Relief Valve, Disassemble 2808
Relief Valve, Clean 2808
Relief Valve, Inspect 2809
Relief Valve, Assemble 2809
Steering Control Unit, Install 2809
524223768-2100YRM1139-(02-2014)-US-EN 2813
524223769-2200YRM1128-(01-2023)-US-EN 2861
Series Code / Model Designation Reference Table 2869
General 2871
Deutsch Crimping Tool 2872
How to Strip a Wire for Use With Deutsch Crimping Tool 2872
How to Crimp With the Deutsch Crimping Tool 2873
Calibration Test for the Deutsch Crimping Tool 2875
Deutsch Connectors 2877
DT, DTM, and DTP Series Connectors 2877
HD Series Connectors 2920
Metri-Pack Connectors 2942
Remove and Install 2942
Micro-Pack Connectors 2945
Weather-Pack Connectors 2946
AMPSEAL Crimping Tools 2948
AMP Hand Crimping Tool With Certi-Crimp 2948
Description 2948
Stripping Wire for Use with AMP Hand Crimping Tool 2949
Insulation Crimp Adjustment 2950
Maintenance and Inspection for AMP Hand Crimping Tool 2950
AMP Hand Crimping Tool 2950
Crimp Height Inspection 2950
How to use AMP Hand Crimping Tool 2951
AMP Pro-Crimper II Tool 2951
Description 2951
Remove and Install Die Set and Locator Assembly 2952
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2952
Contact Support Adjustment 2953
Crimp Height Adjustment 2954
Maintenance and Inspection Procedures 2954
PRO-CRIMPER II Tool 2954
Crimp Height Inspection 2954
How to Use AMP PRO-CRIMPER II Tool 2955
AMPSEAL Connector Assemblies 2956
Description for Plug Connector Assembly 2956
Seal Plug 2957
Contact Crimping 2957
Description for Plug Connector and Header Assembly 2962
Voltage Reading 2965
Seal Plug 2965
Contact Crimping 2965
AMP Superseal 1 5 Crimping Tools 2972
Mini Mic Receptacle and Tab Contacts 2972
Description 2972
Crimping Conditions and Measurements 2972
Insertion of Rubber Seal on Cable 2974
AMP Hand Application Tool 2979
Description 2979
Maintenance and Inspection 2979
Crimp Height Inspection 2979
Crimp Height Adjustment 2980
How to Use AMP Hand Application Tool 2980
AMP Pro-Crimper II Tool 2981
Description 2981
Remove and Install Die Set and Locator Assembly 2981
Adjustments 2982
Contact Support 2982
Crimp Height 2983
Inspections and Maintenance 2984
Crimp Height Inspection 2984
Visual Inspection 2984
Maintenance 2985
How to Use Pro-Crimper II Tool 2985
AMP Superseal 1 5 Connector Assemblies 2986
Description 2986
Repair and Maintenance 2993
Panel Mount Option 2993
AMP Fastin-Faston Hand Tools 2994
Description – AMP Double Action Hand Tool 2994
Maintenance and Inspection Procedures 2994
Daily Maintenance 2994
Periodic Tool Inspection 2995
Lubrication 2995
Visual Inspection 2995
Crimp Height Inspection 2995
Certi-Crimp Ratchet Inspection 2996
How to Use AMP Double Action Hand Tool 2997
Description – AMP Extraction Tool 2998
Maintenance and Inspection 2999
How to Use AMP Extraction Tool 2999
AMP Fastin-Faston Receptacles and Housings 3001
Description 3001
Wire Repair 3009
Wire Splicing Requirements 3009
Deutsch Jiffy Splice 3010
Twisted/Shielded Cable and Leads Repair 3016
Special Tools 3018
524223769-2200YRM1128-(07-2020)-US-EN 3027
Series Code / Model Designation Reference Table 3033
General 3036
Deutsch Crimping Tool 3036
How to Strip a Wire for Use With Deutsch Crimping Tool 3036
How to Crimp With the Deutsch Crimping Tool 3037
Calibration Test for the Deutsch Crimping Tool 3039
Deutsch Connectors 3041
DT, DTM, and DTP Series Connectors 3041
HD Series Connectors 3083
Metri-Pack Connectors 3106
Remove and Install 3106
Micro-Pack Connectors 3108
Weather-Pack Connectors 3109
AMPSEAL Crimping Tools 3111
AMP Hand Crimping Tool With Certi-Crimp 3111
Description 3111
Stripping Wire for Use with AMP Hand Crimping Tool 3111
Insulation Crimp Adjustment 3112
Maintenance and Inspection for AMP Hand Crimping Tool 3112
AMP Hand Crimping Tool 3112
Crimp Height Inspection 3112
How to use AMP Hand Crimping Tool 3113
AMP Pro-Crimper II Tool 3113
Description 3113
Remove and Install Die Set and Locator Assembly 3114
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3115
Contact Support Adjustment 3115
Crimp Height Adjustment 3116
Maintenance and Inspection Procedures 3116
PRO-CRIMPER II Tool 3116
Crimp Height Inspection 3116
How to Use AMP PRO-CRIMPER II Tool 3117
AMPSEAL Connector Assemblies 3118
Description for Plug Connector Assembly 3118
Seal Plug 3119
Contact Crimping 3119
Description for Plug Connector and Header Assembly 3124
Voltage Reading 3126
Seal Plug 3126
Contact Crimping 3126
AMP Superseal 1 5 Crimping Tools 3133
Mini Mic Receptacle and Tab Contacts 3133
Description 3133
Crimping Conditions and Measurements 3133
Insertion of Rubber Seal on Cable 3135
AMP Hand Application Tool 3140
Description 3140
Maintenance and Inspection 3140
Crimp Height Inspection 3140
Crimp Height Adjustment 3141
How to Use AMP Hand Application Tool 3141
AMP Pro-Crimper II Tool 3142
Description 3142
Remove and Install Die Set and Locator Assembly 3143
Adjustments 3143
Contact Support 3143
Crimp Height 3144
Inspections and Maintenance 3145
Crimp Height Inspection 3145
Visual Inspection 3145
Maintenance 3146
How to Use Pro-Crimper II Tool 3146
AMP Superseal 1 5 Connector Assemblies 3147
Description 3147
Repair and Maintenance 3154
Panel Mount Option 3154
AMP Fastin-Faston Hand Tools 3155
Description – AMP Double Action Hand Tool 3155
Maintenance and Inspection Procedures 3155
Daily Maintenance 3155
Periodic Tool Inspection 3156
Lubrication 3156
Visual Inspection 3156
Crimp Height Inspection 3156
Certi-Crimp Ratchet Inspection 3157
How to Use AMP Double Action Hand Tool 3158
Description – AMP Extraction Tool 3159
Maintenance and Inspection 3159
How to Use AMP Extraction Tool 3160
AMP Fastin-Faston Receptacles and Housings 3161
Description 3161
Wire Repair 3168
Wire Splicing Requirements 3168
Deutsch Jiffy Splice 3169
Twisted/Shielded Cable and Leads Repair 3174
Special Tools 3177
524223770-2200YRM1130-(03-2020)-US-EN 3185
General 3189
Description 3189
Dash Display Menu Access 3189
Menu Navigation 3190
Standard Display 3190
Main Menu 3190
Passwords Menu 3191
Password Administration 3191
Add Password 3191
Delete Password 3192
Edit Password 3192
Other Password Functions 3193
Operator Passwords – Enable/Disable 3193
Password Time-Out Delay 3193
Passwords – Number Wrong to Disable 3194
Lockout Reset Password 3194
View Password Log 3195
View Versions 3196
VSM Versions 3196
Dash Display Versions 3197
Engine Controller Version 3198
Transmission (Xmsn) Controller Version 3199
Truck Serial Number 3200
Diagnostics 3201
View Fault Log 3201
Set Travel and Braking 3202
Speed Limit 3202
Acceleration Rate 3203
Auto-Deceleration Rate 3203
Set Power Reversal Rate 3204
Set Inching/Brake Overlap 3205
Setup Display Menu 3206
Set Operator Language 3206
Set Units 3207
Set Time Format (12/24 Hour) 3207
Set Daylight Saving Time 3207
Set Time 3210
Set Date Format 3211
Set Date 3211
Setup Hydraulics 3212
Return to Set Tilt Delay/On/Off 3212
Setup General Items 3213
Light Shutdown Time-Out 3213
Impact Sensor – Enable/Disable 3214
Impact Sensor – Soft Impact Settings 3215
Impact Sensor – Hard Impact Settings 3216
Adjust Impact Sensor Settings 3216
Initial Adjustment of Soft and Hard Impact Settings 3218
Readjustment of Soft and Hard Impact Settings 3218
Impact Sensor – Impact Alarm/Shutdown Reset 3219
Impact Sensor – Alarm Time Duration and Deactivation 3220
Impact Sensor – View Impact Event Log 3221
Engine Mode Indicator 3222
Generation 1 (ECO-eLo ONLY) 3222
Generation 2 3223
Operator Checklist 3224
Operator Checklist Off-On Mode 3224
Edit Operator Checklist 3224
Set Operator Checklist Expiration 3225
View Checklist Log 3225
Clear Operator Checklist Log 3226
Clear Operator Checklist Fault 3226
Calibrations 3227
Set Tilt Stop Point 3227
Calibrate Loaded Weight 3227
524223770-2200YRM1130-(05-2021)-US-EN 3229
General 3233
Description 3233
Dash Display Menu Access 3233
Menu Navigation 3234
Standard Display 3234
Main Menu 3234
Passwords Menu 3235
Password Administration 3235
Add Password 3235
Delete Password 3235
Edit Password 3236
Other Password Functions 3237
Operator Passwords – Enable/Disable 3237
Password Time-Out Delay 3237
Passwords – Number Wrong to Disable 3237
Lockout Reset Password 3238
View Password Log 3238
View Versions 3239
VSM Versions 3239
Dash Display Versions 3240
Engine Controller Version 3241
Transmission (Xmsn) Controller Version 3242
Truck Serial Number 3243
Diagnostics 3244
View Fault Log 3244
Set Travel and Braking 3245
Speed Limit 3245
Acceleration Rate 3246
Auto-Deceleration Rate 3246
Set Power Reversal Rate 3247
Set Inching/Brake Overlap 3248
Setup Display Menu 3249
Set Operator Language 3249
Set Units 3250
Set Time Format (12/24 Hour) 3250
Set Daylight Saving Time 3251
Set Time 3254
Set Date Format 3254
Set Date 3255
Setup Hydraulics 3256
Return to Set Tilt Delay/On/Off 3256
Setup General Items 3257
Light Shutdown Time-Out 3257
Impact Sensor – Enable/Disable 3258
Impact Sensor – Soft Impact Settings 3259
Impact Sensor – Hard Impact Settings 3259
Adjust Impact Sensor Settings 3260
Initial Adjustment of Soft and Hard Impact Settings 3262
Readjustment of Soft and Hard Impact Settings 3262
Impact Sensor – Impact Alarm/Shutdown Reset 3263
Impact Sensor – Alarm Time Duration and Deactivation 3264
Impact Sensor – View Impact Event Log 3265
Engine Mode Indicator 3265
Generation 1 (ECO-eLo ONLY) 3265
Generation 2 3266
Operator Checklist 3267
Operator Checklist Off-On Mode 3267
Edit Operator Checklist 3267
Set Operator Checklist Expiration 3267
View Checklist Log 3268
Clear Operator Checklist Log 3269
Clear Operator Checklist Fault 3269
Calibrations 3270
Set Tilt Stop Point 3270
Calibrate Loaded Weight 3270
524223771-2200YRM1131-(03-2020)-US-EN 3273
Series Code / Model Designation Reference Table 3279
General 3281
Description 3281
Dash Display Menu Access 3281
Menu Navigation 3282
Main Menu 3282
Passwords 3283
Adding Passwords 3283
Hourmeters 3285
View Versions 3286
VSM Versions 3286
Dash Display Versions 3287
Engine Controller Version 3288
Transmission (Xmsn) Controller Version 3289
Truck Serial Number 3290
Truck Configuration 3291
Diagnostics 3292
Clear Fault Log 3292
View Fault Log 3293
No-Run Data Display 3294
Engine Accelerator and Throttle Data Display 3294
Engine Speeds and Governor Data Display 3295
Engine Fuel and Emissions Data Display 3296
Engine General Data Display 3298
XMSN/Brake Data Display 3299
Hydraulic Data Display 3302
General Truck Data Display 3304
Set Travel and Braking 3305
Speed Limit 3305
Acceleration Rate 3306
Auto-Deceleration Rate 3307
Set Power Reversal Rate 3307
Set Inching/Brake Overlap 3308
Setup Hydraulics 3308
Lift Maximum Speed 3309
Lower Maximum Speed 3309
Tilt Maximum Speed 3310
Auxiliary Function One, Direction A, Maximum Speed 3312
Auxiliary Function One, Direction B, Maximum Speed 3314
Auxiliary Function Two, Direction A, Maximum Speed 3314
Auxiliary Function Two, Direction B, Maximum Speed 3315
Auxiliary Function Three, Direction A, Maximum Speed 3316
Auxiliary Function Three, Direction B, Maximum Speed 3316
Lift/Lower Ramp Rate 3317
Hydraulic Auxiliary Ramp Rate 3317
Return to Set Tilt Delay/On/Off 3318
Hydraulic Input Device 3319
Auxiliary Solenoid 3319
Dual Function 3320
Setup Display 3321
Set Service Language 3321
Setup General Items 3321
Motion Alarm Activation Type 3322
Light Shutdown Time-Out 3323
Restore Default Settings 3323
Restore Engine Controller Default Calibration 3324
Impact Sensor – Enable/Disable 3324
Impact Sensor – Soft Impact Settings 3325
Impact Sensor – Hard Impact Settings 3326
Adjust Impact Sensor Settings 3327
Initial Adjustment of Soft and Hard Impact Settings 3329
Readjustment of Soft and Hard Impact Settings 3329
Impact Sensor – Impact Alarm/Shutdown Reset 3330
Impact Sensor – Alarm Time Duration and Deactivation 3331
Impact Sensor – View Impact Event Log 3332
Engine Mode Indicator 3332
Generation 1 (ECO-eLo ONLY) 3332
Generation 2 3333
Diesel Particulate Filter (DPF) Display 3334
General Description 3334
Passive Regeneration Only 3334
Regeneration Level 0 3334
Auto/Active Regeneration Inhibited 3335
Auto/Active Regeneration 3335
Regeneration Level 1 3335
Parked Regeneration Request 3336
Regeneration Level 2 3336
Warning Level 3336
Regeneration Level 3 3336
Service Level 3337
Regeneration Level 4 3337
Display, Diesel Particulate Filter (DPF), Revised 3337
Operator Interface 3337
Refer to Operator Manual 3337
CAN Communication Lost 3338
Passive Regeneration Only 3338
Regeneration Level 0 3338
Auto/Active Regeneration Inhibited 3338
Auto/Active Regeneration 3339
Regeneration Level 1 3339
Idle-up Auto/Active Regeneration 3339
Parked Regeneration Request 3339
Regeneration Level 2 3339
Warning Level 3341
Regeneration Level 3 3341
Service Level 3341
Regeneration Level 4 3341
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3341
Display, Diesel Particulate Filter (DPF), Stage V Engine 3341
Operator Interface 3342
Refer to Operator Manual 3342
CAN Communication Lost 3342
Passive Regeneration Only 3342
Regeneration Level 0 3342
Auto/Active Regeneration Inhibited 3343
Auto/Active Regeneration 3343
Regeneration Level 1 3343
Idle-up Auto/Active Regeneration 3344
Parked Regeneration Request 3344
Regeneration Level 2 3344
Warning Level 3345
Regeneration Level 3 3345
Service Level 3346
Regeneration Level 4 3346
Stage V Content 3346
Emissions System Malfunction 3346
Ash Load 3346
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3347
Operator Interface 3347
Refer to Operator Manual 3347
CAN Communication Lost 3348
Passive Regeneration Only 3348
Regeneration Level 0 3348
Auto/Active Regeneration Inhibited 3348
Auto/Active Regeneration 3349
Regeneration Level 1 3349
Idle-up Auto/Active Regeneration 3349
Parked Regeneration Request 3349
Regeneration Level 2 3349
Warning Level 3351
Regeneration Level 3 3351
Service Level 3351
Regeneration Level 4 3351
Calibrations 3352
Calibrate Transmission Valve 3354
Set Tilt Stop Point 3354
Calibrate Loaded Weight 3354
Calibrate Travel Speed Sensor 3355
Calibrate Mazda LP and Gas Accelerator Pedal 3355
524223771-2200YRM1131-(05-2021)-US-EN 3357
Series Code / Model Designation Reference Table 3363
General 3365
Description 3365
Dash Display Menu Access 3365
Menu Navigation 3366
Main Menu 3367
Passwords 3367
Adding Passwords 3367
Hourmeters 3369
View Versions 3370
VSM Versions 3370
Dash Display Versions 3371
Engine Controller Version 3372
Transmission (Xmsn) Controller Version 3373
Truck Serial Number 3374
Truck Configuration 3375
Diagnostics 3376
Clear Fault Log 3376
View Fault Log 3377
No-Run Data Display 3378
Engine Accelerator and Throttle Data Display 3379
Engine Speeds and Governor Data Display 3381
Engine Fuel and Emissions Data Display 3382
Engine General Data Display 3384
XMSN/Brake Data Display 3385
Hydraulic Data Display 3387
General Truck Data Display 3390
Set Travel and Braking 3392
Speed Limit 3392
Acceleration Rate 3393
Auto-Deceleration Rate 3393
Set Power Reversal Rate 3394
Set Inching/Brake Overlap 3394
Setup Hydraulics 3395
Lift Maximum Speed 3395
Lower Maximum Speed 3396
Tilt Maximum Speed 3396
Auxiliary Function One, Direction A, Maximum Speed 3398
Auxiliary Function One, Direction B, Maximum Speed 3401
Auxiliary Function Two, Direction A, Maximum Speed 3401
Auxiliary Function Two, Direction B, Maximum Speed 3402
Auxiliary Function Three, Direction A, Maximum Speed 3403
Auxiliary Function Three, Direction B, Maximum Speed 3403
Lift/Lower Ramp Rate 3404
Hydraulic Auxiliary Ramp Rate 3404
Return to Set Tilt Delay/On/Off 3405
Hydraulic Input Device 3406
Auxiliary Solenoid 3406
Dual Function 3407
Setup Display 3408
Set Service Language 3408
Setup General Items 3408
Motion Alarm Activation Type 3409
Light Shutdown Time-Out 3410
Restore Default Settings 3410
Restore Engine Controller Default Calibration 3411
Impact Sensor – Enable/Disable 3411
Impact Sensor – Soft Impact Settings 3412
Impact Sensor – Hard Impact Settings 3412
Adjust Impact Sensor Settings 3413
Initial Adjustment of Soft and Hard Impact Settings 3415
Readjustment of Soft and Hard Impact Settings 3415
Impact Sensor – Impact Alarm/Shutdown Reset 3416
Impact Sensor – Alarm Time Duration and Deactivation 3417
Impact Sensor – View Impact Event Log 3418
Engine Mode Indicator 3418
Generation 1 (ECO-eLo ONLY) 3418
Generation 2 3419
Diesel Particulate Filter (DPF) Display 3420
General Description 3420
Passive Regeneration Only 3420
Regeneration Level 0 3420
Auto/Active Regeneration Inhibited 3421
Auto/Active Regeneration 3421
Regeneration Level 1 3421
Parked Regeneration Request 3422
Regeneration Level 2 3422
Warning Level 3423
Regeneration Level 3 3423
Service Level 3423
Regeneration Level 4 3423
Display, Diesel Particulate Filter (DPF), Revised 3423
Operator Interface 3424
Refer to Operator Manual 3424
CAN Communication Lost 3424
Passive Regeneration Only 3424
Regeneration Level 0 3424
Auto/Active Regeneration Inhibited 3425
Auto/Active Regeneration 3425
Regeneration Level 1 3425
Idle-up Auto/Active Regeneration 3425
Parked Regeneration Request 3426
Regeneration Level 2 3426
Warning Level 3427
Regeneration Level 3 3427
Service Level 3427
Regeneration Level 4 3427
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3428
Display, Diesel Particulate Filter (DPF), Stage V Engine 3428
Operator Interface 3428
Refer to Operator Manual 3428
CAN Communication Lost 3429
Passive Regeneration Only 3429
Regeneration Level 0 3429
Auto/Active Regeneration Inhibited 3429
Auto/Active Regeneration 3430
Regeneration Level 1 3430
Idle-up Auto/Active Regeneration 3430
Parked Regeneration Request 3430
Regeneration Level 2 3430
Warning Level 3432
Regeneration Level 3 3432
Service Level 3432
Regeneration Level 4 3432
Stage V Content 3432
Emissions System Malfunction 3432
Ash Load 3433
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3434
Operator Interface 3434
Refer to Operator Manual 3434
CAN Communication Lost 3435
Passive Regeneration Only 3435
Regeneration Level 0 3435
Auto/Active Regeneration Inhibited 3435
Auto/Active Regeneration 3436
Regeneration Level 1 3436
Idle-up Auto/Active Regeneration 3436
Parked Regeneration Request 3436
Regeneration Level 2 3436
Warning Level 3438
Regeneration Level 3 3438
Service Level 3438
Regeneration Level 4 3438
Calibrations 3439
Calibrate Transmission Valve 3441
Set Tilt Stop Point 3441
Calibrate Loaded Weight 3442
Calibrate Travel Speed Sensor 3442
Calibrate Mazda LP and Gas Accelerator Pedal 3443
524223772-2200YRM1142-(01-2020)-US-EN 3445
General 3455
Display Switch Cluster 3458
Remove 3458
Install 3461
Direction Control and Turn Signal Levers 3461
Remove 3461
Install 3463
Key Switch 3463
Remove 3463
Install 3464
Display Switch Cluster Panel Bezel and Overlay 3464
Remove 3464
Install 3464
Steering Column Repair 3464
Remove 3464
Disassemble 3467
Assemble 3467
Install 3467
Sensors and Switches 3468
General 3468
Dash and Kick Panel, Remove and Install 3468
Remove 3468
Install 3469
Accelerator Pedal Position Sensor 3470
Remove 3470
Install 3473
Brake Fluid Level Switch 3474
Remove 3474
Install 3476
Service Brake Pedal Position Sensor 3477
Remove 3477
Install 3480
Parking Brake Sensor 3481
Remove 3481
Install 3482
Service Brake Pressure Sensor 3483
Remove 3483
Install 3485
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3486
Remove 3486
Install 3486
Sensor Microswitch (Foot Directional Control Pedal) 3487
Remove 3487
Install 3490
Low Coolant Level Sensor 3491
Remove 3491
Install 3494
Fuel Level Sensor, Gas and Diesel Engines Only 3495
Remove 3495
Install 3496
Armrest Switch 3496
Remove 3496
Install 3498
Seat Sensor (Operator Presence System) 3498
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) 3498
Remove 3498
Install 3499
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3499
Remove 3499
Install 3500
Full Suspension Seats; All Lift Truck Models 3500
Remove 3500
Install 3500
Hood Shut Off Switch 3500
Remove 3500
Install 3503
Remote Key Switch 3504
Remove 3504
Install 3504
Hydraulic Filter Pressure Switch 3505
Remove 3505
Install 3507
Transmission Speed Sensor 3507
Remove 3507
Install 3510
Transmission Pressure Sensors 3511
Remove 3511
Install 3513
Transmission Temperature Sensor 3514
Remove 3514
Install 3516
Engine Speed Sensor 3518
Remove 3518
Install 3518
Intermediate Speed Sensor 3519
Remove 3519
Install 3519
Return to Set Tilt (Tilt Angle) Sensor 3519
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) 3519
Remove 3519
Install 3520
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) 3521
Remove 3521
Install 3522
Rear Horn Button Switch 3522
Remove 3522
Install 3523
Impact Sensor 3524
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) 3524
Remove 3524
Install 3527
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) 3527
Remove 3527
Install 3528
Load Weight Sensor 3529
Remove 3529
Install 3530
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3531
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3531
Crankshaft Position (CKP) Sensor 3531
Camshaft Position (CMP) Sensor 3531
Oil Pressure Sensor 3531
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3531
Engine Coolant Temperature (ECT) Sensor 3532
Air Flow Restriction Switch 3532
Remove for GM 2 4L Gas and LPG Trucks 3532
Install for GM 2 4L Gas and LPG Trucks 3532
Oxygen Sensor 3533
Remove 3533
Install 3536
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3537
Crankshaft Position (CKP) Sensor 3537
Camshaft Position (CMP) Sensor 3537
Oil Pressure Sensor 3537
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3537
Engine Coolant Temperature (ECT) Sensor 3537
Air Flow Restriction Switch 3537
Oxygen Sensor 3537
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3537
Low LPG Pressure Switch 3537
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3538
Air Filter Restriction Switch 3538
Remove 3538
Install 3538
Oil Pressure Sensor 3538
Remove 3538
Install 3538
Engine Speed Sensor 3538
Remove 3538
Install 3538
Engine Coolant Temperature (ECT) Sensor 3538
Remove 3538
Install 3538
Throttle Position Sensor (TPS) 3541
Remove 3541
Install 3542
Fuel/Water Separator Sensor 3542
Remove 3542
Install 3542
Glow Plug Relay 3543
Remove 3543
Install 3545
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3545
Air Filter Restriction Switch 3545
Remove 3545
Install 3545
Engine Oil Pressure Sensor 3550
Remove 3550
Install 3550
Engine Speed Sensor 3550
Remove 3550
Install 3551
Engine Coolant Temperature (ECT) Sensor 3551
Remove 3551
Install 3552
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3553
Remove 3553
Install 3553
Fuel/Water Separator Sensor 3554
Remove 3554
Install 3554
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3555
Intake Air Temperature Sensor 3555
Remove 3555
Install 3556
Intake Air Pressure Sensor 3556
Remove 3556
Install 3556
Air Inlet Heater 3556
Remove 3556
Install 3557
Engine Oil Pressure Sensor 3557
Remove 3557
Install 3557
Engine Coolant Temperature (ECT) Sensor 3557
Remove 3557
Install 3557
Crankshaft Position Sensor 3558
Remove 3558
Install 3558
Adjust Shim Procedure 3559
Camshaft Position Sensor 3560
Remove 3560
Install 3560
Air Flow Restriction Sensor 3561
Remove 3561
Install 3561
Fuel/Water Separator 3561
Remove 3561
Install 3562
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3562
Intake Air Temperature Sensor 3566
Remove 3566
Install 3567
Boost Sensor 3567
Remove 3567
Install 3568
Throttle Valve Assembly and Air Intake Heater 3568
Remove 3568
Install 3568
Engine Coolant Temperature (ECT) Sensor 3569
Remove 3569
Install 3569
Engine Oil Pressure Sensor 3569
Remove 3569
Install 3570
Crankshaft Position Sensor 3570
Remove 3570
Install 3570
Adjust Shim Procedure 3571
Camshaft Position Sensor 3572
Remove 3572
Install 3573
Differential Pressure Sensor 3573
Remove 3573
Install 3573
Mass Air Flow Sensor 3574
Remove 3574
Install 3575
Fuel/Water Separator 3575
Remove 3575
Install 3576
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3576
Engine Coolant Temperature (ECT) Sensor 3577
Remove 3577
Install 3577
Throttle Position Sensor 3578
Engine Oil Pressure Sensor 3578
Remove 3578
Install 3578
Engine Speed Sensor 3578
Remove 3578
Install 3578
Fuel Shut Off Solenoid 3578
Remove 3578
Install 3578
Vehicle System Manager (VSM) 3579
General 3579
VSM Replacement 3579
Remove 3579
Install 3581
Programming a New VSM and/or Display Switch Cluster 3581
General 3581
PC Service Tool Software 3582
Data Transferring 3582
New VSM 3582
New (Blank) Display Switch Cluster 3582
Used (Non-Blank) Display Switch Cluster 3582
Power Distribution Module (PDM) and Component Parts 3584
Remove 3584
PDM as a Unit 3584
Install 3588
PDM as a Unit 3588
Remove and Install 3589
PDM Component Parts 3589
Transmission Control Unit 3589
Remove 3589
Install 3593
Battery 3595
Remove 3595
Install 3595
Lights 3596
Work Lights (Front and Rear) 3596
Remove 3596
Install 3596
Strobe Light 3597
Remove 3597
Install 3597
LED Tail, Backup, and Brake Lights 3598
Remove 3598
Install 3599
Front Marker/Turn Signal Lights 3600
Replacing Whole Front Marker/Turn Signal Light Assembly 3600
Remove 3600
Install 3600
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3601
Remove 3601
Install 3601
Diesel Particulate Filter (DPF) Display 3601
Remove 3601
Clean and Inspect 3602
Install 3602
Electronic-Hydraulic Controls – Generation 1 3603
E-Hydraulic Controls – Test 3603
Mini-Levers 3603
Full Stroke Test 3603
Function Returns to Neutral Test 3603
Push Button Switch 3603
General 3604
Mini-Lever Replacement 3604
Remove 3604
Clean and Inspect 3605
Install 3605
Push Button Switch Replacement 3606
Remove 3606
Install 3608
Mini-Lever Module (MLM) 3608
Remove 3608
Install 3608
Joystick 3609
Remove and Disassemble 3609
Inspect 3609
Assemble and Install 3609
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3610
General 3610
Mini-levers, Remove and Install 3610
Armrest Assembly 3611
Remove 3611
Install 3614
Horn Button 3614
Remove 3614
Install 3614
Direction Control Switch 3615
Remove 3615
Install 3615
push (override) buttons and Toggle Switch 3615
Remove 3616
Install 3617
Joystick 3618
Remove and Disassemble 3618
Inspect 3618
Assemble and Install 3618
Joystick Armrest Slider Assembly 3619
Remove 3619
Install 3620
Electronic-Hydraulic Controls, After January, 2020 3620
E-Hydraulic Controls – TEST 3620
Mini-Levers 3620
Full Stroke Test 3620
Function Returns to Neutral Test 3620
Push (Override) Button 3621
General 3621
Mini-levers, Remove and Install 3621
Armrest Assembly 3622
Remove 3622
Install 3625
Horn Button 3625
Remove 3625
Install 3625
Direction Control Switch 3625
Remove 3625
Install 3626
Push (Override) buttons and Toggle Switch 3626
Remove 3627
Install 3629
Special Tools 3630
524223772-2200YRM1142-(08-2021)-US-EN 3633
General 3643
Display Switch Cluster 3647
Remove 3647
Install 3649
Direction Control and Turn Signal Levers 3649
Remove 3649
Install 3650
Key Switch 3651
Remove 3651
Install 3652
Display Switch Cluster Panel Bezel and Overlay 3652
Remove 3652
Install 3652
Steering Column Repair 3653
Remove 3653
Disassemble 3656
Assemble 3656
Install 3656
Sensors and Switches 3657
General 3657
Dash and Kick Panel, Remove and Install 3657
Remove 3657
Install 3658
Accelerator Pedal Position Sensor 3658
Remove 3658
Install 3662
Brake Fluid Level Switch 3663
Remove 3663
Install 3664
Service Brake Pedal Position Sensor 3666
Remove 3666
Install 3668
Parking Brake Sensor 3669
Remove 3669
Install 3671
Service Brake Pressure Sensor 3671
Remove 3671
Install 3673
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3675
Remove 3675
Install 3675
Sensor Microswitch (Foot Directional Control Pedal) 3675
Remove 3675
Install 3678
Low Coolant Level Sensor 3679
Remove 3679
Install 3682
Fuel Level Sensor, Gas and Diesel Engines Only 3683
Remove 3683
Install 3684
Armrest Switch 3684
Remove 3684
Install 3686
Seat Sensor (Operator Presence System) 3686
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) 3686
Remove 3686
Install 3687
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3687
Remove 3687
Install 3687
Full Suspension Seats; All Lift Truck Models 3688
Remove 3688
Install 3688
Hood Shut Off Switch 3689
Remove 3689
Install 3691
Remote Key Switch 3692
Remove 3692
Install 3692
Hydraulic Filter Pressure Switch 3693
Remove 3693
Install 3695
Transmission Speed Sensor 3695
Remove 3695
Install 3698
Transmission Pressure Sensors 3699
Remove 3699
Install 3701
Transmission Temperature Sensor 3702
Remove 3702
Install 3704
Engine Speed Sensor 3706
Remove 3706
Install 3707
Intermediate Speed Sensor 3707
Remove 3707
Install 3707
Return to Set Tilt (Tilt Angle) Sensor 3708
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) 3708
Remove 3708
Install 3708
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) 3708
Remove 3709
Install 3710
Rear Horn Button Switch 3711
Remove 3711
Install 3711
Impact Sensor 3712
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) 3712
Remove 3712
Install 3714
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) 3714
Remove 3714
Install 3715
Load Weight Sensor 3715
Remove 3715
Install 3717
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3718
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3718
Crankshaft Position (CKP) Sensor 3718
Camshaft Position (CMP) Sensor 3718
Oil Pressure Sensor 3718
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3718
Engine Coolant Temperature (ECT) Sensor 3719
Air Flow Restriction Switch 3719
Remove for GM 2 4L Gas and LPG Trucks 3719
Install for GM 2 4L Gas and LPG Trucks 3719
Oxygen Sensor 3720
Remove 3720
Install 3723
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3724
Crankshaft Position (CKP) Sensor 3724
Camshaft Position (CMP) Sensor 3724
Oil Pressure Sensor 3724
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3724
Engine Coolant Temperature (ECT) Sensor 3724
Air Flow Restriction Switch 3724
Oxygen Sensor 3724
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3724
Low LPG Pressure Switch 3724
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3725
Air Filter Restriction Switch 3725
Remove 3725
Install 3725
Oil Pressure Sensor 3725
Remove 3725
Install 3725
Engine Speed Sensor 3725
Remove 3725
Install 3725
Engine Coolant Temperature (ECT) Sensor 3725
Remove 3725
Install 3725
Throttle Position Sensor (TPS) 3728
Remove 3728
Install 3729
Fuel/Water Separator Sensor 3729
Remove 3729
Install 3729
Glow Plug Relay 3730
Remove 3730
Install 3732
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3732
Air Filter Restriction Switch 3732
Remove 3732
Install 3733
Engine Oil Pressure Sensor 3737
Remove 3737
Install 3737
Engine Speed Sensor 3737
Remove 3737
Install 3738
Engine Coolant Temperature (ECT) Sensor 3738
Remove 3738
Install 3739
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3740
Remove 3740
Install 3740
Fuel/Water Separator Sensor 3741
Remove 3741
Install 3741
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3742
Intake Air Temperature Sensor 3742
Remove 3742
Install 3743
Intake Air Pressure Sensor 3743
Remove 3743
Install 3743
Air Inlet Heater 3743
Remove 3743
Install 3744
Engine Oil Pressure Sensor 3744
Remove 3744
Install 3744
Engine Coolant Temperature (ECT) Sensor 3744
Remove 3744
Install 3744
Crankshaft Position Sensor 3745
Remove 3745
Install 3745
Adjust Shim Procedure 3746
Camshaft Position Sensor 3747
Remove 3747
Install 3747
Air Flow Restriction Sensor 3747
Remove 3747
Install 3748
Fuel/Water Separator 3748
Remove 3748
Install 3749
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3749
Intake Air Temperature Sensor 3753
Remove 3753
Install 3754
Boost Sensor 3754
Remove 3754
Install 3755
Throttle Valve Assembly and Air Intake Heater 3755
Remove 3755
Install 3755
Engine Coolant Temperature (ECT) Sensor 3756
Remove 3756
Install 3756
Engine Oil Pressure Sensor 3757
Remove 3757
Install 3757
Crankshaft Position Sensor 3757
Remove 3757
Install 3757
Adjust Shim Procedure 3758
Camshaft Position Sensor 3760
Remove 3760
Install 3760
Differential Pressure Sensor 3760
Remove 3760
Install 3761
Mass Air Flow Sensor 3761
Remove 3761
Install 3762
Fuel/Water Separator 3763
Remove 3763
Install 3764
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3765
Engine Coolant Temperature (ECT) Sensor 3766
Remove 3766
Install 3766
Throttle Position Sensor 3766
Engine Oil Pressure Sensor 3766
Remove 3766
Install 3766
Engine Speed Sensor 3766
Remove 3766
Install 3766
Fuel Shut Off Solenoid 3767
Remove 3767
Install 3767
Vehicle System Manager (VSM) 3768
General 3768
VSM Replacement 3768
Remove 3768
Install 3770
Programming a New VSM and/or Display Switch Cluster 3770
General 3770
PC Service Tool Software 3771
Data Transferring 3771
New VSM 3771
New (Blank) Display Switch Cluster 3771
Used (Non-Blank) Display Switch Cluster 3771
Power Distribution Module (PDM) and Component Parts 3774
Remove 3774
PDM as a Unit 3774
Install 3777
PDM as a Unit 3777
Remove and Install 3778
PDM Component Parts 3778
Transmission Control Unit (TCU) 3779
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) 3779
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) 3779
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3780
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3780
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 3780
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 3781
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 3782
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 3784
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 3784
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 3784
Battery 3785
Remove 3785
Install 3785
Lights 3786
Work Lights (Front and Rear) 3786
Remove 3786
Install 3786
Strobe Light 3787
Remove 3787
Install 3787
LED Tail, Backup, and Brake Lights 3788
Remove 3788
Install 3789
Front Marker/Turn Signal Lights 3790
Replacing Whole Front Marker/Turn Signal Light Assembly 3790
Remove 3790
Install 3790
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3791
Remove 3791
Install 3791
Diesel Particulate Filter (DPF) Display 3792
Remove 3792
Clean and Inspect 3793
Install 3793
Electronic-Hydraulic Controls – Generation 1 3794
E-Hydraulic Controls – Test 3794
Mini-Levers 3794
Full Stroke Test 3794
Function Returns to Neutral Test 3794
Push Button Switch 3794
General 3795
Mini-Lever Replacement 3795
Remove 3795
Clean and Inspect 3796
Install 3796
Push Button Switch Replacement 3797
Remove 3797
Install 3799
Mini-Lever Module (MLM) 3799
Remove 3799
Install 3799
Joystick 3800
Remove and Disassemble 3800
Inspect 3800
Assemble and Install 3800
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3801
General 3801
Mini-levers, Remove and Install 3801
Armrest Assembly 3802
Remove 3802
Install 3805
Horn Button 3805
Remove 3805
Install 3805
Direction Control Switch 3806
Remove 3806
Install 3806
push (override) buttons and Toggle Switch 3806
Remove 3807
Install 3808
Joystick 3809
Remove and Disassemble 3809
Inspect 3809
Assemble and Install 3809
Joystick Armrest Slider Assembly 3810
Remove 3810
Install 3811
Electronic-Hydraulic Controls, After January, 2020 3812
E-Hydraulic Controls – TEST 3812
Mini-Levers 3812
Full Stroke Test 3812
Function Returns to Neutral Test 3812
Push (Override) Button 3812
General 3813
Mini-levers, Remove and Install 3813
Armrest Assembly 3814
Remove 3814
Install 3817
Horn Button 3817
Remove 3817
Install 3817
Direction Control Switch 3817
Remove 3817
Install 3818
Push (Override) buttons and Toggle Switch 3818
Remove 3819
Install 3821
Special Tools 3822
524223779-8000YRM1152-(03-2020)-US-EN 3825
General Information About Diagrams and Schematics 3829
Symbol Definitions 3829
Diagrams Manual Applications 3830
Diagrams and Schematics 3832
524223779-8000YRM1152-(06-2021)-US-EN 3895
General Information About Diagrams and Schematics 3899
Symbol Definitions 3899
Diagrams Manual Applications 3900
Diagrams and Schematics 3902
524223780-8000YRM1134-(03-2020)-US-EN 3963
Series Code / Model Designation Reference Table 3969
Description 3971
Proc_Cal_001: Service Password Entry 3973
When to Perform 3973
Why Perform 3973
How to Perform 3973
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3974
When to Perform 3974
Calibration Order 3974
Why Perform 3974
How to Perform 3975
Proc_Cal_003: Save and Exit 3976
When to Perform 3976
Why Perform 3976
How to Perform 3976
Proc_Cal_004: Lift Valve Output Threshold 3977
When to Perform 3977
Calibration Order 3977
Why Perform 3977
How to Perform 3978
Proc_Cal_005: Lower Valve Output Threshold 3980
When to Perform 3980
Calibration Order 3980
Why Perform 3980
How to Perform 3980
Proc_Cal_006: Tilt Back Valve Output Threshold 3983
When to Perform 3983
Calibration Order 3983
Why Perform 3983
How to Perform 3983
Proc_Cal_007: Tilt Forward Valve Output Threshold 3986
When to Perform 3986
Calibration Order 3986
Why Perform 3986
How to Perform 3986
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3989
When to Perform 3989
Calibration Order 3989
Why Perform 3989
How to Perform 3989
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3992
When to Perform 3992
Calibration Order 3992
Why Perform 3992
How to Perform 3992
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3995
When to Perform 3995
Calibration Order 3995
Why Perform 3995
How to Perform 3995
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3998
When to Perform 3998
Calibration Order 3998
Why Perform 3998
How to Perform 3998
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 4001
When to Perform 4001
Calibration Order 4001
Why Perform 4001
How to Perform 4001
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 4004
When to Perform 4004
Calibration Order 4004
Why Perform 4004
How to Perform 4004
Proc_Cal_014: Load Weight Zero Point 4008
When to Perform 4008
Calibration Order 4008
Why Perform 4008
How to Perform 4008
Proc_Cal_015: Loaded Weight Calibration 4010
When to Perform 4010
Calibration Order 4010
Why Perform 4010
How to Perform 4010
Proc_Cal_016: Transmission Valve Calibration 4013
Applicable System/Option 4013
When to Perform 4013
Calibration Order 4013
Why Perform 4013
How to Perform 4013
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 4015
Applicable System/Option 4015
When to Perform 4015
Calibration Order 4015
Why Perform 4015
How to Perform 4015
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 4017
Applicable System/Option 4017
When to Perform 4017
Calibration Order 4017
Why Perform 4017
How to Perform 4018
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 4019
Required Tools 4019
When to Perform 4019
Calibration Order 4019
Why Perform 4020
How to Perform 4020
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 4021
When to Perform 4021
Why Perform 4021
How to Perform 4021
Proc_Cal_026: Travel Speed Calibration 4023
When to Perform 4023
Calibration Order 4023
Why Perform 4023
How to Perform 4023
524223780-8000YRM1134-(05-2022)-US-EN 4027
Series Code / Model Designation Reference Table 4033
Description 4036
Proc_Cal_001: Service Password Entry 4038
When to Perform 4038
Why Perform 4038
How to Perform 4038
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 4039
When to Perform 4039
Calibration Order 4039
Why Perform 4039
How to Perform 4039
Proc_Cal_003: Save and Exit 4041
When to Perform 4041
Why Perform 4041
How to Perform 4041
Proc_Cal_004: Lift Valve Output Threshold 4042
When to Perform 4042
Calibration Order 4042
Why Perform 4042
How to Perform 4042
Proc_Cal_005: Lower Valve Output Threshold 4045
When to Perform 4045
Calibration Order 4045
Why Perform 4045
How to Perform 4045
Proc_Cal_006: Tilt Back Valve Output Threshold 4048
When to Perform 4048
Calibration Order 4048
Why Perform 4048
How to Perform 4048
Proc_Cal_007: Tilt Forward Valve Output Threshold 4051
When to Perform 4051
Calibration Order 4051
Why Perform 4051
How to Perform 4051
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 4054
When to Perform 4054
Calibration Order 4054
Why Perform 4054
How to Perform 4054
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 4057
When to Perform 4057
Calibration Order 4057
Why Perform 4057
How to Perform 4057
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 4060
When to Perform 4060
Calibration Order 4060
Why Perform 4060
How to Perform 4060
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 4063
When to Perform 4063
Calibration Order 4063
Why Perform 4063
How to Perform 4063
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 4066
When to Perform 4066
Calibration Order 4066
Why Perform 4066
How to Perform 4066
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 4069
When to Perform 4069
Calibration Order 4069
Why Perform 4069
How to Perform 4069
Proc_Cal_014: Load Weight Zero Point 4072
When to Perform 4072
Calibration Order 4072
Why Perform 4072
How to Perform 4072
Proc_Cal_015: Loaded Weight Calibration 4074
When to Perform 4074
Calibration Order 4074
Why Perform 4074
How to Perform 4074
Proc_Cal_016: Transmission Valve Calibration 4077
Applicable System/Option 4077
When to Perform 4077
Calibration Order 4077
Why Perform 4077
How to Perform 4077
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 4079
Applicable System/Option 4079
When to Perform 4079
Calibration Order 4079
Why Perform 4079
How to Perform 4079
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 4082
Applicable System/Option 4082
When to Perform 4082
Calibration Order 4082
Why Perform 4082
How to Perform 4082
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 4085
Required Tools 4085
When to Perform 4085
Calibration Order 4085
Why Perform 4085
How to Perform 4085
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 4087
When to Perform 4087
Why Perform 4087
How to Perform 4087
Proc_Cal_026: Travel Speed Calibration 4089
When to Perform 4089
Calibration Order 4089
Why Perform 4089
How to Perform 4089
524262274-0100YRM1243-(11-2016)-US-EN 4093
General 4097
Description 4098
Hood, Seat, and Side Covers Replacement 4100
Remove 4100
Install 4100
Steering Column 4107
Description 4108
Steering Column Repair 4108
Remove 4108
Disassemble 4110
Clean 4113
Inspect 4113
Assemble 4113
Install 4113
LPG Tank and Bracket Replacement 4114
Counterweight Replacement 4114
Remove 4114
Install 4117
Tow Pin 4121
Remove and Install For Lift Truck
Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813) 4121
Remove and Install For Lift Truck
Models GLC55SVX (GC/GLC80XVBCS,
GC/GLC100VXBCS; GC/GLC120SVX; and
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(J813) 4121
Overhead Guard Replacement 4122
Remove 4122
Install 4123
LED Tail, Backup, and Brake Lights, Replace 4123
Operator Restraint System Replacement 4124
Description 4124
Engine Replacement 4125
Remove Engine Only 4125
Install Engine only 4152
Remove Engine and Transmission 4155
Install Engine and Transmission 4159
Electronic Throttle Replacement 4163
Cummins 4 5L Diesel Engine With Electronic Throttle 4163
Remove 4163
Install 4166
Pull Actuator Linkage Adjustment 4168
Low Idle Adjustment 4168
Throttle Pedal and Cable Adjustment 4169
Cummins 4 5L Diesel Engine with Basic Power Shift Transmission 4169
Kubota 3 6L Diesel Engine 4169
Exhaust System Repair 4172
GM 4 3L Engine for Lift Truck Models 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) 4172
Cummins 4 5L Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813) 4172
Remove 4172
Inspect 4172
Install 4174
Cummins QSB 3 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) 4174
Remove 4174
Inspect 4176
Install 4176
Kubota Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) Equipped with Kubota 3 6L Diesel Engine 4176
Remove 4176
Inspect 4178
Install 4178
Kubota Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) 4178
Remove 4178
Inspect 4181
Diesel Particulate Filter 4183
Disassemble 4183
CLEAN AND INSPECT 4184
Assembly 4184
Install 4185
Cooling System 4186
Description 4186
Hydraulic Filter Assembly Repair 4187
Remove 4187
Disassemble 4187
Clean 4188
Inspect 4188
Assemble 4188
Install 4188
Fuel and Hydraulic Tanks Repair 4188
Inspect 4188
Clean 4189
Steam Method of Cleaning 4189
Chemical Solution Method of Cleaning 4190
Additional Preparations for Repair 4190
Small Leaks, Repair 4190
Large Leaks, Repair 4190
Preparations for Use After Repair 4190
Safety Labels 4190
524262275-0900YRM1242-(04-2018)-US-EN 4201
General 4207
Hoses Replacement 4207
LPG Tank and Bracket Replacement 4208
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) 4208
Remove 4208
Install 4211
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) 4212
Remove 4212
Install 4212
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) 4212
Remove 4212
Install 4214
LPG Tank, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 4215
Remove 4215
Install 4217
LPG Tank Bracket, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 4217
Remove 4217
Install 4217
High Pressure Fuel Filter Unit Repair 4217
Fuel Filter Element 4218
Remove 4218
Clean/Inspect 4219
Install 4219
Fuel Filter Housing 4219
Remove 4219
Disassemble 4220
Assemble 4220
Install 4220
Electronic Throttle Body Repair 4221
Remove 4221
Clean/Inspect 4222
Install 4222
Fuel Injector Repair 4223
Fuel Rail 4223
Remove for Lift Trucks Built Before January, 2010 4223
Remove for Lift Trucks Built After January, 2010 4225
Install for Lift Trucks Built Before January, 2010 4226
Install for Lift Trucks Built After January, 2010 4227
Fuel Injectors and Adapters 4227
Remove for Lift Trucks Built Before January, 2010 4227
Remove for Lift Trucks Built After January, 2010 4229
Clean 4230
Install for Lift Trucks Built Before January, 2010 4230
Install for Lift Trucks Built After January, 2010 4232
LPG Regulator Repair 4232
LPG Regulator 4232
Remove for Lift Trucks Built Before January, 2010 4232
Remove for Lift Trucks Built After January, 2010 4233
Install for Lift Trucks Built Before January, 2010 4235
Install for Lift Trucks Built After January, 2010 4235
LPG Regulator Fuel Filter 4236
Remove 4236
Install 4237
Lock-Off Solenoid and Cartridge 4237
Remove 4237
Install 4238
Control System 4238
Electronic Control Unit (ECU) and Injector Driver Modules Assembly 4238
Remove 4238
Install 4239
Electronic Control Unit (ECU) 4240
Remove 4240
Install 4240
Injector Driver Modules 4241
Remove 4241
Install 4241
Fuel Pressure Sensor 4242
Remove 4242
Install 4242
Low LPG Pressure Switch 4242
Remove 4242
Install 4243
LPG Pressure Sensor 4243
Remove 4243
Install 4244
Oxygen Sensor 4244
Exhaust System Repair 4245
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 4245
Remove for Lift Trucks Built Before January, 2010 4245
Remove for Lift Trucks Built After January, 2010 4247
Inspect 4249
Install for Lift Trucks Built Before January, 2010 4249
Install for Lift Trucks Built After January, 2010 4249
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) 4250
Remove for Lift Trucks Built Before January, 2010 4250
Remove for Lift Trucks Built After January, 2010 4252
Inspect 4255
Install for Lift Trucks Built Before January, 2010 4255
Install for Lift Trucks Built After January, 2010 4256
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 4257
Remove for Lift Trucks Built Before January, 2010 4257
Remove for Lift Trucks Built After January, 2010 4260
Inspect 4261
Install for Lift Trucks Built Before January, 2010 4262
Install for Lift Trucks Built After January, 2010 4262
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4263
Remove for Lift Trucks Built Before January, 2010 4263
Remove for Lift Trucks Built After January, 2010 4266
Inspect 4267
Install for Lift Trucks Built Before January, 2010 4268
Install for Lift Trucks Built After January, 2010 4268
Oxygen Sensor 4269
Remove 4269
Install 4270
LPG Fuel Testing 4270
General 4270
Available Fuel Tests 4270
Composition Test (ASTM D-2163) 4270
Ammonia Test (ASTM D-4490) 4271
Basic Nitrogen Test (ASTM UOP269-90) 4271
Residues Test (ASTM D-2158) 4271
Vapor Pressure Test (ASTM D-2598) 4271
Sulfur Compounds Test (ASTM D-5623) 4271
Methanol Test (ASTM D-4864) 4271
Copper Corrosion (ASTM D-1838) 4271
Where To Send LPG Fuel Samples For Testing 4271
524262276-0900YRM1244-(06-2012)-US-EN 4275
toc 4275
Gasoline Fuel System 4275
Safety Precautions Maintenance and Repair 4276
General 4279
Electronic Throttle Body Repair 4279
Electronic Throttle Body 4279
Remove 4279
Clean/Inspect 4279
Install 4280
Fuel System Repair 4281
Before Repair Procedure 4281
After Repair Procedure 4281
Fuel Leakage Check for Lift Trucks Built Before January, 2010 4281
Fuel Leakage Check for Lift Trucks Built After January, 2010 4282
Fuel Line Pressure Check 4284
Fuel Injector Repair 4285
Remove 4285
Install 4295
Control System 4296
Electronic Control Unit (ECU) 4296
Remove for Lift Trucks Built Before January, 2010 4296
Remove for Lift Trucks Built After January, 2010 4297
Install for Lift Trucks Built Before January, 2010 4298
Install for Lift Trucks Built After January, 2010 4299
Exhaust System Repair 4300
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; ( 4300
Remove for Lift Trucks Built Before January, 2010 4300
Remove for Lift Trucks Built After January, 2010 4302
Inspect 4302
Install for Lift Trucks Built Before January, 2010 4304
Install for Lift Trucks Built After January, 2010 4304
GM 4 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45 4305
Remove for Lift Trucks Built Before January, 2010 4305
Remove for Lift Trucks Built After January, 2010 4307
Inspect 4309
Install for Lift Trucks Built Before January, 2010 4309
Install for Lift Trucks Built After January, 2010 4310
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (G 4311
Remove for Lift Trucks Built Before January, 2010 4311
Remove for Lift Trucks Built After January, 2010 4313
Inspect 4315
Install for Lift Trucks Built Before January, 2010 4315
Install for Lift Trucks Built After January, 2010 4316
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (G 4316
Remove for Lift Trucks Built Before January, 2010 4316
Remove for Lift Trucks Built After January, 2010 4319
Inspect 4319
Install for Lift Trucks Built Before January, 2010 4321
Install for Lift Trucks Built After January, 2010 4321
Oxygen Sensor 4322
Remove 4322
Install 4322
524262277-1400YRM1245-(01-2012)-US-EN 4325
toc 4325
Drive Axle and Differential Assembly Repair 4325
Safety Precautions Maintenance and Repair 4326
General 4329
Drive Axle Repair 4329
Remove and Disassemble 4329
Clean and Inspect 4332
Assemble and Install 4332
Differential Repair 4334
Remove 4334
Support Differential Assembly From Differential Housing Assembly 4334
Differential Assembly From Differential Assembly Support 4336
Differential Assembly Support from Drop Box 4339
Drive Pinion and Pinion Gear, From Differential Assembly Support 4341
Disassemble 4342
Differential Assembly 4342
Drop Box Housing 4344
Differential Assembly Support 4345
Differential Housing 4346
Clean and Inspect 4347
Assemble 4347
Differential Housing 4347
Differential Assembly Support 4348
Drop Box Housing 4349
Differential Assembly 4350
Install 4354
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 4354
Drive Pinion and Pinion Gear Into Differential Assembly Support 4356
Differential Assembly Into Differential Assembly Support 4358
Ring Gear Backlash, Adjust 4361
Gear Set, Tooth Contact Pattern Check 4362
Differential Assembly Support Into Differential Housing 4365
Torque Specifications 4366
tables 4325
Table 1 Pinion Variation Numbers Examples 4355
Table 2 Ring and Pinion Tooth Contact Adjustment 4363
Table 3 Correct Tooth Contact 4363
Table 4 Incorrect Tooth Contact 4364
524262278-1400YRM1246-(02-2018)-US-EN 4369
General 4373
Identification Plate 4374
Drive Axle Removal 4374
Hub Seal Replacement 4386
Planetary Reduction Repair 4395
Clean and Inspect 4404
Brake Repair 4417
Clean and Inspect 4433
Wet Brake Noise Reduction 4449
General 4449
Adding Additive To Transmission 4450
Bevel Pinion 4451
Clean and Inspect 4456
Differential Unit 4468
Disassemble 4479
Clean and Inspect 4485
Assemble 4486
Drive Axle Installation 4509
Special Tools 4519
Torque Specifications 4519
524262279-1800YRM1247-(06-2021)-US-EN 4523
General 4527
Dry Brake System 4527
Wet Brake System 4527
Service Brakes Repair (Dry Brake) 4531
Remove and Disassemble 4531
Clean 4533
Inspect 4534
Assemble and Install 4535
Adjust 4538
Parking Brake Repair 4539
Dry Brake System 4539
Remove and Disassembly 4539
Assemble and Install 4541
Wet Brake System 4541
Remove and Install 4541
Assemble and Install 4548
Adjust 4548
Dry Brake System 4548
Wet Brake System 4549
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 4549
Master Cylinder Repair 4551
Remove 4551
Disassemble 4555
Clean and Inspect 4556
Assemble 4557
Install and Adjust 4557
Accumulator 4560
Pre-Charge Check 4560
Remove 4561
Install 4563
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 4564
Remove 4564
Modulating Brake Valve 4566
Disassemble 4566
Clean and Inspect 4567
Assemble 4567
Accumulator Charge Valve 4568
Disassemble 4568
Clean and Inspect 4570
Assemble 4570
Install 4571
Pressure Checks 4572
Accumulator Charge Valve Check 4572
Accumulator Check 4572
Service Brakes Adjustment (Dry Brake) 4573
Service Brakes Adjustment 4573
Brake System Air Removal 4575
Using Pressure Bleed System 4575
Using Brake Pedal Pressure 4575
Lift Truck Models with Master Cylinder 4575
Lift Truck Models with Modulating Brake Valve 4576
Brake Pedal Adjustment 4577
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) 4577
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4578
Free Pedal Adjustment 4580
Torque Specifications 4581
524262279-1800YRM1247-(09-2018)-US-EN 4583
General 4587
Dry Brake System 4587
Wet Brake System 4588
Service Brakes Repair (Dry Brake) 4592
Remove and Disassemble 4592
Clean 4594
Inspect 4595
Assemble and Install 4595
Adjust 4599
Parking Brake Repair 4599
Dry Brake System 4600
Remove and Disassembly 4600
Assemble and Install 4602
Wet Brake System 4602
Remove and Install 4603
Assemble and Install 4609
Adjust 4609
Dry Brake System 4609
Wet Brake System 4610
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 4610
Master Cylinder Repair 4611
Remove 4611
Disassemble 4616
Clean and Inspect 4617
Assemble 4618
Install and Adjust 4618
Accumulator 4620
Pre-Charge Check 4621
Remove 4622
Install 4624
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 4624
Remove 4625
Modulating Brake Valve 4626
Disassemble 4626
Clean and Inspect 4628
Assemble 4628
Accumulator Charge Valve 4629
Disassemble 4629
Clean and Inspect 4631
Assemble 4631
Install 4632
Pressure Checks 4633
Accumulator Charge Valve Check 4633
Accumulator Check 4633
Service Brakes Adjustment (Dry Brake) 4634
Service Brakes Adjustment 4634
Brake System Air Removal 4635
Using Pressure Bleed System 4635
Using Brake Pedal Pressure 4636
Lift Truck Models with Master Cylinder 4636
Lift Truck Models with Modulating Brake Valve 4636
Brake Pedal Adjustment 4637
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) 4637
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4638
Free Pedal Adjustment 4640
Torque Specifications 4641
524262280-8000YRM1248-(12-2018)-US-EN 4645
General 4651
Serial Number Data 4651
How to Move Disabled Lift Truck 4652
How to Tow Lift Truck 4652
How to Put Lift Truck on Blocks 4654
How to Raise Drive Tires 4654
How to Raise Steering Tires 4654
How to Clean a Lift Truck 4655
Maintenance Schedule 4656
Maintenance Procedures Every 8 Hours or Daily 4676
How to Make Checks With Engine Stopped 4676
Tires and Wheels 4676
Safety Labels 4677
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4677
Operator Restraint System 4678
Emergency Locking Retractor (ELR) 4678
Adjust Seat – Full Suspension 4679
Adjust Seat – Internal Suspension 4680
Hood and Seat Latches 4681
Engine Compartment 4681
Paper Application 4681
Fuel, Oil, and Coolant Leaks, Check 4682
Hydraulic Hoses 4682
Coolant Hoses 4682
Steering Column Gas Cylinder 4682
Transmission 4683
Hydraulic System Oil 4683
Engine Oil 4683
Air Filter 4688
Forks 4688
Remove 4688
Inspect 4691
Install 4692
Adjust 4692
How to Make Checks With Engine Running 4692
Indicator Lights, Horn, Fuses, and Relays 4692
Service Brakes 4695
Brake Fluid Level 4695
Operation, Check 4695
Parking Brake 4696
Engine Oil Pressure 4696
Cooling System 4697
Steering System 4698
Control Levers and Pedals 4698
Lift System, Operate 4698
First Service After First 100 Hours of Operation 4698
GM 4 3L Engine Oil and Oil Filter 4698
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 4699
Maintenance Procedures Every 250 Hours or 6 Months 4699
GM 4 3L Engine Oil and Oil Filter 4699
Drive Belt 4700
GM 4 3L Engine 4700
Fan and Alternator Drive Belt 4700
Drain Tar From LPG Converter 4700
Drain Tar From LPG Regulator 4701
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine 4702
Maintenance Procedures Every 500 Hours or 6 Months 4704
Hydraulic System Oil 4704
Hydraulic Tank Breather 4705
Inspect 4705
Battery 4705
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 4706
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 4706
Remove 4706
Install 4706
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 4710
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 4711
Controlled Venting 4711
Manual Bleeding 4711
Drive Belt 4712
Cummins 4 5L and QSB 3 3L Diesel Engine 4712
Fan and Alternator Drive Belt 4712
Clean Debris From Radiator Core 4713
Transmission Oil Level 4713
Wet Brake Center Body Oil Level Check 4715
Forks 4716
Mast Lubrication 4716
Header Hose Checks 4720
Lift Chain Lubrication 4720
Tilt Cylinder Lubrication 4720
Master Brake Cylinder Rod End Pin Lubrication 4721
Manual Hydraulic Levers Lubrication 4722
Brake Oil 4722
Tie Rod Lubrication for Lift Truck Models GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS (E818) 4723
Tie Rod Lubrication for Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813) 4723
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes 4723
Parking Brake Adjustment 4724
Maintenance Procedures Every 1000 Hours or 6 Months 4725
Valve Clearance, Check and Adjust 4725
Ignition System 4725
GM 4 3L Engine 4725
LPG Fuel Filter Element Replace, GM 4 3L Engine 4725
Remove 4725
Install 4726
In-Line Filter Replacement, Cummins 4 5L Engine 4726
Remove 4726
Install 4727
Lift Chains Wear Check 4729
Lift Chain Lubrication 4729
Integral Sideshift Carriage, Check Sliding Surfaces 4729
Steering Axle (Spindle Bearings) for Lift Truck Models GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS (E818) 4731
Steering Axle (Spindle Bearings) for Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813) 4731
Control Levers and Pedals 4731
Parking Brake Lever Lubrication, Wet Brake Axle 4731
Normal Operating Environment 4732
Heavy Duty or Contaminated Environment 4733
Remove 4733
Clean and Inspect 4734
Install 4734
Inspect Engine Electrical System, Connectors 4735
Maintenance Procedures Every 2000 Hours or Annually 4735
Hydraulic System 4735
Hydraulic Filter, Replace 4735
Hydraulic Tank Breather, Replace 4736
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 4737
Cooling System 4737
Air Filter 4737
Oxygen Sensor GM 4 3L LPG Engines with GFI Installed 4739
LPG Regulator Fuel Filter, GM 4 3L Engines Equipped with GFI Installed 4740
Remove 4740
Install 4740
Gasoline Fuel Filter 4741
Remove and Replace for Lift Trucks Equipped with GFI 4741
Remove and Replace for Lift Trucks Equipped with PSI 4741
LPG Fuel Injector, GM 4 3L Engines With GFI Installed 4742
Gasoline Fuel Injector, GM Engines 4742
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 4742
Forks 4742
Transmission Oil and Filter (Dry Brake), Replace 4742
Transmission and Wet Brake Planetary Carrier Housing Oil Change 4744
Wet Brake Center Section Oil Change 4747
Remove 4747
Install 4747
Brake Oil (Master Cylinder), Change 4748
Brake Oil (Dry Brake), Remove 4749
Service Brakes (Dry Brake) 4749
Differential (Dry Brake) 4750
Test LPG/GAS Regulator Pressure 4751
Test LPG Regulator Pressure 4751
Check Throttle Shaft for Sticking 4751
Inspect Exhaust Manifold and Piping for Leaks 4751
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 4751
Wheel Bearings 4752
Steer Wheels, Lubrication 4752
Maintenance Procedures Every 4000 Hours or 2 Years 4752
Hydraulic Oil, Replace 4753
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 4754
Weld Inspection 4756
Safety Procedures When Working Near Mast 4759
Fuel Filter Water Removal 4761
Hood Latch Check 4761
Lift Chain Adjustments 4762
Jump-Starting the Lift Truck 4764
Jump-Starting Using a Battery Charger 4764
Jump-Starting a Lift Truck Using Another Lift Truck 4764
Welding Repairs 4765
Overhead Guard Changes 4765
Wheel and Tire Replacement 4765
General 4765
Solid Rubber Tire, Change (GC/GLC Series) 4765
Remove and Install Tire on Wheel 4766
Pneumatic Tire With Tube, Repair 4767
Remove Wheels From Lift Truck 4767
Remove Tire From Wheel 4767
Install Wheel in Tire 4770
Install Tire on Two-Piece Wheel 4772
Add Air to Pneumatic Tires With Tube 4773
Install the Wheels 4773
Dual Drive Wheels, Install 4774
Pneumatic Tubeless Tire, Repair 4775
Remove Wheels From Lift Truck 4775
Add Air to Pneumatic Tubeless Tire 4780
Wheels, Install 4780
Solid Rubber Tires on Pneumatic Wheels, Change 4780
Adhesives and Sealants 4784
524262281-8000YRM1249-(11-2017)-US-EN 4787
Lift Truck Lifting Capacity 4791
Counterweight Weights 4791
Tire Sizes 4792
Capacities 4792
Electrical System 4798
Transmission Oil Pressures 4800
Hydraulic System Relief Pressures 4803
Steering System 4804
Stall Speeds (in RPM ±100 rpm) 4804
GM 4 3L Gas 4805
GM 4 3L LPG 4805
Cummins 4 5L Diesel 4805
Cummins QSB 3 3L Diesel 4805
Mast Speeds 4805
Tilt Angles 4807
Front End Equipment – Mast Creep 4807
Mast Creep 4808
Engine Specifications 4808
Torque Specifications 4810
Frame 4811
Mast 4811
Steering System 4811
Steer Axle 4811
Drive Axle (Wet Brake) 4811
Drive Axle (Dry Brake) 4812
Transmission 4812
Engine – GM 4 3L 4813
Engine – Cummins 4 5L and QSB 3 3L Diesel 4814
524265337-0600YRM1251-(09-2015)-US-EN 4817
General 4823
Engine Removal and Installation 4823
Cylinder Head Repair 4823
Remove and Disassemble 4823
Clean and Inspect 4825
Valve Oil Seals 4828
Remove and Disassemble 4828
Cylinder Leak Down Test 4828
Clean and Inspect 4829
Assemble and Install 4829
Valve Guides and Seats, Repairs 4831
Valves, Repair 4831
Valve Seats, Repair 4832
Valve Springs 4833
Assemble and Install 4834
Engine Block Cleaning and Inspection 4837
Clean and Inspect 4838
Piston Bore Preparation 4840
Engine Mounts Installation 4840
Remove 4840
Clean and Inspect 4841
Install 4841
Lubrication System Repair 4842
Oil Pump, Remove and Disassemble 4842
Clean and Inspect 4843
Oil Pump, Assemble and Install 4844
Oil Pan, Install 4846
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4848
Timing Cover 4848
Remove 4848
Install 4850
Timing Sprockets 4850
Remove 4850
Install 4850
Camshaft 4850
Remove 4850
Inspect 4851
Install 4851
Balance Shaft 4852
Remove 4852
Install 4853
Valve Lifters 4854
Remove 4854
Clean and Inspect 4854
Install 4855
Crankshaft Repair 4855
Remove 4856
Inspect and Repair 4856
How to Check Clearance Between Main Bearings and Their Journals 4857
Install 4858
Piston and Connecting Rod Assemblies Repair 4860
Connecting Rod Bearings, Replace 4860
Piston and Connecting Rod Assemblies, Remove 4861
Disassemble 4861
Piston, Clean and Inspect 4862
Cylinder Bores, Inspect and Repair 4862
Piston Rings 4863
Assemble 4864
Piston and Connecting Rod Assemblies, Install 4864
Flywheel and Flywheel Housing Repair 4864
Flywheel, Remove 4865
Clean 4865
Inspect 4865
Flywheel, Install 4866
Coolant Pump Repair 4866
Remove 4866
Clean and Inspect 4867
Install 4867
Thermostat Replacement 4867
Remove 4868
Thermostat Operation Check 4868
Install 4868
Starter Replacement 4869
4869
Remove 4869
Install 4872
Fan Assembly Replacement 4873
Remove 4873
Inspect 4875
Install 4875
Drive Belt Installation 4876
Remove 4876
Clean 4876
Inspect 4876
Installation 4877
Compression Check 4878
Engine Specifications 4878
Engine Data 4878
Cylinder Head 4878
Hydraulic Valve Lifter 4879
Camshaft 4879
Pistons 4879
Crankshaft 4880
Connecting Rods 4880
Balance Shaft 4881
Cooling System 4881
Lubrication System 4881
Torque Specifications 4882
524265342-4000YRM1250-(06-2021)-US-EN 4887
Safety Procedures When Working Near Mast 4893
Fork Replacement 4896
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4896
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4897
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) 4899
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4900
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4901
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) 4902
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4902
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) 4903
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4904
Fixed Carriage Replacement 4906
Remove, Carriage With Hook Forks 4906
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4914
Install, Carriage With Hook Forks 4915
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4915
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4916
Connecting Attachment Hydraulic Quick Disconnect Hoses 4916
Integral Sideshift Carriage Repair 4917
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) 4917
Disassemble 4917
Clean and Inspect 4920
Assemble 4920
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) 4921
Hang On Sideshift Carriage Repair 4922
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) 4922
Disassemble 4934
Clean and Inspect 4943
Assemble 4944
Install 4945
Hang-On Sideshift Carriage Repair 4947
Remove 4947
Disassemble Carriage 4949
Clean and Inspect 4952
Assemble 4952
Install 4955
Fork Positioner 4958
Two-Stage Mast With Limited Free-Lift Repair 4959
Remove 4959
Disassemble 4962
Clean and Inspect 4965
Assemble 4983
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) 4985
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) 4987
Header Hose Alignment 4998
Two-Stage Mast With Full Free-Lift Repair 5009
Remove 5009
Disassemble 5011
Clean and Inspect 5022
Assemble 5023
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) 5025
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) 5028
Header Hose Installation and Adjustment 5032
Installation 5032
Adjustment 5033
Three-Stage Mast With Full Free-Lift Repair 5034
Remove 5034
Disassemble 5036
Clean and Inspect 5066
Assemble 5068
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) 5071
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) 5076
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) 5083
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) 5090
Mast Operation Check 5094
Tilt Cylinder Adjustment 5095
Lift Chains Adjustment 5095
Mast Adjustments 5097
Load Roller Adjustment 5097
Mast Side Kicking Adjustment 5099
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 5100
Carriage Adjustments 5102
Series Code / Model Designation Reference Table 5103
524265342-4000YRM1250-(09-2018)-US-EN 5107
Safety Procedures When Working Near Mast 5113
Fork Replacement 5115
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 5115
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 5117
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) 5118
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 5119
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 5120
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) 5121
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 5121
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) 5123
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 5123
Fixed Carriage Replacement 5125
Remove, Carriage With Hook Forks 5125
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5134
Install, Carriage With Hook Forks 5135
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5135
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 5136
Connecting Attachment Hydraulic Quick Disconnect Hoses 5136
Integral Sideshift Carriage Repair 5137
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) 5137
Disassemble 5137
Clean and Inspect 5140
Assemble 5140
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) 5141
Hang On Sideshift Carriage Repair 5141
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) 5141
Disassemble 5153
Clean and Inspect 5162
Assemble 5163
Install 5164
Bolzoni Hang-On Sideshift Carriage Repair 5166
Remove 5166
Disassemble Carriage 5168
Clean and Inspect 5171
Assemble 5171
Install 5174
Fork Positioner 5176
Two-Stage Mast With Limited Free-Lift Repair 5177
Remove 5177
Disassemble 5181
Clean and Inspect 5184
Assemble 5201
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) 5203
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) 5204
Header Hose Alignment 5216
Two-Stage Mast With Full Free-Lift Repair 5226
Remove 5226
Disassemble 5228
Clean and Inspect 5240
Assemble 5241
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) 5243
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) 5246
Header Hose Installation and Adjustment 5250
Installation 5250
Adjustment 5250
Three-Stage Mast With Full Free-Lift Repair 5251
Remove 5251
Disassemble 5253
Clean and Inspect 5283
Assemble 5284
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) 5288
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) 5293
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) 5300
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) 5306
Mast Operation Check 5310
Tilt Cylinder Adjustment 5310
Lift Chains Adjustment 5311
Mast Adjustments 5312
Load Roller Adjustment 5312
Mast Side Kicking Adjustment 5314
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 5315
Carriage Adjustments 5318
524329117-8000YRM1387-(03-2020)-US-EN 5321
General Information About Diagrams and Schematics 5325
Symbol Definitions 5325
Diagrams Manual Applications 5326
Diagrams and Schematics 5328
524329117-8000YRM1387-(06-2021)-US-EN 5393
General Information About Diagrams and Schematics 5397
Symbol Definitions 5397
Diagrams Manual Applications 5398
Diagrams and Schematics 5400
550001092-8000YRM1409-(03-2020)-US-EN 5463
General Information About Diagrams and Schematics 5467
Symbol Definitions 5467
Diagrams Manual Applications 5468
Diagrams and Schematics 5470
550001092-8000YRM1409-(06-2021)-US-EN 5551
General Information About Diagrams and Schematics 5555
Symbol Definitions 5555
Diagrams Manual Applications 5556
Diagrams and Schematics 5558
550043436-1300YRM1529-(11-2018)-US-EN 5633
General 5637
Serial Number 5637
Charge Pump Repair 5637
Lift Trucks Manufactured Before July, 2013 5637
Remove 5637
Inspect 5637
Install 5637
Lift Trucks Manufactured After July, 2013 5638
Remove 5638
Inspect 5638
Install 5638
Torque Converter Replace 5639
Remove 5639
Install 5648
Housings and Chain Drive Repair 5654
Remove 5654
Clean 5665
Inspect 5665
Install 5665
Clutch Packs Repair 5672
Remove and Disassemble 5672
Transmission, Remove and Disassemble 5672
Clean 5691
Inspect 5691
Assemble and Install 5692
Transmission, Assemble and Install 5700
Control Valve Repair 5704
Remove and Disassemble 5704
Clean 5708
Inspect 5708
Assemble and Install 5708
Foot Directional Control Pedal Repair 5709
Remove and Disassemble 5709
Assemble and Install 5713
Direction Control Lever 5714
Remove 5714
Install 5714
550043871-0900YRM1556-(04-2018)-US-EN 5719
General 5723
LPG Tank and Bracket 5723
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) 5723
Remove 5723
Install 5731
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) 5732
Remove 5732
Install 5734
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 5734
Remove 5734
Install 5736
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 5736
Remove 5736
Install 5736
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) 5737
Remove 5737
Install 5739
Fuel Filter Unit 5739
Fuel Filter Element 5740
Remove 5740
Clean and Inspect 5740
Install 5741
Fuel Filter Housing with LP Vapor Sensor 5741
Remove 5741
Disassemble 5743
Clean and Inspect 5744
Assemble 5744
Install 5745
Throttle Body 5746
Remove 5746
Clean 5750
Install 5750
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 5751
Remove 5751
Install 5752
Control System 5752
Engine Control Unit (ECU) 5753
Remove 5753
Install 5754
Low Pressure Switch 5754
Remove 5754
Install 5754
Low Fuel Sensor 5755
Remove 5755
Install 5755
LP Converter 5756
Remove and Disassemble 5756
Assemble and Install 5757
LPG Lock-Off 5757
Remove 5758
Install 5759
Exhaust System 5760
Counterweight Exhaust 5760
Remove and Disassemble 5760
Inspect 5762
Assemble and Install 5762
Overhead Exhaust 5763
Remove and Disassemble 5763
Inspect 5765
Assemble and Install 5765
Exhaust Manifold 5765
Remove 5765
Install 5767
Oxygen (HEGO) Sensor 5767
Remove 5767
Install 5767
LPG Fuel Testing 5768
General 5768
Available Fuel Tests 5768
Composition Test (ASTM D-2163) 5768
Ammonia Test (ASTM D-4490) 5768
Basic Nitrogen Test (ASTM UOP269-90) 5768
Residues Test (ASTM D-2158) 5768
Vapor Pressure Test (ASTM D-2598) 5768
Sulfur Compounds Test (ASTM D-5623) 5768
Methanol Test (ASTM D-4864) 5769
Copper Corrosion (ASTM D-1838) 5769
Where To Send LPG Fuel Samples For Testing 5769
550048401-0900YRM1570-(03-2015)-US-EN 5773
550055283-8000YRM1585-(06-2021)-US-EN 5803
General Information About Diagrams and Schematics 5807
Symbol Definitions 5807
Diagrams Manual Applications 5808
Diagrams and Schematics 5810
550055283-8000YRM1585-(07-2020)-US-EN 5899
General Information About Diagrams and Schematics 5903
Symbol Definitions 5903
Diagrams Manual Applications 5904
Diagrams and Schematics 5906
550073240-1900YRM1620-(01-2023)-US-EN 5995
Proper Flushing after Major Hydraulic Repairs 6001
Introduction 6001
The Phases of Wear 6001
Causes of Hydraulic System Failure 6001
Progression of Contaminant Caused Hydraulic System Failure 6002
Hydraulic System Flushing Techniques 6002
Double Oil and Filter Change 6002
Mechanical Cleaning 6003
Cleaning of Components 6003
How to Clean Tubes and Hoses 6003
Filter Caddy 6003
Start-Up Procedure for Cleaned System 6004
Contaminated Oil Coolers 6004
Additional Filter Caddy Functions 6005
How to Handle Different Fluids 6005
Water Removal Filters 6005
Fluid Conditioning and System Flushing Procedures 6006
Operation of the Filter Caddy 6006
Filter Caddy operation 6006
Fluid Conditioning Procedure 6006
Filter Caddy Start-Up 6007
System Flushing Procedure 6007
Component Cleaning Procedure 6008
Reservoir Cleaning Procedure 6008
Cylinder Cleaning Procedure 6008
Hose and Tube Cleaning Procedure 6008
Valve Cleaning Procedure 6009
Front-End Attachment Cleaning Procedure 6010
System Flushing Procedure 6010
Filter Caddy Start-Up 6011
System Start-Up and Flushing 6011
Reservoir Fluid Cleaning Times 6012
Dealing With Different Fluid Types 6013
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 6013
Filter Caddy Maintenance 6013
Servicing the Strainer 6013
DC Motor 6013
Hydraulic Oil Sampling Method and Procedure 6014
Hydraulic Oil Sampling Method 6014
Objective 6014
General Guidelines 6014
Synopsis 6015
Hydraulic Oil Analysis Report Guidelines 6016
Sampling Conditions 6016
Equipment 6016
Sampling Procedure 6017
Hydraulic Oil Sampling 6017
Sample Labeling 6017
Results Documentation 6017
550073240-1900YRM1620-(03-2020)-US-EN 6019
Proper Flushing after Major Hydraulic Repairs 6023
Introduction 6023
The Phases of Wear 6023
Causes of Hydraulic System Failure 6023
Progression of Contaminant Caused Hydraulic System Failure 6024
Hydraulic System Flushing Techniques 6024
Double Oil and Filter Change 6024
Mechanical Cleaning 6025
Cleaning of Components 6025
How to Clean Tubes and Hoses 6025
Filter Caddy 6025
Start-Up Procedure for Cleaned System 6026
Contaminated Oil Coolers 6026
Additional Filter Caddy Functions 6026
How to Handle Different Fluids 6026
Water Removal Filters 6027
Fluid Conditioning and System Flushing Procedures 6027
Operation of the Filter Caddy 6027
Filter Caddy operation 6027
Fluid Conditioning Procedure 6028
Filter Caddy Start-Up 6028
System Flushing Procedure 6029
Component Cleaning Procedure 6029
Reservoir Cleaning Procedure 6029
Cylinder Cleaning Procedure 6029
Hose and Tube Cleaning Procedure 6030
Valve Cleaning Procedure 6030
Front-End Attachment Cleaning Procedure 6031
System Flushing Procedure 6031
Filter Caddy Start-Up 6032
System Start-Up and Flushing 6032
Reservoir Fluid Cleaning Times 6033
Dealing With Different Fluid Types 6033
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 6033
Filter Caddy Maintenance 6034
Servicing the Strainer 6034
DC Motor 6034
Hydraulic Oil Sampling Method and Procedure 6034
Hydraulic Oil Sampling Method 6034
Objective 6034
General Guidelines 6034
Synopsis 6035
Hydraulic Oil Analysis Report Guidelines 6036
Sampling Conditions 6037
Equipment 6037
Sampling Procedure 6037
Hydraulic Oil Sampling 6037
Sample Labeling 6038
Results Documentation 6038

S.V 06/24