Yale Forklift E818 (GLC40-45-55VX, GLC55SVX) Service Manual – PDF DOWNLOAD

Description

Yale Forklift E818 (GLC40-45-55VX, GLC55SVX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift E818 (GLC40-45-55VX, GLC55SVX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 6250
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift E818 (GLC40-45-55VX, GLC55SVX) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-UK-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524208014-2200YRM1097-(03-2020)-US-EN 43
Series Code / Model Designation Reference Table 47
Description 48
Distributor Ignition (DI) System 48
Crankshaft Position (CKP) Sensor 48
Camshaft Position (CMP) Sensor 48
Ignition Coil and Ignition Control Module (ICM) 48
Secondary Ignition Components 48
Spark Plugs and Wires 49
Spark Plug Wire Inspection 49
Spark Plug Wire Replacement 49
Remove 49
Install 50
Spark Plug Inspection 50
Usage 50
Inspection 50
Visual Inspection 52
Spark Plug Replacement 52
Remove 52
Install 52
Distributor Repair 53
Inspect 53
Overhaul 53
Disassemble 53
Assemble 56
Replace 57
Remove 57
Install Procedure 1 59
Install Procedure 2 60
Ignition Coil Replacement 61
Remove 61
Install 61
Ignition Control Module Replacement 62
Remove 62
Install 62
Starter Replacement 63
Remove 63
Install 66
Sensors and Switches 67
Gas and LPG Trucks 67
Crankshaft Position (CKP) Sensor 67
Remove 67
Install 67
Camshaft Position (CMP) Sensor 68
Remove 68
Install 70
Oil Pressure Sensor 70
Remove 70
Install 71
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 72
Remove 72
Install 72
Engine Coolant Temperature (ECT) Sensor 73
Remove 73
Install 74
Air Flow Restriction Switch 74
Remove 74
Install 75
Specifications and Special Tools 76
524221866-9000YRM1112-(10-2020)-US-EN 81
SECTION 9010 Operational Diagnostic Procedures 97
Group 05 – Operational Checkout 99
SECTION 9020 Engine 117
Group 10 – Principles of Operation 127
Group 30 – Observed Symptoms 325
Group 40 – Tests and Adjustments 427
SECTION 9030 Electrical System 459
Group 03 – General Maintenance and Diagnostic Data 483
Group 10 – Principles of Operation 577
Group 20 – Diagnostic Trouble Codes 601
Group 30 – Observed Symptoms 1573
SECTION 9040 Drive Train 1629
Group 10 – Principles of Operation 1633
Group 30 – Observed Symptoms 1689
Group 40 – Tests and Adjustments 1739
SECTION 9050 Hydraulic Systems 1749
Group 10 – Principles of Operation 1753
Group 30 – Observed Symptoms 1811
Group 33 – Observed Symptoms-Gear Pump 1813
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1901
Group 40 – Tests and Adjustments 1945
Group 43 – Tests and Adjustments-Gear Pump 1947
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1971
SECTION 9060 Operators Station 1989
Group 10 – Principles of Operation 1991
SECTION 9070 Front End (Mast) and Chassis 2027
Group 10 – Principles of Operation 2029
Group 30 – Observed Symptoms 2051
SECTION 9080 Supplementary Data 2109
Group 50 – Abbreviations and Acronyms 2111
Group 60 – Special Tools List 2119
Group 70 – Fault Mode Indicator Reference 2129
Group 80 – Supplier Specification Data 2131
524223757-0700YRM1123-(06-2016)-UK-EN 2135
General 2139
Cooling System Checks 2139
Exhaust Leaks Into Cooling System 2139
Water Flow Restrictions in Radiator 2139
Radiator Hoses 2139
Water Pump 2140
Flushing the Cooling System 2140
Cooling System, Clean 2140
Radiator Replacement 2141
Radiator, Remove GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2142
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2157
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2160
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 2163
Radiator, Install for Lift Truck Models GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2170
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2175
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2177
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2180
Fan Assembly Replacement 2192
Fan Removal 2192
Inspect 2207
Fan Installation 2207
524223757-0700YRM1123-(06-2021)-US-EN 2213
General 2217
Cooling System Checks 2217
Exhaust Leaks Into Cooling System 2217
Water Flow Restrictions in Radiator 2217
Radiator Hoses 2217
Water Pump 2217
Flushing the Cooling System 2219
Cooling System, Clean 2219
Radiator Replacement 2221
Radiator, Remove GC/GLC030VX,GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX (GP/GLP/GDP030VX,GP/GLP/GDP035VX, GP/GLP/GDP040SVX)(C810); GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910); GLC050LX(A967); GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875);GLP/GDP20-25LX (GLP/GDP050LX)(A974); GLC40, 45, 55VX, GLC55SVX,(GC/GLC080, 100, 120VX, GC/GLC080,100VXBCS, GC/GLC120SVX,GC/GLC120VXPRS) (E818, F818) ANDGLP/GDP40VX5/VX6, GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) 2221
Radiator, Remove for Lift Trucks Models Equipped with Oil CoolerGC/GLC030VX, GC/GLC035VX,GC/GLC040SVX (C809); GLP/GDP16VX,GLP/GDP18VX, GLP/GDP20SVX(GP/GLP/GDP030VX, GP/GLP/GDP035VX,GP/GLP/GDP040SVX) (C810); GLC050LX(A967) AND GLP/GDP20-25LX(GLP/GDP050LX) (A974) 2236
Radiator, Remove for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2239
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX(GP/GLP/GDP135VX, GP/GLP/GDP155VX)(C878, D878, E878) and GLP/GDP80VX,GLP/GDP80VX9, GLP/GDP90VX(GLP/GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (A909, B909) 2242
Radiator, Install for Lift Truck Models GC/GLC030VX,GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX (GP/GLP/GDP030VX,GP/GLP/GDP035VX, GP/GLP/GDP040SVX)(C810); GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910); GLC050LX(A967); GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875);GLP/GDP20-25LX (GLP/GDP050LX)(A974); GLC40, 45, 55VX; GLC55SVX;(GC/GLC080, 100, 120VX; GC/GLC080,100VXBCS; GC/GLC120SVX;GC/GLC120VXPRS) (E818, F818) andGLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) 2248
Radiator, Install for Lift Truck Models Equipped with Oil CoolerGC/GLC030VX, GC/GLC035VX,GC/GLC040SVX (C809); GLP/GDP16VX,GLP/GDP18VX, GLP/GDP20SVX(GP/GLP/GDP030VX, GP/GLP/GDP035VX,GP/GLP/GDP040SVX) (C810); GLC050LX(A967) and GLP/GDP20-25LX(GLP/GDP050LX) (A974) 2252
Radiator, Install for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2253
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2256
Fan Assembly Replacement 2267
Fan Removal 2267
Inspect 2281
Fan Installation 2282
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)-UK-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
524223764-1600YRM1133-(07-2013)-US-EN 2419
toc 2419
Steering Axle 2419
Safety Precautions Maintenance and Repair 2420
General 2423
Steering Axle Assembly Repair 2425
Remove 2425
Disassemble 2426
Clean 2434
Inspect 2434
Assemble 2434
Install 2440
Spindles, Bearings, and Tie Rods Repair 2442
Spindles and Bearings 2442
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2442
Remove 2442
Disassemble 2444
Clean 2445
Inspect 2445
Assemble 2445
Install 2446
Spindles and Bearings 2449
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2449
Remove and Disassemble 2449
Assemble and Install 2450
Tie Rods 2450
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2450
Remove 2450
Install 2451
Tie Rods 2452
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2452
Remove 2452
Install 2458
Steering Cylinder Repair 2458
Remove and Disassemble 2458
Clean and Inspect 2459
Assemble and Install 2459
Torque Specifications 2460
524223766-1900YRM1136-(01-2022)-US-EN 2465
General 2469
Hydraulic Gear Pump Assembly 2470
Variable Displacement Pump Assembly 2471
Single Gear Pump Assembly Repair 2472
Remove 2472
Disassemble 2478
Clean 2480
Inspect 2480
Assemble 2480
Install 2480
Tandem Gear Pump Assembly 2485
Remove 2485
Disassemble 2486
Clean 2489
Inspect 2489
Assemble 2489
Install 2490
Gear Pump Specifications 2491
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2497
Remove 2497
Disassemble 2507
Clean 2510
Inspect 2511
Assemble 2511
Install 2511
63 0 cc/rev – Variable Displacement Pump Repair 2516
Remove 2516
Disassemble 2519
Clean 2521
Inspect 2521
Assemble 2521
Install 2521
Variable Displacement Pump Checks and Adjustments (Single Pump) 2525
Margin Pressure Check 2525
Flow Compensator Adjustment 2526
Pressure Compensator Adjustment 2526
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2528
Variable Displacement Pump Specifications 2531
Torque Specifications 2533
Hydraulic Gear Pump 2533
Variable Displacement Pump 2534
Special Tools 2535
524223766-1900YRM1136-(11-2017)-UK-EN 2537
General 2541
Hydraulic Gear Pump Assembly 2542
Variable Displacement Pump Assembly 2543
Single Gear Pump Assembly Repair 2543
Remove 2543
Disassemble 2550
Clean 2550
Inspect 2552
Assemble 2552
Install 2552
Tandem Gear Pump Assembly 2556
Remove 2557
Disassemble 2559
Clean 2561
Inspect 2561
Assemble 2561
Install 2562
Gear Pump Specifications 2562
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2568
Remove 2568
Disassemble 2578
Clean 2581
Inspect 2581
Assemble 2581
Install 2582
63 0 cc/rev – Variable Displacement Pump Repair 2585
Remove 2585
Disassemble 2588
Clean 2588
Inspect 2588
Assemble 2590
Install 2590
Variable Displacement Pump Checks and Adjustments (Single Pump) 2592
Margin Pressure Check 2592
Flow Compensator Adjustment 2593
Pressure Compensator Adjustment 2593
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2594
Variable Displacement Pump Specifications 2597
Torque Specifications 2598
Hydraulic Gear Pump 2599
Variable Displacement Pump 2600
Special Tools 2600
524223767-2000YRM1137-(01-2017)-UK-EN 2605
General 2611
Electro-Hydraulic Main Control Valve 2612
Description 2612
Remove 2620
Electro-Hydraulic Control Valve Sections 2625
General 2625
Outlet Control Valve Section 2625
Remove 2625
Disassemble 2626
Clean 2628
Inspect 2628
Assemble 2628
Install 2629
Auxiliary Control Valve Sections 2629
Remove 2629
Disassemble 2636
Clean 2637
Inspect 2638
Assemble 2638
Install 2640
Tilt Control Valve Section 2641
Remove 2641
Disassemble 2641
Clean 2647
Inspect 2647
Assemble 2647
Install 2648
Lift/Lower Control Valve Section 2649
Remove 2649
Disassemble 2649
Clean 2658
Inspect 2658
Assemble 2658
Install 2659
Mid-Inlet Section 2659
Remove 2659
Clean 2660
Inspect 2660
Install 2660
Install 2660
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2665
Lift Pilot Pin 2665
Lower Pilot Pin 2669
Abnormal/Erroneous EHPV Adjustment 2671
Manual Main Control Valve 2672
Description 2672
Remove 2676
OPS Solenoid Assembly 2684
General 2684
Remove 2685
Clean and Inspect 2688
Install 2688
Manual Control Valve Sections 2689
General 2689
Outlet Control Valve Section 2689
Remove 2689
Disassemble 2689
Clean 2692
Inspect 2692
Assemble 2692
Install 2693
Auxiliary Control Valve Sections 2693
Remove 2693
Disassemble 2693
Clean 2696
Inspect 2696
Assemble 2696
Install 2697
Lift/Tilt Control Valve Section 2697
Remove 2697
Disassemble 2697
Clean 2704
Inspect 2704
Assemble 2705
Install 2706
Mid-Inlet Section 2707
Remove 2707
Clean 2707
Inspect 2707
Install 2707
Install 2708
Pressure Relief Valve Check and Adjustment 2714
Primary Relief Valve 2715
Secondary Relief Valve 2719
Steering Control Unit Repair 2726
Steering Control Unit, Remove 2726
Steering Control Unit, Disassemble 2730
Steering Control Unit, Clean 2732
Steering Control Unit, Inspect 2732
Steering Control Unit, Assemble 2732
Relief Valve, Disassemble 2733
Relief Valve, Clean 2733
Relief Valve, Inspect 2734
Relief Valve, Assemble 2734
Steering Control Unit, Install 2734
524223767-2000YRM1137-(06-2021)-US-EN 2739
General 2743
Electro-Hydraulic Main Control Valve 2744
Description 2744
Remove 2752
Electro-Hydraulic Control Valve Sections 2757
General 2757
Outlet Control Valve Section 2757
Remove 2757
Disassemble 2757
Clean 2760
Inspect 2760
Assemble 2761
Install 2761
Auxiliary Control Valve Sections 2761
Remove 2762
Disassemble 2767
Clean 2769
Inspect 2769
Assemble 2769
Install 2771
Tilt Control Valve Section 2772
Remove 2772
Disassemble 2773
Clean 2777
Inspect 2777
Assemble 2778
Install 2779
Lift/Lower Control Valve Section 2779
Remove 2779
Disassemble 2779
Clean 2785
Inspect 2785
Assemble 2785
Install 2786
Mid-Inlet Section 2786
Remove 2786
Clean 2787
Inspect 2787
Install 2787
Install 2787
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2792
Lift Pilot Pin 2792
Lower Pilot Pin 2795
Abnormal/Erroneous EHPV Adjustment 2797
Manual Main Control Valve 2798
Description 2798
Remove 2802
OPS Solenoid Assembly 2810
General 2810
Remove 2811
Clean and Inspect 2813
Install 2813
Manual Control Valve Sections 2814
General 2814
Outlet Control Valve Section 2814
Remove 2814
Disassemble 2814
Clean 2817
Inspect 2817
Assemble 2817
Install 2817
Auxiliary Control Valve Sections 2818
Remove 2818
Disassemble 2818
Clean 2821
Inspect 2821
Assemble 2821
Install 2821
Lift/Tilt Control Valve Section 2822
Remove 2822
Disassemble 2822
Clean 2828
Inspect 2828
Assemble 2828
Install 2830
Mid-Inlet Section 2830
Remove 2830
Clean 2831
Inspect 2831
Install 2831
Install 2831
Pressure Relief Valve Check and Adjustment 2839
Primary Relief Valve 2839
Secondary Relief Valve 2842
Steering Control Unit Repair 2847
Steering Control Unit, Remove 2847
Steering Control Unit, Disassemble 2851
Steering Control Unit, Clean 2853
Steering Control Unit, Inspect 2853
Steering Control Unit, Assemble 2853
Relief Valve, Disassemble 2854
Relief Valve, Clean 2854
Relief Valve, Inspect 2855
Relief Valve, Assemble 2855
Steering Control Unit, Install 2855
524223768-2100YRM1139-(02-2014)-US-EN 2859
524223769-2200YRM1128-(01-2023)-US-EN 2907
Series Code / Model Designation Reference Table 2915
General 2917
Deutsch Crimping Tool 2918
How to Strip a Wire for Use With Deutsch Crimping Tool 2918
How to Crimp With the Deutsch Crimping Tool 2919
Calibration Test for the Deutsch Crimping Tool 2921
Deutsch Connectors 2923
DT, DTM, and DTP Series Connectors 2923
HD Series Connectors 2966
Metri-Pack Connectors 2988
Remove and Install 2988
Micro-Pack Connectors 2991
Weather-Pack Connectors 2992
AMPSEAL Crimping Tools 2994
AMP Hand Crimping Tool With Certi-Crimp 2994
Description 2994
Stripping Wire for Use with AMP Hand Crimping Tool 2995
Insulation Crimp Adjustment 2996
Maintenance and Inspection for AMP Hand Crimping Tool 2996
AMP Hand Crimping Tool 2996
Crimp Height Inspection 2996
How to use AMP Hand Crimping Tool 2997
AMP Pro-Crimper II Tool 2997
Description 2997
Remove and Install Die Set and Locator Assembly 2998
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2998
Contact Support Adjustment 2999
Crimp Height Adjustment 3000
Maintenance and Inspection Procedures 3000
PRO-CRIMPER II Tool 3000
Crimp Height Inspection 3000
How to Use AMP PRO-CRIMPER II Tool 3001
AMPSEAL Connector Assemblies 3002
Description for Plug Connector Assembly 3002
Seal Plug 3003
Contact Crimping 3003
Description for Plug Connector and Header Assembly 3008
Voltage Reading 3011
Seal Plug 3011
Contact Crimping 3011
AMP Superseal 1 5 Crimping Tools 3018
Mini Mic Receptacle and Tab Contacts 3018
Description 3018
Crimping Conditions and Measurements 3018
Insertion of Rubber Seal on Cable 3020
AMP Hand Application Tool 3025
Description 3025
Maintenance and Inspection 3025
Crimp Height Inspection 3025
Crimp Height Adjustment 3026
How to Use AMP Hand Application Tool 3026
AMP Pro-Crimper II Tool 3027
Description 3027
Remove and Install Die Set and Locator Assembly 3027
Adjustments 3028
Contact Support 3028
Crimp Height 3029
Inspections and Maintenance 3030
Crimp Height Inspection 3030
Visual Inspection 3030
Maintenance 3031
How to Use Pro-Crimper II Tool 3031
AMP Superseal 1 5 Connector Assemblies 3032
Description 3032
Repair and Maintenance 3039
Panel Mount Option 3039
AMP Fastin-Faston Hand Tools 3040
Description – AMP Double Action Hand Tool 3040
Maintenance and Inspection Procedures 3040
Daily Maintenance 3040
Periodic Tool Inspection 3041
Lubrication 3041
Visual Inspection 3041
Crimp Height Inspection 3041
Certi-Crimp Ratchet Inspection 3042
How to Use AMP Double Action Hand Tool 3043
Description – AMP Extraction Tool 3044
Maintenance and Inspection 3045
How to Use AMP Extraction Tool 3045
AMP Fastin-Faston Receptacles and Housings 3047
Description 3047
Wire Repair 3055
Wire Splicing Requirements 3055
Deutsch Jiffy Splice 3056
Twisted/Shielded Cable and Leads Repair 3062
Special Tools 3064
524223769-2200YRM1128-(07-2020)-UK-EN 3073
Series Code / Model Designation Reference Table 3079
General 3082
Deutsch Crimping Tool 3082
How to Strip a Wire for Use With Deutsch Crimping Tool 3082
How to Crimp With the Deutsch Crimping Tool 3083
Calibration Test for the Deutsch Crimping Tool 3085
Deutsch Connectors 3087
DT, DTM, and DTP Series Connectors 3087
HD Series Connectors 3129
Metri-Pack Connectors 3152
Remove and Install 3152
Micro-Pack Connectors 3154
Weather-Pack Connectors 3155
AMPSEAL Crimping Tools 3157
AMP Hand Crimping Tool With Certi-Crimp 3157
Description 3157
Stripping Wire for Use with AMP Hand Crimping Tool 3157
Insulation Crimp Adjustment 3158
Maintenance and Inspection for AMP Hand Crimping Tool 3158
AMP Hand Crimping Tool 3158
Crimp Height Inspection 3158
How to use AMP Hand Crimping Tool 3159
AMP Pro-Crimper II Tool 3159
Description 3159
Remove and Install Die Set and Locator Assembly 3160
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3161
Contact Support Adjustment 3161
Crimp Height Adjustment 3162
Maintenance and Inspection Procedures 3162
PRO-CRIMPER II Tool 3162
Crimp Height Inspection 3162
How to Use AMP PRO-CRIMPER II Tool 3163
AMPSEAL Connector Assemblies 3164
Description for Plug Connector Assembly 3164
Seal Plug 3165
Contact Crimping 3165
Description for Plug Connector and Header Assembly 3170
Voltage Reading 3172
Seal Plug 3172
Contact Crimping 3172
AMP Superseal 1 5 Crimping Tools 3179
Mini Mic Receptacle and Tab Contacts 3179
Description 3179
Crimping Conditions and Measurements 3179
Insertion of Rubber Seal on Cable 3181
AMP Hand Application Tool 3186
Description 3186
Maintenance and Inspection 3186
Crimp Height Inspection 3186
Crimp Height Adjustment 3187
How to Use AMP Hand Application Tool 3187
AMP Pro-Crimper II Tool 3188
Description 3188
Remove and Install Die Set and Locator Assembly 3189
Adjustments 3189
Contact Support 3189
Crimp Height 3190
Inspections and Maintenance 3191
Crimp Height Inspection 3191
Visual Inspection 3191
Maintenance 3192
How to Use Pro-Crimper II Tool 3192
AMP Superseal 1 5 Connector Assemblies 3193
Description 3193
Repair and Maintenance 3200
Panel Mount Option 3200
AMP Fastin-Faston Hand Tools 3201
Description – AMP Double Action Hand Tool 3201
Maintenance and Inspection Procedures 3201
Daily Maintenance 3201
Periodic Tool Inspection 3202
Lubrication 3202
Visual Inspection 3202
Crimp Height Inspection 3202
Certi-Crimp Ratchet Inspection 3203
How to Use AMP Double Action Hand Tool 3204
Description – AMP Extraction Tool 3205
Maintenance and Inspection 3205
How to Use AMP Extraction Tool 3206
AMP Fastin-Faston Receptacles and Housings 3207
Description 3207
Wire Repair 3214
Wire Splicing Requirements 3214
Deutsch Jiffy Splice 3215
Twisted/Shielded Cable and Leads Repair 3220
Special Tools 3223
524223770-2200YRM1130-(03-2020)-UK-EN 3231
General 3235
Description 3235
Dash Display Menu Access 3235
Menu Navigation 3236
Standard Display 3236
Main Menu 3236
Passwords Menu 3237
Password Administration 3237
Add Password 3237
Delete Password 3238
Edit Password 3238
Other Password Functions 3239
Operator Passwords – Enable/Disable 3239
Password Time-Out Delay 3239
Passwords – Number Wrong to Disable 3240
Lockout Reset Password 3240
View Password Log 3241
View Versions 3242
VSM Versions 3242
Dash Display Versions 3243
Engine Controller Version 3244
Transmission (Xmsn) Controller Version 3245
Truck Serial Number 3246
Diagnostics 3247
View Fault Log 3247
Set Travel and Braking 3248
Speed Limit 3248
Acceleration Rate 3249
Auto-Deceleration Rate 3249
Set Power Reversal Rate 3250
Set Inching/Brake Overlap 3251
Setup Display Menu 3252
Set Operator Language 3252
Set Units 3253
Set Time Format (12/24 Hour) 3253
Set Daylight Saving Time 3253
Set Time 3256
Set Date Format 3257
Set Date 3257
Setup Hydraulics 3258
Return to Set Tilt Delay/On/Off 3258
Setup General Items 3259
Light Shutdown Time-Out 3259
Impact Sensor – Enable/Disable 3260
Impact Sensor – Soft Impact Settings 3261
Impact Sensor – Hard Impact Settings 3262
Adjust Impact Sensor Settings 3262
Initial Adjustment of Soft and Hard Impact Settings 3264
Readjustment of Soft and Hard Impact Settings 3264
Impact Sensor – Impact Alarm/Shutdown Reset 3265
Impact Sensor – Alarm Time Duration and Deactivation 3266
Impact Sensor – View Impact Event Log 3267
Engine Mode Indicator 3268
Generation 1 (ECO-eLo ONLY) 3268
Generation 2 3269
Operator Checklist 3270
Operator Checklist Off-On Mode 3270
Edit Operator Checklist 3270
Set Operator Checklist Expiration 3271
View Checklist Log 3271
Clear Operator Checklist Log 3272
Clear Operator Checklist Fault 3272
Calibrations 3273
Set Tilt Stop Point 3273
Calibrate Loaded Weight 3273
524223770-2200YRM1130-(05-2021)-US-EN 3275
General 3279
Description 3279
Dash Display Menu Access 3279
Menu Navigation 3280
Standard Display 3280
Main Menu 3280
Passwords Menu 3281
Password Administration 3281
Add Password 3281
Delete Password 3281
Edit Password 3282
Other Password Functions 3283
Operator Passwords – Enable/Disable 3283
Password Time-Out Delay 3283
Passwords – Number Wrong to Disable 3283
Lockout Reset Password 3284
View Password Log 3284
View Versions 3285
VSM Versions 3285
Dash Display Versions 3286
Engine Controller Version 3287
Transmission (Xmsn) Controller Version 3288
Truck Serial Number 3289
Diagnostics 3290
View Fault Log 3290
Set Travel and Braking 3291
Speed Limit 3291
Acceleration Rate 3292
Auto-Deceleration Rate 3292
Set Power Reversal Rate 3293
Set Inching/Brake Overlap 3294
Setup Display Menu 3295
Set Operator Language 3295
Set Units 3296
Set Time Format (12/24 Hour) 3296
Set Daylight Saving Time 3297
Set Time 3300
Set Date Format 3300
Set Date 3301
Setup Hydraulics 3302
Return to Set Tilt Delay/On/Off 3302
Setup General Items 3303
Light Shutdown Time-Out 3303
Impact Sensor – Enable/Disable 3304
Impact Sensor – Soft Impact Settings 3305
Impact Sensor – Hard Impact Settings 3305
Adjust Impact Sensor Settings 3306
Initial Adjustment of Soft and Hard Impact Settings 3308
Readjustment of Soft and Hard Impact Settings 3308
Impact Sensor – Impact Alarm/Shutdown Reset 3309
Impact Sensor – Alarm Time Duration and Deactivation 3310
Impact Sensor – View Impact Event Log 3311
Engine Mode Indicator 3311
Generation 1 (ECO-eLo ONLY) 3311
Generation 2 3312
Operator Checklist 3313
Operator Checklist Off-On Mode 3313
Edit Operator Checklist 3313
Set Operator Checklist Expiration 3313
View Checklist Log 3314
Clear Operator Checklist Log 3315
Clear Operator Checklist Fault 3315
Calibrations 3316
Set Tilt Stop Point 3316
Calibrate Loaded Weight 3316
524223771-2200YRM1131-(03-2020)-UK-EN 3319
Series Code / Model Designation Reference Table 3325
General 3327
Description 3327
Dash Display Menu Access 3327
Menu Navigation 3328
Main Menu 3328
Passwords 3329
Adding Passwords 3329
Hourmeters 3331
View Versions 3332
VSM Versions 3332
Dash Display Versions 3333
Engine Controller Version 3334
Transmission (Xmsn) Controller Version 3335
Truck Serial Number 3336
Truck Configuration 3337
Diagnostics 3338
Clear Fault Log 3338
View Fault Log 3339
No-Run Data Display 3340
Engine Accelerator and Throttle Data Display 3340
Engine Speeds and Governor Data Display 3341
Engine Fuel and Emissions Data Display 3342
Engine General Data Display 3344
XMSN/Brake Data Display 3345
Hydraulic Data Display 3348
General Truck Data Display 3350
Set Travel and Braking 3351
Speed Limit 3351
Acceleration Rate 3352
Auto-Deceleration Rate 3353
Set Power Reversal Rate 3353
Set Inching/Brake Overlap 3354
Setup Hydraulics 3354
Lift Maximum Speed 3355
Lower Maximum Speed 3355
Tilt Maximum Speed 3356
Auxiliary Function One, Direction A, Maximum Speed 3358
Auxiliary Function One, Direction B, Maximum Speed 3360
Auxiliary Function Two, Direction A, Maximum Speed 3360
Auxiliary Function Two, Direction B, Maximum Speed 3361
Auxiliary Function Three, Direction A, Maximum Speed 3362
Auxiliary Function Three, Direction B, Maximum Speed 3362
Lift/Lower Ramp Rate 3363
Hydraulic Auxiliary Ramp Rate 3363
Return to Set Tilt Delay/On/Off 3364
Hydraulic Input Device 3365
Auxiliary Solenoid 3365
Dual Function 3366
Setup Display 3367
Set Service Language 3367
Setup General Items 3367
Motion Alarm Activation Type 3368
Light Shutdown Time-Out 3369
Restore Default Settings 3369
Restore Engine Controller Default Calibration 3370
Impact Sensor – Enable/Disable 3370
Impact Sensor – Soft Impact Settings 3371
Impact Sensor – Hard Impact Settings 3372
Adjust Impact Sensor Settings 3373
Initial Adjustment of Soft and Hard Impact Settings 3375
Readjustment of Soft and Hard Impact Settings 3375
Impact Sensor – Impact Alarm/Shutdown Reset 3376
Impact Sensor – Alarm Time Duration and Deactivation 3377
Impact Sensor – View Impact Event Log 3378
Engine Mode Indicator 3378
Generation 1 (ECO-eLo ONLY) 3378
Generation 2 3379
Diesel Particulate Filter (DPF) Display 3380
General Description 3380
Passive Regeneration Only 3380
Regeneration Level 0 3380
Auto/Active Regeneration Inhibited 3381
Auto/Active Regeneration 3381
Regeneration Level 1 3381
Parked Regeneration Request 3382
Regeneration Level 2 3382
Warning Level 3382
Regeneration Level 3 3382
Service Level 3383
Regeneration Level 4 3383
Display, Diesel Particulate Filter (DPF), Revised 3383
Operator Interface 3383
Refer to Operator Manual 3383
CAN Communication Lost 3384
Passive Regeneration Only 3384
Regeneration Level 0 3384
Auto/Active Regeneration Inhibited 3384
Auto/Active Regeneration 3385
Regeneration Level 1 3385
Idle-up Auto/Active Regeneration 3385
Parked Regeneration Request 3385
Regeneration Level 2 3385
Warning Level 3387
Regeneration Level 3 3387
Service Level 3387
Regeneration Level 4 3387
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3387
Display, Diesel Particulate Filter (DPF), Stage V Engine 3387
Operator Interface 3388
Refer to Operator Manual 3388
CAN Communication Lost 3388
Passive Regeneration Only 3388
Regeneration Level 0 3388
Auto/Active Regeneration Inhibited 3389
Auto/Active Regeneration 3389
Regeneration Level 1 3389
Idle-up Auto/Active Regeneration 3390
Parked Regeneration Request 3390
Regeneration Level 2 3390
Warning Level 3391
Regeneration Level 3 3391
Service Level 3392
Regeneration Level 4 3392
Stage V Content 3392
Emissions System Malfunction 3392
Ash Load 3392
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3393
Operator Interface 3393
Refer to Operator Manual 3393
CAN Communication Lost 3394
Passive Regeneration Only 3394
Regeneration Level 0 3394
Auto/Active Regeneration Inhibited 3394
Auto/Active Regeneration 3395
Regeneration Level 1 3395
Idle-up Auto/Active Regeneration 3395
Parked Regeneration Request 3395
Regeneration Level 2 3395
Warning Level 3397
Regeneration Level 3 3397
Service Level 3397
Regeneration Level 4 3397
Calibrations 3398
Calibrate Transmission Valve 3400
Set Tilt Stop Point 3400
Calibrate Loaded Weight 3400
Calibrate Travel Speed Sensor 3401
Calibrate Mazda LP and Gas Accelerator Pedal 3401
524223771-2200YRM1131-(05-2021)-US-EN 3403
Series Code / Model Designation Reference Table 3409
General 3411
Description 3411
Dash Display Menu Access 3411
Menu Navigation 3412
Main Menu 3413
Passwords 3413
Adding Passwords 3413
Hourmeters 3415
View Versions 3416
VSM Versions 3416
Dash Display Versions 3417
Engine Controller Version 3418
Transmission (Xmsn) Controller Version 3419
Truck Serial Number 3420
Truck Configuration 3421
Diagnostics 3422
Clear Fault Log 3422
View Fault Log 3423
No-Run Data Display 3424
Engine Accelerator and Throttle Data Display 3425
Engine Speeds and Governor Data Display 3427
Engine Fuel and Emissions Data Display 3428
Engine General Data Display 3430
XMSN/Brake Data Display 3431
Hydraulic Data Display 3433
General Truck Data Display 3436
Set Travel and Braking 3438
Speed Limit 3438
Acceleration Rate 3439
Auto-Deceleration Rate 3439
Set Power Reversal Rate 3440
Set Inching/Brake Overlap 3440
Setup Hydraulics 3441
Lift Maximum Speed 3441
Lower Maximum Speed 3442
Tilt Maximum Speed 3442
Auxiliary Function One, Direction A, Maximum Speed 3444
Auxiliary Function One, Direction B, Maximum Speed 3447
Auxiliary Function Two, Direction A, Maximum Speed 3447
Auxiliary Function Two, Direction B, Maximum Speed 3448
Auxiliary Function Three, Direction A, Maximum Speed 3449
Auxiliary Function Three, Direction B, Maximum Speed 3449
Lift/Lower Ramp Rate 3450
Hydraulic Auxiliary Ramp Rate 3450
Return to Set Tilt Delay/On/Off 3451
Hydraulic Input Device 3452
Auxiliary Solenoid 3452
Dual Function 3453
Setup Display 3454
Set Service Language 3454
Setup General Items 3454
Motion Alarm Activation Type 3455
Light Shutdown Time-Out 3456
Restore Default Settings 3456
Restore Engine Controller Default Calibration 3457
Impact Sensor – Enable/Disable 3457
Impact Sensor – Soft Impact Settings 3458
Impact Sensor – Hard Impact Settings 3458
Adjust Impact Sensor Settings 3459
Initial Adjustment of Soft and Hard Impact Settings 3461
Readjustment of Soft and Hard Impact Settings 3461
Impact Sensor – Impact Alarm/Shutdown Reset 3462
Impact Sensor – Alarm Time Duration and Deactivation 3463
Impact Sensor – View Impact Event Log 3464
Engine Mode Indicator 3464
Generation 1 (ECO-eLo ONLY) 3464
Generation 2 3465
Diesel Particulate Filter (DPF) Display 3466
General Description 3466
Passive Regeneration Only 3466
Regeneration Level 0 3466
Auto/Active Regeneration Inhibited 3467
Auto/Active Regeneration 3467
Regeneration Level 1 3467
Parked Regeneration Request 3468
Regeneration Level 2 3468
Warning Level 3469
Regeneration Level 3 3469
Service Level 3469
Regeneration Level 4 3469
Display, Diesel Particulate Filter (DPF), Revised 3469
Operator Interface 3470
Refer to Operator Manual 3470
CAN Communication Lost 3470
Passive Regeneration Only 3470
Regeneration Level 0 3470
Auto/Active Regeneration Inhibited 3471
Auto/Active Regeneration 3471
Regeneration Level 1 3471
Idle-up Auto/Active Regeneration 3471
Parked Regeneration Request 3472
Regeneration Level 2 3472
Warning Level 3473
Regeneration Level 3 3473
Service Level 3473
Regeneration Level 4 3473
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3474
Display, Diesel Particulate Filter (DPF), Stage V Engine 3474
Operator Interface 3474
Refer to Operator Manual 3474
CAN Communication Lost 3475
Passive Regeneration Only 3475
Regeneration Level 0 3475
Auto/Active Regeneration Inhibited 3475
Auto/Active Regeneration 3476
Regeneration Level 1 3476
Idle-up Auto/Active Regeneration 3476
Parked Regeneration Request 3476
Regeneration Level 2 3476
Warning Level 3478
Regeneration Level 3 3478
Service Level 3478
Regeneration Level 4 3478
Stage V Content 3478
Emissions System Malfunction 3478
Ash Load 3479
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3480
Operator Interface 3480
Refer to Operator Manual 3480
CAN Communication Lost 3481
Passive Regeneration Only 3481
Regeneration Level 0 3481
Auto/Active Regeneration Inhibited 3481
Auto/Active Regeneration 3482
Regeneration Level 1 3482
Idle-up Auto/Active Regeneration 3482
Parked Regeneration Request 3482
Regeneration Level 2 3482
Warning Level 3484
Regeneration Level 3 3484
Service Level 3484
Regeneration Level 4 3484
Calibrations 3485
Calibrate Transmission Valve 3487
Set Tilt Stop Point 3487
Calibrate Loaded Weight 3488
Calibrate Travel Speed Sensor 3488
Calibrate Mazda LP and Gas Accelerator Pedal 3489
524223772-2200YRM1142-(01-2020)-UK-EN 3491
General 3501
Display Switch Cluster 3504
Remove 3504
Install 3507
Direction Control and Turn Signal Levers 3507
Remove 3507
Install 3509
Key Switch 3509
Remove 3509
Install 3510
Display Switch Cluster Panel Bezel and Overlay 3510
Remove 3510
Install 3510
Steering Column Repair 3510
Remove 3510
Disassemble 3513
Assemble 3513
Install 3513
Sensors and Switches 3514
General 3514
Dash and Kick Panel, Remove and Install 3514
Remove 3514
Install 3515
Accelerator Pedal Position Sensor 3516
Remove 3516
Install 3519
Brake Fluid Level Switch 3520
Remove 3520
Install 3522
Service Brake Pedal Position Sensor 3523
Remove 3523
Install 3526
Parking Brake Sensor 3527
Remove 3527
Install 3528
Service Brake Pressure Sensor 3529
Remove 3529
Install 3531
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3532
Remove 3532
Install 3532
Sensor Microswitch (Foot Directional Control Pedal) 3533
Remove 3533
Install 3536
Low Coolant Level Sensor 3537
Remove 3537
Install 3540
Fuel Level Sensor, Gas and Diesel Engines Only 3541
Remove 3541
Install 3542
Armrest Switch 3542
Remove 3542
Install 3544
Seat Sensor (Operator Presence System) 3544
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) 3544
Remove 3544
Install 3545
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3545
Remove 3545
Install 3546
Full Suspension Seats; All Lift Truck Models 3546
Remove 3546
Install 3546
Hood Shut Off Switch 3546
Remove 3546
Install 3549
Remote Key Switch 3550
Remove 3550
Install 3550
Hydraulic Filter Pressure Switch 3551
Remove 3551
Install 3553
Transmission Speed Sensor 3553
Remove 3553
Install 3556
Transmission Pressure Sensors 3557
Remove 3557
Install 3559
Transmission Temperature Sensor 3560
Remove 3560
Install 3562
Engine Speed Sensor 3564
Remove 3564
Install 3564
Intermediate Speed Sensor 3565
Remove 3565
Install 3565
Return to Set Tilt (Tilt Angle) Sensor 3565
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) 3565
Remove 3565
Install 3566
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) 3567
Remove 3567
Install 3568
Rear Horn Button Switch 3568
Remove 3568
Install 3569
Impact Sensor 3570
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) 3570
Remove 3570
Install 3573
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) 3573
Remove 3573
Install 3574
Load Weight Sensor 3575
Remove 3575
Install 3576
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3577
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3577
Crankshaft Position (CKP) Sensor 3577
Camshaft Position (CMP) Sensor 3577
Oil Pressure Sensor 3577
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3577
Engine Coolant Temperature (ECT) Sensor 3578
Air Flow Restriction Switch 3578
Remove for GM 2 4L Gas and LPG Trucks 3578
Install for GM 2 4L Gas and LPG Trucks 3578
Oxygen Sensor 3579
Remove 3579
Install 3582
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3583
Crankshaft Position (CKP) Sensor 3583
Camshaft Position (CMP) Sensor 3583
Oil Pressure Sensor 3583
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3583
Engine Coolant Temperature (ECT) Sensor 3583
Air Flow Restriction Switch 3583
Oxygen Sensor 3583
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3583
Low LPG Pressure Switch 3583
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3584
Air Filter Restriction Switch 3584
Remove 3584
Install 3584
Oil Pressure Sensor 3584
Remove 3584
Install 3584
Engine Speed Sensor 3584
Remove 3584
Install 3584
Engine Coolant Temperature (ECT) Sensor 3584
Remove 3584
Install 3584
Throttle Position Sensor (TPS) 3587
Remove 3587
Install 3588
Fuel/Water Separator Sensor 3588
Remove 3588
Install 3588
Glow Plug Relay 3589
Remove 3589
Install 3591
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3591
Air Filter Restriction Switch 3591
Remove 3591
Install 3591
Engine Oil Pressure Sensor 3596
Remove 3596
Install 3596
Engine Speed Sensor 3596
Remove 3596
Install 3597
Engine Coolant Temperature (ECT) Sensor 3597
Remove 3597
Install 3598
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3599
Remove 3599
Install 3599
Fuel/Water Separator Sensor 3600
Remove 3600
Install 3600
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3601
Intake Air Temperature Sensor 3601
Remove 3601
Install 3602
Intake Air Pressure Sensor 3602
Remove 3602
Install 3602
Air Inlet Heater 3602
Remove 3602
Install 3603
Engine Oil Pressure Sensor 3603
Remove 3603
Install 3603
Engine Coolant Temperature (ECT) Sensor 3603
Remove 3603
Install 3603
Crankshaft Position Sensor 3604
Remove 3604
Install 3604
Adjust Shim Procedure 3605
Camshaft Position Sensor 3606
Remove 3606
Install 3606
Air Flow Restriction Sensor 3607
Remove 3607
Install 3607
Fuel/Water Separator 3607
Remove 3607
Install 3608
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3608
Intake Air Temperature Sensor 3612
Remove 3612
Install 3613
Boost Sensor 3613
Remove 3613
Install 3614
Throttle Valve Assembly and Air Intake Heater 3614
Remove 3614
Install 3614
Engine Coolant Temperature (ECT) Sensor 3615
Remove 3615
Install 3615
Engine Oil Pressure Sensor 3615
Remove 3615
Install 3616
Crankshaft Position Sensor 3616
Remove 3616
Install 3616
Adjust Shim Procedure 3617
Camshaft Position Sensor 3618
Remove 3618
Install 3619
Differential Pressure Sensor 3619
Remove 3619
Install 3619
Mass Air Flow Sensor 3620
Remove 3620
Install 3621
Fuel/Water Separator 3621
Remove 3621
Install 3622
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3622
Engine Coolant Temperature (ECT) Sensor 3623
Remove 3623
Install 3623
Throttle Position Sensor 3624
Engine Oil Pressure Sensor 3624
Remove 3624
Install 3624
Engine Speed Sensor 3624
Remove 3624
Install 3624
Fuel Shut Off Solenoid 3624
Remove 3624
Install 3624
Vehicle System Manager (VSM) 3625
General 3625
VSM Replacement 3625
Remove 3625
Install 3627
Programming a New VSM and/or Display Switch Cluster 3627
General 3627
PC Service Tool Software 3628
Data Transferring 3628
New VSM 3628
New (Blank) Display Switch Cluster 3628
Used (Non-Blank) Display Switch Cluster 3628
Power Distribution Module (PDM) and Component Parts 3630
Remove 3630
PDM as a Unit 3630
Install 3634
PDM as a Unit 3634
Remove and Install 3635
PDM Component Parts 3635
Transmission Control Unit 3635
Remove 3635
Install 3639
Battery 3641
Remove 3641
Install 3641
Lights 3642
Work Lights (Front and Rear) 3642
Remove 3642
Install 3642
Strobe Light 3643
Remove 3643
Install 3643
LED Tail, Backup, and Brake Lights 3644
Remove 3644
Install 3645
Front Marker/Turn Signal Lights 3646
Replacing Whole Front Marker/Turn Signal Light Assembly 3646
Remove 3646
Install 3646
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3647
Remove 3647
Install 3647
Diesel Particulate Filter (DPF) Display 3647
Remove 3647
Clean and Inspect 3648
Install 3648
Electronic-Hydraulic Controls – Generation 1 3649
E-Hydraulic Controls – Test 3649
Mini-Levers 3649
Full Stroke Test 3649
Function Returns to Neutral Test 3649
Push Button Switch 3649
General 3650
Mini-Lever Replacement 3650
Remove 3650
Clean and Inspect 3651
Install 3651
Push Button Switch Replacement 3652
Remove 3652
Install 3654
Mini-Lever Module (MLM) 3654
Remove 3654
Install 3654
Joystick 3655
Remove and Disassemble 3655
Inspect 3655
Assemble and Install 3655
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3656
General 3656
Mini-levers, Remove and Install 3656
Armrest Assembly 3657
Remove 3657
Install 3660
Horn Button 3660
Remove 3660
Install 3660
Direction Control Switch 3661
Remove 3661
Install 3661
push (override) buttons and Toggle Switch 3661
Remove 3662
Install 3663
Joystick 3664
Remove and Disassemble 3664
Inspect 3664
Assemble and Install 3664
Joystick Armrest Slider Assembly 3665
Remove 3665
Install 3666
Electronic-Hydraulic Controls, After January, 2020 3666
E-Hydraulic Controls – TEST 3666
Mini-Levers 3666
Full Stroke Test 3666
Function Returns to Neutral Test 3666
Push (Override) Button 3667
General 3667
Mini-levers, Remove and Install 3667
Armrest Assembly 3668
Remove 3668
Install 3671
Horn Button 3671
Remove 3671
Install 3671
Direction Control Switch 3671
Remove 3671
Install 3672
Push (Override) buttons and Toggle Switch 3672
Remove 3673
Install 3675
Special Tools 3676
524223772-2200YRM1142-(08-2021)-US-EN 3679
General 3689
Display Switch Cluster 3693
Remove 3693
Install 3695
Direction Control and Turn Signal Levers 3695
Remove 3695
Install 3696
Key Switch 3697
Remove 3697
Install 3698
Display Switch Cluster Panel Bezel and Overlay 3698
Remove 3698
Install 3698
Steering Column Repair 3699
Remove 3699
Disassemble 3702
Assemble 3702
Install 3702
Sensors and Switches 3703
General 3703
Dash and Kick Panel, Remove and Install 3703
Remove 3703
Install 3704
Accelerator Pedal Position Sensor 3704
Remove 3704
Install 3708
Brake Fluid Level Switch 3709
Remove 3709
Install 3710
Service Brake Pedal Position Sensor 3712
Remove 3712
Install 3714
Parking Brake Sensor 3715
Remove 3715
Install 3717
Service Brake Pressure Sensor 3717
Remove 3717
Install 3719
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3721
Remove 3721
Install 3721
Sensor Microswitch (Foot Directional Control Pedal) 3721
Remove 3721
Install 3724
Low Coolant Level Sensor 3725
Remove 3725
Install 3728
Fuel Level Sensor, Gas and Diesel Engines Only 3729
Remove 3729
Install 3730
Armrest Switch 3730
Remove 3730
Install 3732
Seat Sensor (Operator Presence System) 3732
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) 3732
Remove 3732
Install 3733
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3733
Remove 3733
Install 3733
Full Suspension Seats; All Lift Truck Models 3734
Remove 3734
Install 3734
Hood Shut Off Switch 3735
Remove 3735
Install 3737
Remote Key Switch 3738
Remove 3738
Install 3738
Hydraulic Filter Pressure Switch 3739
Remove 3739
Install 3741
Transmission Speed Sensor 3741
Remove 3741
Install 3744
Transmission Pressure Sensors 3745
Remove 3745
Install 3747
Transmission Temperature Sensor 3748
Remove 3748
Install 3750
Engine Speed Sensor 3752
Remove 3752
Install 3753
Intermediate Speed Sensor 3753
Remove 3753
Install 3753
Return to Set Tilt (Tilt Angle) Sensor 3754
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) 3754
Remove 3754
Install 3754
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) 3754
Remove 3755
Install 3756
Rear Horn Button Switch 3757
Remove 3757
Install 3757
Impact Sensor 3758
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) 3758
Remove 3758
Install 3760
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) 3760
Remove 3760
Install 3761
Load Weight Sensor 3761
Remove 3761
Install 3763
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3764
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3764
Crankshaft Position (CKP) Sensor 3764
Camshaft Position (CMP) Sensor 3764
Oil Pressure Sensor 3764
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3764
Engine Coolant Temperature (ECT) Sensor 3765
Air Flow Restriction Switch 3765
Remove for GM 2 4L Gas and LPG Trucks 3765
Install for GM 2 4L Gas and LPG Trucks 3765
Oxygen Sensor 3766
Remove 3766
Install 3769
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3770
Crankshaft Position (CKP) Sensor 3770
Camshaft Position (CMP) Sensor 3770
Oil Pressure Sensor 3770
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3770
Engine Coolant Temperature (ECT) Sensor 3770
Air Flow Restriction Switch 3770
Oxygen Sensor 3770
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3770
Low LPG Pressure Switch 3770
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3771
Air Filter Restriction Switch 3771
Remove 3771
Install 3771
Oil Pressure Sensor 3771
Remove 3771
Install 3771
Engine Speed Sensor 3771
Remove 3771
Install 3771
Engine Coolant Temperature (ECT) Sensor 3771
Remove 3771
Install 3771
Throttle Position Sensor (TPS) 3774
Remove 3774
Install 3775
Fuel/Water Separator Sensor 3775
Remove 3775
Install 3775
Glow Plug Relay 3776
Remove 3776
Install 3778
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3778
Air Filter Restriction Switch 3778
Remove 3778
Install 3779
Engine Oil Pressure Sensor 3783
Remove 3783
Install 3783
Engine Speed Sensor 3783
Remove 3783
Install 3784
Engine Coolant Temperature (ECT) Sensor 3784
Remove 3784
Install 3785
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3786
Remove 3786
Install 3786
Fuel/Water Separator Sensor 3787
Remove 3787
Install 3787
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3788
Intake Air Temperature Sensor 3788
Remove 3788
Install 3789
Intake Air Pressure Sensor 3789
Remove 3789
Install 3789
Air Inlet Heater 3789
Remove 3789
Install 3790
Engine Oil Pressure Sensor 3790
Remove 3790
Install 3790
Engine Coolant Temperature (ECT) Sensor 3790
Remove 3790
Install 3790
Crankshaft Position Sensor 3791
Remove 3791
Install 3791
Adjust Shim Procedure 3792
Camshaft Position Sensor 3793
Remove 3793
Install 3793
Air Flow Restriction Sensor 3793
Remove 3793
Install 3794
Fuel/Water Separator 3794
Remove 3794
Install 3795
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3795
Intake Air Temperature Sensor 3799
Remove 3799
Install 3800
Boost Sensor 3800
Remove 3800
Install 3801
Throttle Valve Assembly and Air Intake Heater 3801
Remove 3801
Install 3801
Engine Coolant Temperature (ECT) Sensor 3802
Remove 3802
Install 3802
Engine Oil Pressure Sensor 3803
Remove 3803
Install 3803
Crankshaft Position Sensor 3803
Remove 3803
Install 3803
Adjust Shim Procedure 3804
Camshaft Position Sensor 3806
Remove 3806
Install 3806
Differential Pressure Sensor 3806
Remove 3806
Install 3807
Mass Air Flow Sensor 3807
Remove 3807
Install 3808
Fuel/Water Separator 3809
Remove 3809
Install 3810
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3811
Engine Coolant Temperature (ECT) Sensor 3812
Remove 3812
Install 3812
Throttle Position Sensor 3812
Engine Oil Pressure Sensor 3812
Remove 3812
Install 3812
Engine Speed Sensor 3812
Remove 3812
Install 3812
Fuel Shut Off Solenoid 3813
Remove 3813
Install 3813
Vehicle System Manager (VSM) 3814
General 3814
VSM Replacement 3814
Remove 3814
Install 3816
Programming a New VSM and/or Display Switch Cluster 3816
General 3816
PC Service Tool Software 3817
Data Transferring 3817
New VSM 3817
New (Blank) Display Switch Cluster 3817
Used (Non-Blank) Display Switch Cluster 3817
Power Distribution Module (PDM) and Component Parts 3820
Remove 3820
PDM as a Unit 3820
Install 3823
PDM as a Unit 3823
Remove and Install 3824
PDM Component Parts 3824
Transmission Control Unit (TCU) 3825
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) 3825
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) 3825
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3826
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3826
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 3826
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 3827
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 3828
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 3830
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 3830
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 3830
Battery 3831
Remove 3831
Install 3831
Lights 3832
Work Lights (Front and Rear) 3832
Remove 3832
Install 3832
Strobe Light 3833
Remove 3833
Install 3833
LED Tail, Backup, and Brake Lights 3834
Remove 3834
Install 3835
Front Marker/Turn Signal Lights 3836
Replacing Whole Front Marker/Turn Signal Light Assembly 3836
Remove 3836
Install 3836
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3837
Remove 3837
Install 3837
Diesel Particulate Filter (DPF) Display 3838
Remove 3838
Clean and Inspect 3839
Install 3839
Electronic-Hydraulic Controls – Generation 1 3840
E-Hydraulic Controls – Test 3840
Mini-Levers 3840
Full Stroke Test 3840
Function Returns to Neutral Test 3840
Push Button Switch 3840
General 3841
Mini-Lever Replacement 3841
Remove 3841
Clean and Inspect 3842
Install 3842
Push Button Switch Replacement 3843
Remove 3843
Install 3845
Mini-Lever Module (MLM) 3845
Remove 3845
Install 3845
Joystick 3846
Remove and Disassemble 3846
Inspect 3846
Assemble and Install 3846
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3847
General 3847
Mini-levers, Remove and Install 3847
Armrest Assembly 3848
Remove 3848
Install 3851
Horn Button 3851
Remove 3851
Install 3851
Direction Control Switch 3852
Remove 3852
Install 3852
push (override) buttons and Toggle Switch 3852
Remove 3853
Install 3854
Joystick 3855
Remove and Disassemble 3855
Inspect 3855
Assemble and Install 3855
Joystick Armrest Slider Assembly 3856
Remove 3856
Install 3857
Electronic-Hydraulic Controls, After January, 2020 3858
E-Hydraulic Controls – TEST 3858
Mini-Levers 3858
Full Stroke Test 3858
Function Returns to Neutral Test 3858
Push (Override) Button 3858
General 3859
Mini-levers, Remove and Install 3859
Armrest Assembly 3860
Remove 3860
Install 3863
Horn Button 3863
Remove 3863
Install 3863
Direction Control Switch 3863
Remove 3863
Install 3864
Push (Override) buttons and Toggle Switch 3864
Remove 3865
Install 3867
Special Tools 3868
524223779-8000YRM1152-(03-2020)-UK-EN 3871
General Information About Diagrams and Schematics 3875
Symbol Definitions 3875
Diagrams Manual Applications 3876
Diagrams and Schematics 3878
524223779-8000YRM1152-(06-2021)-US-EN 3941
General Information About Diagrams and Schematics 3945
Symbol Definitions 3945
Diagrams Manual Applications 3946
Diagrams and Schematics 3948
524223780-8000YRM1134-(03-2020)-UK-EN 4009
Series Code / Model Designation Reference Table 4015
Description 4017
Proc_Cal_001: Service Password Entry 4019
When to Perform 4019
Why Perform 4019
How to Perform 4019
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 4020
When to Perform 4020
Calibration Order 4020
Why Perform 4020
How to Perform 4021
Proc_Cal_003: Save and Exit 4022
When to Perform 4022
Why Perform 4022
How to Perform 4022
Proc_Cal_004: Lift Valve Output Threshold 4023
When to Perform 4023
Calibration Order 4023
Why Perform 4023
How to Perform 4024
Proc_Cal_005: Lower Valve Output Threshold 4026
When to Perform 4026
Calibration Order 4026
Why Perform 4026
How to Perform 4026
Proc_Cal_006: Tilt Back Valve Output Threshold 4029
When to Perform 4029
Calibration Order 4029
Why Perform 4029
How to Perform 4029
Proc_Cal_007: Tilt Forward Valve Output Threshold 4032
When to Perform 4032
Calibration Order 4032
Why Perform 4032
How to Perform 4032
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 4035
When to Perform 4035
Calibration Order 4035
Why Perform 4035
How to Perform 4035
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 4038
When to Perform 4038
Calibration Order 4038
Why Perform 4038
How to Perform 4038
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 4041
When to Perform 4041
Calibration Order 4041
Why Perform 4041
How to Perform 4041
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 4044
When to Perform 4044
Calibration Order 4044
Why Perform 4044
How to Perform 4044
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 4047
When to Perform 4047
Calibration Order 4047
Why Perform 4047
How to Perform 4047
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 4050
When to Perform 4050
Calibration Order 4050
Why Perform 4050
How to Perform 4050
Proc_Cal_014: Load Weight Zero Point 4054
When to Perform 4054
Calibration Order 4054
Why Perform 4054
How to Perform 4054
Proc_Cal_015: Loaded Weight Calibration 4056
When to Perform 4056
Calibration Order 4056
Why Perform 4056
How to Perform 4056
Proc_Cal_016: Transmission Valve Calibration 4059
Applicable System/Option 4059
When to Perform 4059
Calibration Order 4059
Why Perform 4059
How to Perform 4059
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 4061
Applicable System/Option 4061
When to Perform 4061
Calibration Order 4061
Why Perform 4061
How to Perform 4061
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 4063
Applicable System/Option 4063
When to Perform 4063
Calibration Order 4063
Why Perform 4063
How to Perform 4064
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 4065
Required Tools 4065
When to Perform 4065
Calibration Order 4065
Why Perform 4066
How to Perform 4066
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 4067
When to Perform 4067
Why Perform 4067
How to Perform 4067
Proc_Cal_026: Travel Speed Calibration 4069
When to Perform 4069
Calibration Order 4069
Why Perform 4069
How to Perform 4069
524223780-8000YRM1134-(05-2022)-US-EN 4073
Series Code / Model Designation Reference Table 4079
Description 4082
Proc_Cal_001: Service Password Entry 4084
When to Perform 4084
Why Perform 4084
How to Perform 4084
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 4085
When to Perform 4085
Calibration Order 4085
Why Perform 4085
How to Perform 4085
Proc_Cal_003: Save and Exit 4087
When to Perform 4087
Why Perform 4087
How to Perform 4087
Proc_Cal_004: Lift Valve Output Threshold 4088
When to Perform 4088
Calibration Order 4088
Why Perform 4088
How to Perform 4088
Proc_Cal_005: Lower Valve Output Threshold 4091
When to Perform 4091
Calibration Order 4091
Why Perform 4091
How to Perform 4091
Proc_Cal_006: Tilt Back Valve Output Threshold 4094
When to Perform 4094
Calibration Order 4094
Why Perform 4094
How to Perform 4094
Proc_Cal_007: Tilt Forward Valve Output Threshold 4097
When to Perform 4097
Calibration Order 4097
Why Perform 4097
How to Perform 4097
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 4100
When to Perform 4100
Calibration Order 4100
Why Perform 4100
How to Perform 4100
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 4103
When to Perform 4103
Calibration Order 4103
Why Perform 4103
How to Perform 4103
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 4106
When to Perform 4106
Calibration Order 4106
Why Perform 4106
How to Perform 4106
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 4109
When to Perform 4109
Calibration Order 4109
Why Perform 4109
How to Perform 4109
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 4112
When to Perform 4112
Calibration Order 4112
Why Perform 4112
How to Perform 4112
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 4115
When to Perform 4115
Calibration Order 4115
Why Perform 4115
How to Perform 4115
Proc_Cal_014: Load Weight Zero Point 4118
When to Perform 4118
Calibration Order 4118
Why Perform 4118
How to Perform 4118
Proc_Cal_015: Loaded Weight Calibration 4120
When to Perform 4120
Calibration Order 4120
Why Perform 4120
How to Perform 4120
Proc_Cal_016: Transmission Valve Calibration 4123
Applicable System/Option 4123
When to Perform 4123
Calibration Order 4123
Why Perform 4123
How to Perform 4123
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 4125
Applicable System/Option 4125
When to Perform 4125
Calibration Order 4125
Why Perform 4125
How to Perform 4125
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 4128
Applicable System/Option 4128
When to Perform 4128
Calibration Order 4128
Why Perform 4128
How to Perform 4128
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 4131
Required Tools 4131
When to Perform 4131
Calibration Order 4131
Why Perform 4131
How to Perform 4131
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 4133
When to Perform 4133
Why Perform 4133
How to Perform 4133
Proc_Cal_026: Travel Speed Calibration 4135
When to Perform 4135
Calibration Order 4135
Why Perform 4135
How to Perform 4135
524262274-0100YRM1243-(11-2016)-US-EN 4139
General 4143
Description 4144
Hood, Seat, and Side Covers Replacement 4146
Remove 4146
Install 4146
Steering Column 4153
Description 4154
Steering Column Repair 4154
Remove 4154
Disassemble 4156
Clean 4159
Inspect 4159
Assemble 4159
Install 4159
LPG Tank and Bracket Replacement 4160
Counterweight Replacement 4160
Remove 4160
Install 4163
Tow Pin 4167
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) 4167
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) 4167
Overhead Guard Replacement 4168
Remove 4168
Install 4169
LED Tail, Backup, and Brake Lights, Replace 4169
Operator Restraint System Replacement 4170
Description 4170
Engine Replacement 4171
Remove Engine Only 4171
Install Engine only 4198
Remove Engine and Transmission 4201
Install Engine and Transmission 4205
Electronic Throttle Replacement 4209
Cummins 4 5L Diesel Engine With Electronic Throttle 4209
Remove 4209
Install 4212
Pull Actuator Linkage Adjustment 4214
Low Idle Adjustment 4214
Throttle Pedal and Cable Adjustment 4215
Cummins 4 5L Diesel Engine with Basic Power Shift Transmission 4215
Kubota 3 6L Diesel Engine 4215
Exhaust System Repair 4218
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) 4218
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) 4218
Remove 4218
Inspect 4218
Install 4220
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) 4220
Remove 4220
Inspect 4222
Install 4222
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 4222
Remove 4222
Inspect 4224
Install 4224
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) 4224
Remove 4224
Inspect 4227
Diesel Particulate Filter 4229
Disassemble 4229
CLEAN AND INSPECT 4230
Assembly 4230
Install 4231
Cooling System 4232
Description 4232
Hydraulic Filter Assembly Repair 4233
Remove 4233
Disassemble 4233
Clean 4234
Inspect 4234
Assemble 4234
Install 4234
Fuel and Hydraulic Tanks Repair 4234
Inspect 4234
Clean 4235
Steam Method of Cleaning 4235
Chemical Solution Method of Cleaning 4236
Additional Preparations for Repair 4236
Small Leaks, Repair 4236
Large Leaks, Repair 4236
Preparations for Use After Repair 4236
Safety Labels 4236
524262275-0900YRM1242-(04-2018)-US-EN 4247
General 4253
Hoses Replacement 4253
LPG Tank and Bracket Replacement 4254
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) 4254
Remove 4254
Install 4257
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) 4258
Remove 4258
Install 4258
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) 4258
Remove 4258
Install 4260
LPG Tank, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 4261
Remove 4261
Install 4263
LPG Tank Bracket, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 4263
Remove 4263
Install 4263
High Pressure Fuel Filter Unit Repair 4263
Fuel Filter Element 4264
Remove 4264
Clean/Inspect 4265
Install 4265
Fuel Filter Housing 4265
Remove 4265
Disassemble 4266
Assemble 4266
Install 4266
Electronic Throttle Body Repair 4267
Remove 4267
Clean/Inspect 4268
Install 4268
Fuel Injector Repair 4269
Fuel Rail 4269
Remove for Lift Trucks Built Before January, 2010 4269
Remove for Lift Trucks Built After January, 2010 4271
Install for Lift Trucks Built Before January, 2010 4272
Install for Lift Trucks Built After January, 2010 4273
Fuel Injectors and Adapters 4273
Remove for Lift Trucks Built Before January, 2010 4273
Remove for Lift Trucks Built After January, 2010 4275
Clean 4276
Install for Lift Trucks Built Before January, 2010 4276
Install for Lift Trucks Built After January, 2010 4278
LPG Regulator Repair 4278
LPG Regulator 4278
Remove for Lift Trucks Built Before January, 2010 4278
Remove for Lift Trucks Built After January, 2010 4279
Install for Lift Trucks Built Before January, 2010 4281
Install for Lift Trucks Built After January, 2010 4281
LPG Regulator Fuel Filter 4282
Remove 4282
Install 4283
Lock-Off Solenoid and Cartridge 4283
Remove 4283
Install 4284
Control System 4284
Electronic Control Unit (ECU) and Injector Driver Modules Assembly 4284
Remove 4284
Install 4285
Electronic Control Unit (ECU) 4286
Remove 4286
Install 4286
Injector Driver Modules 4287
Remove 4287
Install 4287
Fuel Pressure Sensor 4288
Remove 4288
Install 4288
Low LPG Pressure Switch 4288
Remove 4288
Install 4289
LPG Pressure Sensor 4289
Remove 4289
Install 4290
Oxygen Sensor 4290
Exhaust System Repair 4291
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 4291
Remove for Lift Trucks Built Before January, 2010 4291
Remove for Lift Trucks Built After January, 2010 4293
Inspect 4295
Install for Lift Trucks Built Before January, 2010 4295
Install for Lift Trucks Built After January, 2010 4295
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) 4296
Remove for Lift Trucks Built Before January, 2010 4296
Remove for Lift Trucks Built After January, 2010 4298
Inspect 4301
Install for Lift Trucks Built Before January, 2010 4301
Install for Lift Trucks Built After January, 2010 4302
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 4303
Remove for Lift Trucks Built Before January, 2010 4303
Remove for Lift Trucks Built After January, 2010 4306
Inspect 4307
Install for Lift Trucks Built Before January, 2010 4308
Install for Lift Trucks Built After January, 2010 4308
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4309
Remove for Lift Trucks Built Before January, 2010 4309
Remove for Lift Trucks Built After January, 2010 4312
Inspect 4313
Install for Lift Trucks Built Before January, 2010 4314
Install for Lift Trucks Built After January, 2010 4314
Oxygen Sensor 4315
Remove 4315
Install 4316
LPG Fuel Testing 4316
General 4316
Available Fuel Tests 4316
Composition Test (ASTM D-2163) 4316
Ammonia Test (ASTM D-4490) 4317
Basic Nitrogen Test (ASTM UOP269-90) 4317
Residues Test (ASTM D-2158) 4317
Vapor Pressure Test (ASTM D-2598) 4317
Sulfur Compounds Test (ASTM D-5623) 4317
Methanol Test (ASTM D-4864) 4317
Copper Corrosion (ASTM D-1838) 4317
Where To Send LPG Fuel Samples For Testing 4317
524262276-0900YRM1244-(06-2012)-US-EN 4321
toc 4321
Gasoline Fuel System 4321
Safety Precautions Maintenance and Repair 4322
General 4325
Electronic Throttle Body Repair 4325
Electronic Throttle Body 4325
Remove 4325
Clean/Inspect 4325
Install 4326
Fuel System Repair 4327
Before Repair Procedure 4327
After Repair Procedure 4327
Fuel Leakage Check for Lift Trucks Built Before January, 2010 4327
Fuel Leakage Check for Lift Trucks Built After January, 2010 4328
Fuel Line Pressure Check 4330
Fuel Injector Repair 4331
Remove 4331
Install 4341
Control System 4342
Electronic Control Unit (ECU) 4342
Remove for Lift Trucks Built Before January, 2010 4342
Remove for Lift Trucks Built After January, 2010 4343
Install for Lift Trucks Built Before January, 2010 4344
Install for Lift Trucks Built After January, 2010 4345
Exhaust System Repair 4346
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; ( 4346
Remove for Lift Trucks Built Before January, 2010 4346
Remove for Lift Trucks Built After January, 2010 4348
Inspect 4348
Install for Lift Trucks Built Before January, 2010 4350
Install for Lift Trucks Built After January, 2010 4350
GM 4 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45 4351
Remove for Lift Trucks Built Before January, 2010 4351
Remove for Lift Trucks Built After January, 2010 4353
Inspect 4355
Install for Lift Trucks Built Before January, 2010 4355
Install for Lift Trucks Built After January, 2010 4356
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (G 4357
Remove for Lift Trucks Built Before January, 2010 4357
Remove for Lift Trucks Built After January, 2010 4359
Inspect 4361
Install for Lift Trucks Built Before January, 2010 4361
Install for Lift Trucks Built After January, 2010 4362
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (G 4362
Remove for Lift Trucks Built Before January, 2010 4362
Remove for Lift Trucks Built After January, 2010 4365
Inspect 4365
Install for Lift Trucks Built Before January, 2010 4367
Install for Lift Trucks Built After January, 2010 4367
Oxygen Sensor 4368
Remove 4368
Install 4368
524262277-1400YRM1245-(01-2012)-UK-EN 4371
toc 4371
Drive Axle and Differential Assembly Repair 4371
Safety Precautions Maintenance and Repair 4372
General 4375
Drive Axle Repair 4375
Remove and Disassemble 4375
Clean and Inspect 4378
Assemble and Install 4378
Differential Repair 4380
Remove 4380
Support Differential Assembly From Differential Housing Assembly 4380
Differential Assembly From Differential Assembly Support 4382
Differential Assembly Support from Drop Box 4385
Drive Pinion and Pinion Gear, From Differential Assembly Support 4387
Disassemble 4388
Differential Assembly 4388
Drop Box Housing 4390
Differential Assembly Support 4391
Differential Housing 4392
Clean and Inspect 4393
Assemble 4393
Differential Housing 4393
Differential Assembly Support 4394
Drop Box Housing 4395
Differential Assembly 4396
Install 4400
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 4400
Drive Pinion and Pinion Gear Into Differential Assembly Support 4402
Differential Assembly Into Differential Assembly Support 4404
Ring Gear Backlash, Adjust 4407
Gear Set, Tooth Contact Pattern Check 4408
Differential Assembly Support Into Differential Housing 4411
Torque Specifications 4412
tables 4371
Table 1 Pinion Variation Numbers Examples 4401
Table 2 Ring and Pinion Tooth Contact Adjustment 4409
Table 3 Correct Tooth Contact 4409
Table 4 Incorrect Tooth Contact 4410
524262277-1400YRM1245-(01-2012)-US-EN 4415
toc 4415
Drive Axle and Differential Assembly Repair 4415
Safety Precautions Maintenance and Repair 4416
General 4419
Drive Axle Repair 4419
Remove and Disassemble 4419
Clean and Inspect 4422
Assemble and Install 4422
Differential Repair 4424
Remove 4424
Support Differential Assembly From Differential Housing Assembly 4424
Differential Assembly From Differential Assembly Support 4426
Differential Assembly Support from Drop Box 4429
Drive Pinion and Pinion Gear, From Differential Assembly Support 4431
Disassemble 4432
Differential Assembly 4432
Drop Box Housing 4434
Differential Assembly Support 4435
Differential Housing 4436
Clean and Inspect 4437
Assemble 4437
Differential Housing 4437
Differential Assembly Support 4438
Drop Box Housing 4439
Differential Assembly 4440
Install 4444
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 4444
Drive Pinion and Pinion Gear Into Differential Assembly Support 4446
Differential Assembly Into Differential Assembly Support 4448
Ring Gear Backlash, Adjust 4451
Gear Set, Tooth Contact Pattern Check 4452
Differential Assembly Support Into Differential Housing 4455
Torque Specifications 4456
tables 4415
Table 1 Pinion Variation Numbers Examples 4445
Table 2 Ring and Pinion Tooth Contact Adjustment 4453
Table 3 Correct Tooth Contact 4453
Table 4 Incorrect Tooth Contact 4454
524262278-1400YRM1246-(02-2018)-US-EN 4459
General 4463
Identification Plate 4464
Drive Axle Removal 4464
Hub Seal Replacement 4476
Planetary Reduction Repair 4485
Clean and Inspect 4494
Brake Repair 4507
Clean and Inspect 4523
Wet Brake Noise Reduction 4539
General 4539
Adding Additive To Transmission 4540
Bevel Pinion 4541
Clean and Inspect 4546
Differential Unit 4558
Disassemble 4569
Clean and Inspect 4575
Assemble 4576
Drive Axle Installation 4599
Special Tools 4609
Torque Specifications 4609
524262279-1800YRM1247-(06-2021)-US-EN 4613
General 4617
Dry Brake System 4617
Wet Brake System 4617
Service Brakes Repair (Dry Brake) 4621
Remove and Disassemble 4621
Clean 4623
Inspect 4624
Assemble and Install 4625
Adjust 4628
Parking Brake Repair 4629
Dry Brake System 4629
Remove and Disassembly 4629
Assemble and Install 4631
Wet Brake System 4631
Remove and Install 4631
Assemble and Install 4638
Adjust 4638
Dry Brake System 4638
Wet Brake System 4639
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 4639
Master Cylinder Repair 4641
Remove 4641
Disassemble 4645
Clean and Inspect 4646
Assemble 4647
Install and Adjust 4647
Accumulator 4650
Pre-Charge Check 4650
Remove 4651
Install 4653
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 4654
Remove 4654
Modulating Brake Valve 4656
Disassemble 4656
Clean and Inspect 4657
Assemble 4657
Accumulator Charge Valve 4658
Disassemble 4658
Clean and Inspect 4660
Assemble 4660
Install 4661
Pressure Checks 4662
Accumulator Charge Valve Check 4662
Accumulator Check 4662
Service Brakes Adjustment (Dry Brake) 4663
Service Brakes Adjustment 4663
Brake System Air Removal 4665
Using Pressure Bleed System 4665
Using Brake Pedal Pressure 4665
Lift Truck Models with Master Cylinder 4665
Lift Truck Models with Modulating Brake Valve 4666
Brake Pedal Adjustment 4667
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) 4667
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4668
Free Pedal Adjustment 4670
Torque Specifications 4671
524262279-1800YRM1247-(09-2018)-UK-EN 4673
General 4677
Dry Brake System 4677
Wet Brake System 4678
Service Brakes Repair (Dry Brake) 4682
Remove and Disassemble 4682
Clean 4684
Inspect 4685
Assemble and Install 4685
Adjust 4689
Parking Brake Repair 4689
Dry Brake System 4690
Remove and Disassembly 4690
Assemble and Install 4692
Wet Brake System 4692
Remove and Install 4693
Assemble and Install 4699
Adjust 4699
Dry Brake System 4699
Wet Brake System 4700
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 4700
Master Cylinder Repair 4701
Remove 4701
Disassemble 4706
Clean and Inspect 4707
Assemble 4708
Install and Adjust 4708
Accumulator 4710
Pre-Charge Check 4711
Remove 4712
Install 4714
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 4714
Remove 4715
Modulating Brake Valve 4716
Disassemble 4716
Clean and Inspect 4718
Assemble 4718
Accumulator Charge Valve 4719
Disassemble 4719
Clean and Inspect 4721
Assemble 4721
Install 4722
Pressure Checks 4723
Accumulator Charge Valve Check 4723
Accumulator Check 4723
Service Brakes Adjustment (Dry Brake) 4724
Service Brakes Adjustment 4724
Brake System Air Removal 4725
Using Pressure Bleed System 4725
Using Brake Pedal Pressure 4726
Lift Truck Models with Master Cylinder 4726
Lift Truck Models with Modulating Brake Valve 4726
Brake Pedal Adjustment 4727
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) 4727
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4728
Free Pedal Adjustment 4730
Torque Specifications 4731
524262280-8000YRM1248-(12-2018)-US-EN 4735
General 4741
Serial Number Data 4741
How to Move Disabled Lift Truck 4742
How to Tow Lift Truck 4742
How to Put Lift Truck on Blocks 4744
How to Raise Drive Tires 4744
How to Raise Steering Tires 4744
How to Clean a Lift Truck 4745
Maintenance Schedule 4746
Maintenance Procedures Every 8 Hours or Daily 4766
How to Make Checks With Engine Stopped 4766
Tires and Wheels 4766
Safety Labels 4767
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4767
Operator Restraint System 4768
Emergency Locking Retractor (ELR) 4768
Adjust Seat – Full Suspension 4769
Adjust Seat – Internal Suspension 4770
Hood and Seat Latches 4771
Engine Compartment 4771
Paper Application 4771
Fuel, Oil, and Coolant Leaks, Check 4772
Hydraulic Hoses 4772
Coolant Hoses 4772
Steering Column Gas Cylinder 4772
Transmission 4773
Hydraulic System Oil 4773
Engine Oil 4773
Air Filter 4778
Forks 4778
Remove 4778
Inspect 4781
Install 4782
Adjust 4782
How to Make Checks With Engine Running 4782
Indicator Lights, Horn, Fuses, and Relays 4782
Service Brakes 4785
Brake Fluid Level 4785
Operation, Check 4785
Parking Brake 4786
Engine Oil Pressure 4786
Cooling System 4787
Steering System 4788
Control Levers and Pedals 4788
Lift System, Operate 4788
First Service After First 100 Hours of Operation 4788
GM 4 3L Engine Oil and Oil Filter 4788
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 4789
Maintenance Procedures Every 250 Hours or 6 Months 4789
GM 4 3L Engine Oil and Oil Filter 4789
Drive Belt 4790
GM 4 3L Engine 4790
Fan and Alternator Drive Belt 4790
Drain Tar From LPG Converter 4790
Drain Tar From LPG Regulator 4791
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine 4792
Maintenance Procedures Every 500 Hours or 6 Months 4794
Hydraulic System Oil 4794
Hydraulic Tank Breather 4795
Inspect 4795
Battery 4795
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 4796
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 4796
Remove 4796
Install 4796
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 4800
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 4801
Controlled Venting 4801
Manual Bleeding 4801
Drive Belt 4802
Cummins 4 5L and QSB 3 3L Diesel Engine 4802
Fan and Alternator Drive Belt 4802
Clean Debris From Radiator Core 4803
Transmission Oil Level 4803
Wet Brake Center Body Oil Level Check 4805
Forks 4806
Mast Lubrication 4806
Header Hose Checks 4810
Lift Chain Lubrication 4810
Tilt Cylinder Lubrication 4810
Master Brake Cylinder Rod End Pin Lubrication 4811
Manual Hydraulic Levers Lubrication 4812
Brake Oil 4812
Tie Rod Lubrication for Lift Truck Models GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS (E818) 4813
Tie Rod Lubrication for Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813) 4813
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes 4813
Parking Brake Adjustment 4814
Maintenance Procedures Every 1000 Hours or 6 Months 4815
Valve Clearance, Check and Adjust 4815
Ignition System 4815
GM 4 3L Engine 4815
LPG Fuel Filter Element Replace, GM 4 3L Engine 4815
Remove 4815
Install 4816
In-Line Filter Replacement, Cummins 4 5L Engine 4816
Remove 4816
Install 4817
Lift Chains Wear Check 4819
Lift Chain Lubrication 4819
Integral Sideshift Carriage, Check Sliding Surfaces 4819
Steering Axle (Spindle Bearings) for Lift Truck Models GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS (E818) 4821
Steering Axle (Spindle Bearings) for Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813) 4821
Control Levers and Pedals 4821
Parking Brake Lever Lubrication, Wet Brake Axle 4821
Normal Operating Environment 4822
Heavy Duty or Contaminated Environment 4823
Remove 4823
Clean and Inspect 4824
Install 4824
Inspect Engine Electrical System, Connectors 4825
Maintenance Procedures Every 2000 Hours or Annually 4825
Hydraulic System 4825
Hydraulic Filter, Replace 4825
Hydraulic Tank Breather, Replace 4826
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 4827
Cooling System 4827
Air Filter 4827
Oxygen Sensor GM 4 3L LPG Engines with GFI Installed 4829
LPG Regulator Fuel Filter, GM 4 3L Engines Equipped with GFI Installed 4830
Remove 4830
Install 4830
Gasoline Fuel Filter 4831
Remove and Replace for Lift Trucks Equipped with GFI 4831
Remove and Replace for Lift Trucks Equipped with PSI 4831
LPG Fuel Injector, GM 4 3L Engines With GFI Installed 4832
Gasoline Fuel Injector, GM Engines 4832
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 4832
Forks 4832
Transmission Oil and Filter (Dry Brake), Replace 4832
Transmission and Wet Brake Planetary Carrier Housing Oil Change 4834
Wet Brake Center Section Oil Change 4837
Remove 4837
Install 4837
Brake Oil (Master Cylinder), Change 4838
Brake Oil (Dry Brake), Remove 4839
Service Brakes (Dry Brake) 4839
Differential (Dry Brake) 4840
Test LPG/GAS Regulator Pressure 4841
Test LPG Regulator Pressure 4841
Check Throttle Shaft for Sticking 4841
Inspect Exhaust Manifold and Piping for Leaks 4841
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 4841
Wheel Bearings 4842
Steer Wheels, Lubrication 4842
Maintenance Procedures Every 4000 Hours or 2 Years 4842
Hydraulic Oil, Replace 4843
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 4844
Weld Inspection 4846
Safety Procedures When Working Near Mast 4849
Fuel Filter Water Removal 4851
Hood Latch Check 4851
Lift Chain Adjustments 4852
Jump-Starting the Lift Truck 4854
Jump-Starting Using a Battery Charger 4854
Jump-Starting a Lift Truck Using Another Lift Truck 4854
Welding Repairs 4855
Overhead Guard Changes 4855
Wheel and Tire Replacement 4855
General 4855
Solid Rubber Tire, Change (GC/GLC Series) 4855
Remove and Install Tire on Wheel 4856
Pneumatic Tire With Tube, Repair 4857
Remove Wheels From Lift Truck 4857
Remove Tire From Wheel 4857
Install Wheel in Tire 4860
Install Tire on Two-Piece Wheel 4862
Add Air to Pneumatic Tires With Tube 4863
Install the Wheels 4863
Dual Drive Wheels, Install 4864
Pneumatic Tubeless Tire, Repair 4865
Remove Wheels From Lift Truck 4865
Add Air to Pneumatic Tubeless Tire 4870
Wheels, Install 4870
Solid Rubber Tires on Pneumatic Wheels, Change 4870
Adhesives and Sealants 4874
524262281-8000YRM1249-(11-2017)-US-EN 4877
Lift Truck Lifting Capacity 4881
Counterweight Weights 4881
Tire Sizes 4882
Capacities 4882
Electrical System 4888
Transmission Oil Pressures 4890
Hydraulic System Relief Pressures 4893
Steering System 4894
Stall Speeds (in RPM ±100 rpm) 4894
GM 4 3L Gas 4895
GM 4 3L LPG 4895
Cummins 4 5L Diesel 4895
Cummins QSB 3 3L Diesel 4895
Mast Speeds 4895
Tilt Angles 4897
Front End Equipment – Mast Creep 4897
Mast Creep 4898
Engine Specifications 4898
Torque Specifications 4900
Frame 4901
Mast 4901
Steering System 4901
Steer Axle 4901
Drive Axle (Wet Brake) 4901
Drive Axle (Dry Brake) 4902
Transmission 4902
Engine – GM 4 3L 4903
Engine – Cummins 4 5L and QSB 3 3L Diesel 4904
524262298-8000YRM1248-(05-2019)-UK-EN 4907
General 4913
Serial Number Data 4913
How to Move Disabled Lift Truck 4914
How to Tow Lift Truck 4914
How to Put Lift Truck on Blocks 4915
How to Raise Drive Tires 4915
How to Raise Steering Tires 4916
How to Clean a Lift Truck 4917
Maintenance Schedule 4917
Maintenance Procedures Every 8 Hours or Daily 4932
How to Make Checks With Engine Stopped 4932
Tires and Wheels 4932
Safety Labels 4933
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4933
Operator Restraint System 4934
Emergency Locking Retractor (ELR) 4934
Adjust Seat – Full Suspension 4935
Adjust Seat – Internal Suspension 4936
Hood and Seat Latches 4936
Engine Compartment 4937
Paper Application 4937
Fuel, Oil, and Coolant Leaks, Check 4937
Hydraulic Hoses 4938
Coolant Hoses 4938
Steering Column Gas Cylinder 4938
Transmission 4938
Hydraulic System Oil 4938
Engine Oil 4938
Air Filter 4942
Forks 4942
Remove 4942
Inspect 4942
Install 4942
Adjust 4943
Integral Sideshift Carriage 4943
How to Make Checks With Engine Running 4944
Indicator Lights, Horn, Fuses, and Relays 4944
Service Brakes 4946
Brake Oil Level 4946
Operation, Check 4947
Parking Brake 4947
Engine Oil Pressure 4947
Cooling System 4947
Steering System 4948
Control Levers and Pedals 4948
Lift System, Operate 4948
First Service After First 100 Hours of Operation 4949
GM 4 3L Engine Oil and Oil Filter 4949
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 4950
Maintenance Procedures Every 500 Hours or 1 Year 4950
Hydraulic System Oil 4950
Hydraulic Tank Breather 4951
Inspect 4951
Battery 4951
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 4952
GM 4 3L Engine Oil and Oil Filter 4952
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 4952
Remove 4952
Install 4953
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 4955
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 4956
Controlled Venting 4956
Manual Bleeding 4956
Drain Tar From LPG Regulator 4957
Drain Tar From LPG Converter 4957
Drive Belt 4958
GM 4 3L Engine 4958
Fan and Alternator Drive Belt 4958
Cummins 4 5L and QSB 3 3L Diesel Engine 4958
Fan and Alternator Drive Belt 4958
Clean Debris From Radiator Core 4959
Transmission Oil Level 4960
Wet Brake Center Body Oil Level Check 4961
Forks 4963
Mast Lubrication 4963
Header Hose Checks 4966
Lift Chain Lubrication 4966
Tilt Cylinder Lubrication 4966
Master Brake Cylinder Rod End Pin Lubrication 4967
Manual Hydraulic Levers Lubrication 4968
Brake Oil 4968
Tie Rod Lubrication for Lift Truck Models GLC40, 45, 55VX; GLC55SVX (E818) 4969
Tie Rod Lubrication for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (F813, G813) 4969
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes 4969
Parking Brake Adjustment 4970
Maintenance Procedures Every 1000 Hours or 1 Year 4971
Valve Clearance, Check and Adjust 4971
Ignition System 4971
GM 4 3L Engine 4971
LPG Fuel Filter Element Replace, GM 4 3L Engine 4971
Remove 4971
Install 4972
In-Line Filter Replacement, Cummins 4 5L Engine 4973
Remove 4973
Install 4973
Lift Chains Wear Check 4975
Lift Chain Lubrication 4975
Integral Sideshift Carriage, Check Sliding Surfaces 4975
Steering Axle (Spindle Bearings) for Lift Truck Models GLC40, 45, 55VX; GLC55SVX (E818) 4976
Steering Axle (Spindle Bearings) for Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (F813, G813) 4976
Control Levers and Pedals 4977
Inspect Engine Electrical System, Connectors 4977
Maintenance Procedures Every 2000 Hours or Annually 4977
Hydraulic System 4977
Hydraulic Filter, Replace 4977
Hydraulic Tank Breather, Replace 4979
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 4979
Cooling System 4979
Air Filter 4980
Oxygen Sensor GM 4 3L LPG Engines with GFI Installed 4981
LPG Regulator Fuel Filter, GM 4 3L Engines With GFI Installed 4981
Remove 4981
Install 4982
LPG Fuel Injector, GM 4 3L Engines With GFI Installed 4982
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 4982
Forks 4982
Transmission Oil and Filter (Dry Brake), Replace 4983
Transmission and Wet Brake Planetary Carrier Housing Oil Change 4984
Wet Brake Center Section Oil Change 4986
Remove 4986
Install 4987
Brake Oil (Master Cylinder), Change 4988
Brake Oil (Dry Brake), Remove 4988
Service Brakes (Dry Brake) 4989
Differential (Dry Brake) 4989
Test LPG Regulator Pressure 4990
Check Throttle Shaft for Sticking 4990
Inspect Exhaust Manifold and Piping for Leaks 4990
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 4990
Wheel Bearings 4991
Steer Wheels, Lubrication 4991
Maintenance Procedures Every 4000 Hours or 2 Years 4991
Hydraulic Oil, Replace 4992
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 4993
Weld Inspection 4995
Safety Procedures When Working Near Mast 4998
Fuel Filter Water Removal 5000
Hood Latch Check 5000
Lift Chain Adjustments 5001
Jump-Starting the Lift Truck 5003
Jump-Starting Using a Battery Charger 5003
Jump-Starting a Lift Truck Using Another Lift Truck 5003
Welding Repairs 5004
Overhead Guard Changes 5004
Wheel and Tire Replacement 5004
General 5004
Solid Rubber Tire, Change ( Series)GLC 5004
Remove and Install Tire on Wheel 5005
Pneumatic Tire With Tube, Repair 5006
Remove Wheels From Lift Truck 5006
Remove Tire From Wheel 5006
Install Wheel in Tire 5009
Install Tire on Two-Piece Wheel 5011
Add Air to Pneumatic Tires With Tube 5012
Install the Wheels 5012
Dual Drive Wheels, Install 5012
Pneumatic Tubeless Tire, Repair 5014
Remove Wheels From Lift Truck 5014
Add Air to Pneumatic Tubeless Tire 5019
Wheels, Install 5019
Solid Rubber Tires On Pneumatic Wheels, Change 5019
Remove Tire From Wheel 5019
Install Tire on Wheel 5020
Snap-On-Tire, Change 5021
Adhesives and Sealants 5024
524265337-0600YRM1251-(09-2015)-US-EN 5027
General 5033
Engine Removal and Installation 5033
Cylinder Head Repair 5033
Remove and Disassemble 5033
Clean and Inspect 5035
Valve Oil Seals 5038
Remove and Disassemble 5038
Cylinder Leak Down Test 5038
Clean and Inspect 5039
Assemble and Install 5039
Valve Guides and Seats, Repairs 5041
Valves, Repair 5041
Valve Seats, Repair 5042
Valve Springs 5043
Assemble and Install 5044
Engine Block Cleaning and Inspection 5047
Clean and Inspect 5048
Piston Bore Preparation 5050
Engine Mounts Installation 5050
Remove 5050
Clean and Inspect 5051
Install 5051
Lubrication System Repair 5052
Oil Pump, Remove and Disassemble 5052
Clean and Inspect 5053
Oil Pump, Assemble and Install 5054
Oil Pan, Install 5056
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 5058
Timing Cover 5058
Remove 5058
Install 5060
Timing Sprockets 5060
Remove 5060
Install 5060
Camshaft 5060
Remove 5060
Inspect 5061
Install 5061
Balance Shaft 5062
Remove 5062
Install 5063
Valve Lifters 5064
Remove 5064
Clean and Inspect 5064
Install 5065
Crankshaft Repair 5065
Remove 5066
Inspect and Repair 5066
How to Check Clearance Between Main Bearings and Their Journals 5067
Install 5068
Piston and Connecting Rod Assemblies Repair 5070
Connecting Rod Bearings, Replace 5070
Piston and Connecting Rod Assemblies, Remove 5071
Disassemble 5071
Piston, Clean and Inspect 5072
Cylinder Bores, Inspect and Repair 5072
Piston Rings 5073
Assemble 5074
Piston and Connecting Rod Assemblies, Install 5074
Flywheel and Flywheel Housing Repair 5074
Flywheel, Remove 5075
Clean 5075
Inspect 5075
Flywheel, Install 5076
Coolant Pump Repair 5076
Remove 5076
Clean and Inspect 5077
Install 5077
Thermostat Replacement 5077
Remove 5078
Thermostat Operation Check 5078
Install 5078
Starter Replacement 5079
5079
Remove 5079
Install 5082
Fan Assembly Replacement 5083
Remove 5083
Inspect 5085
Install 5085
Drive Belt Installation 5086
Remove 5086
Clean 5086
Inspect 5086
Installation 5087
Compression Check 5088
Engine Specifications 5088
Engine Data 5088
Cylinder Head 5088
Hydraulic Valve Lifter 5089
Camshaft 5089
Pistons 5089
Crankshaft 5090
Connecting Rods 5090
Balance Shaft 5091
Cooling System 5091
Lubrication System 5091
Torque Specifications 5092
524265342-4000YRM1250-(06-2021)-US-EN 5097
Safety Procedures When Working Near Mast 5103
Fork Replacement 5106
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 5106
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 5107
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) 5109
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 5110
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 5111
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) 5112
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 5112
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) 5113
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 5114
Fixed Carriage Replacement 5116
Remove, Carriage With Hook Forks 5116
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5124
Install, Carriage With Hook Forks 5125
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5125
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 5126
Connecting Attachment Hydraulic Quick Disconnect Hoses 5126
Integral Sideshift Carriage Repair 5127
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) 5127
Disassemble 5127
Clean and Inspect 5130
Assemble 5130
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) 5131
Hang On Sideshift Carriage Repair 5132
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) 5132
Disassemble 5144
Clean and Inspect 5153
Assemble 5154
Install 5155
Hang-On Sideshift Carriage Repair 5157
Remove 5157
Disassemble Carriage 5159
Clean and Inspect 5162
Assemble 5162
Install 5165
Fork Positioner 5168
Two-Stage Mast With Limited Free-Lift Repair 5169
Remove 5169
Disassemble 5172
Clean and Inspect 5175
Assemble 5193
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) 5195
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) 5197
Header Hose Alignment 5208
Two-Stage Mast With Full Free-Lift Repair 5219
Remove 5219
Disassemble 5221
Clean and Inspect 5232
Assemble 5233
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) 5235
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) 5238
Header Hose Installation and Adjustment 5242
Installation 5242
Adjustment 5243
Three-Stage Mast With Full Free-Lift Repair 5244
Remove 5244
Disassemble 5246
Clean and Inspect 5276
Assemble 5278
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) 5281
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) 5286
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) 5293
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) 5300
Mast Operation Check 5304
Tilt Cylinder Adjustment 5305
Lift Chains Adjustment 5305
Mast Adjustments 5307
Load Roller Adjustment 5307
Mast Side Kicking Adjustment 5309
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 5310
Carriage Adjustments 5312
Series Code / Model Designation Reference Table 5313
524265342-4000YRM1250-(09-2018)-UK-EN 5317
Safety Procedures When Working Near Mast 5323
Fork Replacement 5325
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 5325
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 5327
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) 5328
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 5329
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 5330
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) 5331
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 5331
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) 5333
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 5333
Fixed Carriage Replacement 5335
Remove, Carriage With Hook Forks 5335
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5344
Install, Carriage With Hook Forks 5345
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5345
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 5346
Connecting Attachment Hydraulic Quick Disconnect Hoses 5346
Integral Sideshift Carriage Repair 5347
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) 5347
Disassemble 5347
Clean and Inspect 5350
Assemble 5350
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) 5351
Hang On Sideshift Carriage Repair 5351
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) 5351
Disassemble 5363
Clean and Inspect 5372
Assemble 5373
Install 5374
Bolzoni Hang-On Sideshift Carriage Repair 5376
Remove 5376
Disassemble Carriage 5378
Clean and Inspect 5381
Assemble 5381
Install 5384
Fork Positioner 5386
Two-Stage Mast With Limited Free-Lift Repair 5387
Remove 5387
Disassemble 5391
Clean and Inspect 5394
Assemble 5411
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) 5413
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) 5414
Header Hose Alignment 5426
Two-Stage Mast With Full Free-Lift Repair 5436
Remove 5436
Disassemble 5438
Clean and Inspect 5450
Assemble 5451
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) 5453
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) 5456
Header Hose Installation and Adjustment 5460
Installation 5460
Adjustment 5460
Three-Stage Mast With Full Free-Lift Repair 5461
Remove 5461
Disassemble 5463
Clean and Inspect 5493
Assemble 5494
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) 5498
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) 5503
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) 5510
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) 5516
Mast Operation Check 5520
Tilt Cylinder Adjustment 5520
Lift Chains Adjustment 5521
Mast Adjustments 5522
Load Roller Adjustment 5522
Mast Side Kicking Adjustment 5524
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 5525
Carriage Adjustments 5528
524329117-8000YRM1387-(03-2020)-UK-EN 5531
General Information About Diagrams and Schematics 5535
Symbol Definitions 5535
Diagrams Manual Applications 5536
Diagrams and Schematics 5538
524329117-8000YRM1387-(06-2021)-US-EN 5603
General Information About Diagrams and Schematics 5607
Symbol Definitions 5607
Diagrams Manual Applications 5608
Diagrams and Schematics 5610
550001092-8000YRM1409-(03-2020)-UK-EN 5673
General Information About Diagrams and Schematics 5677
Symbol Definitions 5677
Diagrams Manual Applications 5678
Diagrams and Schematics 5680
550001092-8000YRM1409-(06-2021)-US-EN 5761
General Information About Diagrams and Schematics 5765
Symbol Definitions 5765
Diagrams Manual Applications 5766
Diagrams and Schematics 5768
550043436-1300YRM1529-(11-2018)-US-EN 5843
General 5847
Serial Number 5847
Charge Pump Repair 5847
Lift Trucks Manufactured Before July, 2013 5847
Remove 5847
Inspect 5847
Install 5847
Lift Trucks Manufactured After July, 2013 5848
Remove 5848
Inspect 5848
Install 5848
Torque Converter Replace 5849
Remove 5849
Install 5858
Housings and Chain Drive Repair 5864
Remove 5864
Clean 5875
Inspect 5875
Install 5875
Clutch Packs Repair 5882
Remove and Disassemble 5882
Transmission, Remove and Disassemble 5882
Clean 5901
Inspect 5901
Assemble and Install 5902
Transmission, Assemble and Install 5910
Control Valve Repair 5914
Remove and Disassemble 5914
Clean 5918
Inspect 5918
Assemble and Install 5918
Foot Directional Control Pedal Repair 5919
Remove and Disassemble 5919
Assemble and Install 5923
Direction Control Lever 5924
Remove 5924
Install 5924
550043871-0900YRM1556-(04-2018)-US-EN 5929
General 5933
LPG Tank and Bracket 5933
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) 5933
Remove 5933
Install 5941
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) 5942
Remove 5942
Install 5944
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 5944
Remove 5944
Install 5946
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 5946
Remove 5946
Install 5946
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) 5947
Remove 5947
Install 5949
Fuel Filter Unit 5949
Fuel Filter Element 5950
Remove 5950
Clean and Inspect 5950
Install 5951
Fuel Filter Housing with LP Vapor Sensor 5951
Remove 5951
Disassemble 5953
Clean and Inspect 5954
Assemble 5954
Install 5955
Throttle Body 5956
Remove 5956
Clean 5960
Install 5960
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 5961
Remove 5961
Install 5962
Control System 5962
Engine Control Unit (ECU) 5963
Remove 5963
Install 5964
Low Pressure Switch 5964
Remove 5964
Install 5964
Low Fuel Sensor 5965
Remove 5965
Install 5965
LP Converter 5966
Remove and Disassemble 5966
Assemble and Install 5967
LPG Lock-Off 5967
Remove 5968
Install 5969
Exhaust System 5970
Counterweight Exhaust 5970
Remove and Disassemble 5970
Inspect 5972
Assemble and Install 5972
Overhead Exhaust 5973
Remove and Disassemble 5973
Inspect 5975
Assemble and Install 5975
Exhaust Manifold 5975
Remove 5975
Install 5977
Oxygen (HEGO) Sensor 5977
Remove 5977
Install 5977
LPG Fuel Testing 5978
General 5978
Available Fuel Tests 5978
Composition Test (ASTM D-2163) 5978
Ammonia Test (ASTM D-4490) 5978
Basic Nitrogen Test (ASTM UOP269-90) 5978
Residues Test (ASTM D-2158) 5978
Vapor Pressure Test (ASTM D-2598) 5978
Sulfur Compounds Test (ASTM D-5623) 5978
Methanol Test (ASTM D-4864) 5979
Copper Corrosion (ASTM D-1838) 5979
Where To Send LPG Fuel Samples For Testing 5979
550048401-0900YRM1570-(03-2015)-US-EN 5983
550055283-8000YRM1585-(06-2021)-US-EN 6013
General Information About Diagrams and Schematics 6017
Symbol Definitions 6017
Diagrams Manual Applications 6018
Diagrams and Schematics 6020
550055283-8000YRM1585-(07-2020)-UK-EN 6109
General Information About Diagrams and Schematics 6113
Symbol Definitions 6113
Diagrams Manual Applications 6114
Diagrams and Schematics 6116
550073240-1900YRM1620-(01-2023)-US-EN 6205
Proper Flushing after Major Hydraulic Repairs 6211
Introduction 6211
The Phases of Wear 6211
Causes of Hydraulic System Failure 6211
Progression of Contaminant Caused Hydraulic System Failure 6212
Hydraulic System Flushing Techniques 6212
Double Oil and Filter Change 6212
Mechanical Cleaning 6213
Cleaning of Components 6213
How to Clean Tubes and Hoses 6213
Filter Caddy 6213
Start-Up Procedure for Cleaned System 6214
Contaminated Oil Coolers 6214
Additional Filter Caddy Functions 6215
How to Handle Different Fluids 6215
Water Removal Filters 6215
Fluid Conditioning and System Flushing Procedures 6216
Operation of the Filter Caddy 6216
Filter Caddy operation 6216
Fluid Conditioning Procedure 6216
Filter Caddy Start-Up 6217
System Flushing Procedure 6217
Component Cleaning Procedure 6218
Reservoir Cleaning Procedure 6218
Cylinder Cleaning Procedure 6218
Hose and Tube Cleaning Procedure 6218
Valve Cleaning Procedure 6219
Front-End Attachment Cleaning Procedure 6220
System Flushing Procedure 6220
Filter Caddy Start-Up 6221
System Start-Up and Flushing 6221
Reservoir Fluid Cleaning Times 6222
Dealing With Different Fluid Types 6223
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 6223
Filter Caddy Maintenance 6223
Servicing the Strainer 6223
DC Motor 6223
Hydraulic Oil Sampling Method and Procedure 6224
Hydraulic Oil Sampling Method 6224
Objective 6224
General Guidelines 6224
Synopsis 6225
Hydraulic Oil Analysis Report Guidelines 6226
Sampling Conditions 6226
Equipment 6226
Sampling Procedure 6227
Hydraulic Oil Sampling 6227
Sample Labeling 6227
Results Documentation 6227
550073240-1900YRM1620-(03-2020)-UK-EN 6229
Proper Flushing after Major Hydraulic Repairs 6233
Introduction 6233
The Phases of Wear 6233
Causes of Hydraulic System Failure 6233
Progression of Contaminant Caused Hydraulic System Failure 6234
Hydraulic System Flushing Techniques 6234
Double Oil and Filter Change 6234
Mechanical Cleaning 6235
Cleaning of Components 6235
How to Clean Tubes and Hoses 6235
Filter Caddy 6235
Start-Up Procedure for Cleaned System 6236
Contaminated Oil Coolers 6236
Additional Filter Caddy Functions 6236
How to Handle Different Fluids 6236
Water Removal Filters 6237
Fluid Conditioning and System Flushing Procedures 6237
Operation of the Filter Caddy 6237
Filter Caddy operation 6237
Fluid Conditioning Procedure 6238
Filter Caddy Start-Up 6238
System Flushing Procedure 6239
Component Cleaning Procedure 6239
Reservoir Cleaning Procedure 6239
Cylinder Cleaning Procedure 6239
Hose and Tube Cleaning Procedure 6240
Valve Cleaning Procedure 6240
Front-End Attachment Cleaning Procedure 6241
System Flushing Procedure 6241
Filter Caddy Start-Up 6242
System Start-Up and Flushing 6242
Reservoir Fluid Cleaning Times 6243
Dealing With Different Fluid Types 6243
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 6243
Filter Caddy Maintenance 6244
Servicing the Strainer 6244
DC Motor 6244
Hydraulic Oil Sampling Method and Procedure 6244
Hydraulic Oil Sampling Method 6244
Objective 6244
General Guidelines 6244
Synopsis 6245
Hydraulic Oil Analysis Report Guidelines 6246
Sampling Conditions 6247
Equipment 6247
Sampling Procedure 6247
Hydraulic Oil Sampling 6247
Sample Labeling 6248
Results Documentation 6248

S.V 06/24