Yale Forklift E879 (GC_GLC_GDC135VX-155VX) Service Manual – PDF DOWNLOAD

Description

Yale Forklift E879 (GC_GLC_GDC135VX-155VX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift E879 (GC_GLC_GDC135VX-155VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 6050
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift E879 (GC_GLC_GDC135VX-155VX) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524208014-2200YRM1097-(03-2020)-US-EN 43
Series Code / Model Designation Reference Table 47
Description 48
Distributor Ignition (DI) System 48
Crankshaft Position (CKP) Sensor 48
Camshaft Position (CMP) Sensor 48
Ignition Coil and Ignition Control Module (ICM) 48
Secondary Ignition Components 48
Spark Plugs and Wires 49
Spark Plug Wire Inspection 49
Spark Plug Wire Replacement 49
Remove 49
Install 50
Spark Plug Inspection 50
Usage 50
Inspection 50
Visual Inspection 52
Spark Plug Replacement 52
Remove 52
Install 52
Distributor Repair 53
Inspect 53
Overhaul 53
Disassemble 53
Assemble 56
Replace 57
Remove 57
Install Procedure 1 59
Install Procedure 2 60
Ignition Coil Replacement 61
Remove 61
Install 61
Ignition Control Module Replacement 62
Remove 62
Install 62
Starter Replacement 63
Remove 63
Install 66
Sensors and Switches 67
Gas and LPG Trucks 67
Crankshaft Position (CKP) Sensor 67
Remove 67
Install 67
Camshaft Position (CMP) Sensor 68
Remove 68
Install 70
Oil Pressure Sensor 70
Remove 70
Install 71
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 72
Remove 72
Install 72
Engine Coolant Temperature (ECT) Sensor 73
Remove 73
Install 74
Air Flow Restriction Switch 74
Remove 74
Install 75
Specifications and Special Tools 76
524221866-9000YRM1112-(10-2020)-US-EN 81
SECTION 9010 Operational Diagnostic Procedures 97
Group 05 – Operational Checkout 99
SECTION 9020 Engine 117
Group 10 – Principles of Operation 127
Group 30 – Observed Symptoms 325
Group 40 – Tests and Adjustments 427
SECTION 9030 Electrical System 459
Group 03 – General Maintenance and Diagnostic Data 483
Group 10 – Principles of Operation 577
Group 20 – Diagnostic Trouble Codes 601
Group 30 – Observed Symptoms 1573
SECTION 9040 Drive Train 1629
Group 10 – Principles of Operation 1633
Group 30 – Observed Symptoms 1689
Group 40 – Tests and Adjustments 1739
SECTION 9050 Hydraulic Systems 1749
Group 10 – Principles of Operation 1753
Group 30 – Observed Symptoms 1811
Group 33 – Observed Symptoms-Gear Pump 1813
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1901
Group 40 – Tests and Adjustments 1945
Group 43 – Tests and Adjustments-Gear Pump 1947
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1971
SECTION 9060 Operators Station 1989
Group 10 – Principles of Operation 1991
SECTION 9070 Front End (Mast) and Chassis 2027
Group 10 – Principles of Operation 2029
Group 30 – Observed Symptoms 2051
SECTION 9080 Supplementary Data 2109
Group 50 – Abbreviations and Acronyms 2111
Group 60 – Special Tools List 2119
Group 70 – Fault Mode Indicator Reference 2129
Group 80 – Supplier Specification Data 2131
524223757-0700YRM1123-(06-2016)-US-EN 2135
General 2139
Cooling System Checks 2139
Exhaust Leaks Into Cooling System 2139
Water Flow Restrictions in Radiator 2139
Radiator Hoses 2139
Water Pump 2140
Flushing the Cooling System 2140
Cooling System, Clean 2140
Radiator Replacement 2141
Radiator, Remove GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2142
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2157
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2160
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 2163
Radiator, Install for Lift Truck Models GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2170
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2175
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2177
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2180
Fan Assembly Replacement 2192
Fan Removal 2192
Inspect 2207
Fan Installation 2207
524223757-0700YRM1123-(06-2021)-US-EN 2213
General 2217
Cooling System Checks 2217
Exhaust Leaks Into Cooling System 2217
Water Flow Restrictions in Radiator 2217
Radiator Hoses 2217
Water Pump 2217
Flushing the Cooling System 2219
Cooling System, Clean 2219
Radiator Replacement 2221
Radiator, Remove GC/GLC030VX,GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX (GP/GLP/GDP030VX,GP/GLP/GDP035VX, GP/GLP/GDP040SVX)(C810); GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910); GLC050LX(A967); GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875);GLP/GDP20-25LX (GLP/GDP050LX)(A974); GLC40, 45, 55VX, GLC55SVX,(GC/GLC080, 100, 120VX, GC/GLC080,100VXBCS, GC/GLC120SVX,GC/GLC120VXPRS) (E818, F818) ANDGLP/GDP40VX5/VX6, GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) 2221
Radiator, Remove for Lift Trucks Models Equipped with Oil CoolerGC/GLC030VX, GC/GLC035VX,GC/GLC040SVX (C809); GLP/GDP16VX,GLP/GDP18VX, GLP/GDP20SVX(GP/GLP/GDP030VX, GP/GLP/GDP035VX,GP/GLP/GDP040SVX) (C810); GLC050LX(A967) AND GLP/GDP20-25LX(GLP/GDP050LX) (A974) 2236
Radiator, Remove for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2239
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX(GP/GLP/GDP135VX, GP/GLP/GDP155VX)(C878, D878, E878) and GLP/GDP80VX,GLP/GDP80VX9, GLP/GDP90VX(GLP/GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (A909, B909) 2242
Radiator, Install for Lift Truck Models GC/GLC030VX,GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX (GP/GLP/GDP030VX,GP/GLP/GDP035VX, GP/GLP/GDP040SVX)(C810); GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910); GLC050LX(A967); GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875);GLP/GDP20-25LX (GLP/GDP050LX)(A974); GLC40, 45, 55VX; GLC55SVX;(GC/GLC080, 100, 120VX; GC/GLC080,100VXBCS; GC/GLC120SVX;GC/GLC120VXPRS) (E818, F818) andGLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) 2248
Radiator, Install for Lift Truck Models Equipped with Oil CoolerGC/GLC030VX, GC/GLC035VX,GC/GLC040SVX (C809); GLP/GDP16VX,GLP/GDP18VX, GLP/GDP20SVX(GP/GLP/GDP030VX, GP/GLP/GDP035VX,GP/GLP/GDP040SVX) (C810); GLC050LX(A967) and GLP/GDP20-25LX(GLP/GDP050LX) (A974) 2252
Radiator, Install for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2253
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2256
Fan Assembly Replacement 2267
Fan Removal 2267
Inspect 2281
Fan Installation 2282
524223764-1600YRM1133-(07-2013)-US-EN 2287
toc 2287
Steering Axle 2287
Safety Precautions Maintenance and Repair 2288
General 2291
Steering Axle Assembly Repair 2293
Remove 2293
Disassemble 2294
Clean 2302
Inspect 2302
Assemble 2302
Install 2308
Spindles, Bearings, and Tie Rods Repair 2310
Spindles and Bearings 2310
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2310
Remove 2310
Disassemble 2312
Clean 2313
Inspect 2313
Assemble 2313
Install 2314
Spindles and Bearings 2317
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2317
Remove and Disassemble 2317
Assemble and Install 2318
Tie Rods 2318
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2318
Remove 2318
Install 2319
Tie Rods 2320
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2320
Remove 2320
Install 2326
Steering Cylinder Repair 2326
Remove and Disassemble 2326
Clean and Inspect 2327
Assemble and Install 2327
Torque Specifications 2328
524223766-1900YRM1136-(01-2022)-US-EN 2333
General 2337
Hydraulic Gear Pump Assembly 2338
Variable Displacement Pump Assembly 2339
Single Gear Pump Assembly Repair 2340
Remove 2340
Disassemble 2346
Clean 2348
Inspect 2348
Assemble 2348
Install 2348
Tandem Gear Pump Assembly 2353
Remove 2353
Disassemble 2354
Clean 2357
Inspect 2357
Assemble 2357
Install 2358
Gear Pump Specifications 2359
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2365
Remove 2365
Disassemble 2375
Clean 2378
Inspect 2379
Assemble 2379
Install 2379
63 0 cc/rev – Variable Displacement Pump Repair 2384
Remove 2384
Disassemble 2387
Clean 2389
Inspect 2389
Assemble 2389
Install 2389
Variable Displacement Pump Checks and Adjustments (Single Pump) 2393
Margin Pressure Check 2393
Flow Compensator Adjustment 2394
Pressure Compensator Adjustment 2394
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2396
Variable Displacement Pump Specifications 2399
Torque Specifications 2401
Hydraulic Gear Pump 2401
Variable Displacement Pump 2402
Special Tools 2403
524223766-1900YRM1136-(11-2017)-US-EN 2405
General 2409
Hydraulic Gear Pump Assembly 2410
Variable Displacement Pump Assembly 2411
Single Gear Pump Assembly Repair 2411
Remove 2411
Disassemble 2418
Clean 2418
Inspect 2420
Assemble 2420
Install 2420
Tandem Gear Pump Assembly 2424
Remove 2425
Disassemble 2427
Clean 2429
Inspect 2429
Assemble 2429
Install 2430
Gear Pump Specifications 2430
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2436
Remove 2436
Disassemble 2446
Clean 2449
Inspect 2449
Assemble 2449
Install 2450
63 0 cc/rev – Variable Displacement Pump Repair 2453
Remove 2453
Disassemble 2456
Clean 2456
Inspect 2456
Assemble 2458
Install 2458
Variable Displacement Pump Checks and Adjustments (Single Pump) 2460
Margin Pressure Check 2460
Flow Compensator Adjustment 2461
Pressure Compensator Adjustment 2461
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2462
Variable Displacement Pump Specifications 2465
Torque Specifications 2466
Hydraulic Gear Pump 2467
Variable Displacement Pump 2468
Special Tools 2468
524223767-2000YRM1137-(01-2017)-US-EN 2473
General 2479
Electro-Hydraulic Main Control Valve 2480
Description 2480
Remove 2488
Electro-Hydraulic Control Valve Sections 2493
General 2493
Outlet Control Valve Section 2493
Remove 2493
Disassemble 2494
Clean 2496
Inspect 2496
Assemble 2496
Install 2497
Auxiliary Control Valve Sections 2497
Remove 2497
Disassemble 2504
Clean 2505
Inspect 2506
Assemble 2506
Install 2508
Tilt Control Valve Section 2509
Remove 2509
Disassemble 2509
Clean 2515
Inspect 2515
Assemble 2515
Install 2516
Lift/Lower Control Valve Section 2517
Remove 2517
Disassemble 2517
Clean 2526
Inspect 2526
Assemble 2526
Install 2527
Mid-Inlet Section 2527
Remove 2527
Clean 2528
Inspect 2528
Install 2528
Install 2528
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2533
Lift Pilot Pin 2533
Lower Pilot Pin 2537
Abnormal/Erroneous EHPV Adjustment 2539
Manual Main Control Valve 2540
Description 2540
Remove 2544
OPS Solenoid Assembly 2552
General 2552
Remove 2553
Clean and Inspect 2556
Install 2556
Manual Control Valve Sections 2557
General 2557
Outlet Control Valve Section 2557
Remove 2557
Disassemble 2557
Clean 2560
Inspect 2560
Assemble 2560
Install 2561
Auxiliary Control Valve Sections 2561
Remove 2561
Disassemble 2561
Clean 2564
Inspect 2564
Assemble 2564
Install 2565
Lift/Tilt Control Valve Section 2565
Remove 2565
Disassemble 2565
Clean 2572
Inspect 2572
Assemble 2573
Install 2574
Mid-Inlet Section 2575
Remove 2575
Clean 2575
Inspect 2575
Install 2575
Install 2576
Pressure Relief Valve Check and Adjustment 2582
Primary Relief Valve 2583
Secondary Relief Valve 2587
Steering Control Unit Repair 2594
Steering Control Unit, Remove 2594
Steering Control Unit, Disassemble 2598
Steering Control Unit, Clean 2600
Steering Control Unit, Inspect 2600
Steering Control Unit, Assemble 2600
Relief Valve, Disassemble 2601
Relief Valve, Clean 2601
Relief Valve, Inspect 2602
Relief Valve, Assemble 2602
Steering Control Unit, Install 2602
524223767-2000YRM1137-(06-2021)-US-EN 2607
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 2625
Clean 2628
Inspect 2628
Assemble 2629
Install 2629
Auxiliary Control Valve Sections 2629
Remove 2630
Disassemble 2635
Clean 2637
Inspect 2637
Assemble 2637
Install 2639
Tilt Control Valve Section 2640
Remove 2640
Disassemble 2641
Clean 2645
Inspect 2645
Assemble 2646
Install 2647
Lift/Lower Control Valve Section 2647
Remove 2647
Disassemble 2647
Clean 2653
Inspect 2653
Assemble 2653
Install 2654
Mid-Inlet Section 2654
Remove 2654
Clean 2655
Inspect 2655
Install 2655
Install 2655
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2660
Lift Pilot Pin 2660
Lower Pilot Pin 2663
Abnormal/Erroneous EHPV Adjustment 2665
Manual Main Control Valve 2666
Description 2666
Remove 2670
OPS Solenoid Assembly 2678
General 2678
Remove 2679
Clean and Inspect 2681
Install 2681
Manual Control Valve Sections 2682
General 2682
Outlet Control Valve Section 2682
Remove 2682
Disassemble 2682
Clean 2685
Inspect 2685
Assemble 2685
Install 2685
Auxiliary Control Valve Sections 2686
Remove 2686
Disassemble 2686
Clean 2689
Inspect 2689
Assemble 2689
Install 2689
Lift/Tilt Control Valve Section 2690
Remove 2690
Disassemble 2690
Clean 2696
Inspect 2696
Assemble 2696
Install 2698
Mid-Inlet Section 2698
Remove 2698
Clean 2699
Inspect 2699
Install 2699
Install 2699
Pressure Relief Valve Check and Adjustment 2707
Primary Relief Valve 2707
Secondary Relief Valve 2710
Steering Control Unit Repair 2715
Steering Control Unit, Remove 2715
Steering Control Unit, Disassemble 2719
Steering Control Unit, Clean 2721
Steering Control Unit, Inspect 2721
Steering Control Unit, Assemble 2721
Relief Valve, Disassemble 2722
Relief Valve, Clean 2722
Relief Valve, Inspect 2723
Relief Valve, Assemble 2723
Steering Control Unit, Install 2723
524223769-2200YRM1128-(01-2023)-US-EN 2727
Series Code / Model Designation Reference Table 2735
General 2737
Deutsch Crimping Tool 2738
How to Strip a Wire for Use With Deutsch Crimping Tool 2738
How to Crimp With the Deutsch Crimping Tool 2739
Calibration Test for the Deutsch Crimping Tool 2741
Deutsch Connectors 2743
DT, DTM, and DTP Series Connectors 2743
HD Series Connectors 2786
Metri-Pack Connectors 2808
Remove and Install 2808
Micro-Pack Connectors 2811
Weather-Pack Connectors 2812
AMPSEAL Crimping Tools 2814
AMP Hand Crimping Tool With Certi-Crimp 2814
Description 2814
Stripping Wire for Use with AMP Hand Crimping Tool 2815
Insulation Crimp Adjustment 2816
Maintenance and Inspection for AMP Hand Crimping Tool 2816
AMP Hand Crimping Tool 2816
Crimp Height Inspection 2816
How to use AMP Hand Crimping Tool 2817
AMP Pro-Crimper II Tool 2817
Description 2817
Remove and Install Die Set and Locator Assembly 2818
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2818
Contact Support Adjustment 2819
Crimp Height Adjustment 2820
Maintenance and Inspection Procedures 2820
PRO-CRIMPER II Tool 2820
Crimp Height Inspection 2820
How to Use AMP PRO-CRIMPER II Tool 2821
AMPSEAL Connector Assemblies 2822
Description for Plug Connector Assembly 2822
Seal Plug 2823
Contact Crimping 2823
Description for Plug Connector and Header Assembly 2828
Voltage Reading 2831
Seal Plug 2831
Contact Crimping 2831
AMP Superseal 1 5 Crimping Tools 2838
Mini Mic Receptacle and Tab Contacts 2838
Description 2838
Crimping Conditions and Measurements 2838
Insertion of Rubber Seal on Cable 2840
AMP Hand Application Tool 2845
Description 2845
Maintenance and Inspection 2845
Crimp Height Inspection 2845
Crimp Height Adjustment 2846
How to Use AMP Hand Application Tool 2846
AMP Pro-Crimper II Tool 2847
Description 2847
Remove and Install Die Set and Locator Assembly 2847
Adjustments 2848
Contact Support 2848
Crimp Height 2849
Inspections and Maintenance 2850
Crimp Height Inspection 2850
Visual Inspection 2850
Maintenance 2851
How to Use Pro-Crimper II Tool 2851
AMP Superseal 1 5 Connector Assemblies 2852
Description 2852
Repair and Maintenance 2859
Panel Mount Option 2859
AMP Fastin-Faston Hand Tools 2860
Description – AMP Double Action Hand Tool 2860
Maintenance and Inspection Procedures 2860
Daily Maintenance 2860
Periodic Tool Inspection 2861
Lubrication 2861
Visual Inspection 2861
Crimp Height Inspection 2861
Certi-Crimp Ratchet Inspection 2862
How to Use AMP Double Action Hand Tool 2863
Description – AMP Extraction Tool 2864
Maintenance and Inspection 2865
How to Use AMP Extraction Tool 2865
AMP Fastin-Faston Receptacles and Housings 2867
Description 2867
Wire Repair 2875
Wire Splicing Requirements 2875
Deutsch Jiffy Splice 2876
Twisted/Shielded Cable and Leads Repair 2882
Special Tools 2884
524223769-2200YRM1128-(07-2020)-US-EN 2893
Series Code / Model Designation Reference Table 2899
General 2902
Deutsch Crimping Tool 2902
How to Strip a Wire for Use With Deutsch Crimping Tool 2902
How to Crimp With the Deutsch Crimping Tool 2903
Calibration Test for the Deutsch Crimping Tool 2905
Deutsch Connectors 2907
DT, DTM, and DTP Series Connectors 2907
HD Series Connectors 2949
Metri-Pack Connectors 2972
Remove and Install 2972
Micro-Pack Connectors 2974
Weather-Pack Connectors 2975
AMPSEAL Crimping Tools 2977
AMP Hand Crimping Tool With Certi-Crimp 2977
Description 2977
Stripping Wire for Use with AMP Hand Crimping Tool 2977
Insulation Crimp Adjustment 2978
Maintenance and Inspection for AMP Hand Crimping Tool 2978
AMP Hand Crimping Tool 2978
Crimp Height Inspection 2978
How to use AMP Hand Crimping Tool 2979
AMP Pro-Crimper II Tool 2979
Description 2979
Remove and Install Die Set and Locator Assembly 2980
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2981
Contact Support Adjustment 2981
Crimp Height Adjustment 2982
Maintenance and Inspection Procedures 2982
PRO-CRIMPER II Tool 2982
Crimp Height Inspection 2982
How to Use AMP PRO-CRIMPER II Tool 2983
AMPSEAL Connector Assemblies 2984
Description for Plug Connector Assembly 2984
Seal Plug 2985
Contact Crimping 2985
Description for Plug Connector and Header Assembly 2990
Voltage Reading 2992
Seal Plug 2992
Contact Crimping 2992
AMP Superseal 1 5 Crimping Tools 2999
Mini Mic Receptacle and Tab Contacts 2999
Description 2999
Crimping Conditions and Measurements 2999
Insertion of Rubber Seal on Cable 3001
AMP Hand Application Tool 3006
Description 3006
Maintenance and Inspection 3006
Crimp Height Inspection 3006
Crimp Height Adjustment 3007
How to Use AMP Hand Application Tool 3007
AMP Pro-Crimper II Tool 3008
Description 3008
Remove and Install Die Set and Locator Assembly 3009
Adjustments 3009
Contact Support 3009
Crimp Height 3010
Inspections and Maintenance 3011
Crimp Height Inspection 3011
Visual Inspection 3011
Maintenance 3012
How to Use Pro-Crimper II Tool 3012
AMP Superseal 1 5 Connector Assemblies 3013
Description 3013
Repair and Maintenance 3020
Panel Mount Option 3020
AMP Fastin-Faston Hand Tools 3021
Description – AMP Double Action Hand Tool 3021
Maintenance and Inspection Procedures 3021
Daily Maintenance 3021
Periodic Tool Inspection 3022
Lubrication 3022
Visual Inspection 3022
Crimp Height Inspection 3022
Certi-Crimp Ratchet Inspection 3023
How to Use AMP Double Action Hand Tool 3024
Description – AMP Extraction Tool 3025
Maintenance and Inspection 3025
How to Use AMP Extraction Tool 3026
AMP Fastin-Faston Receptacles and Housings 3027
Description 3027
Wire Repair 3034
Wire Splicing Requirements 3034
Deutsch Jiffy Splice 3035
Twisted/Shielded Cable and Leads Repair 3040
Special Tools 3043
524223770-2200YRM1130-(03-2020)-US-EN 3051
General 3055
Description 3055
Dash Display Menu Access 3055
Menu Navigation 3056
Standard Display 3056
Main Menu 3056
Passwords Menu 3057
Password Administration 3057
Add Password 3057
Delete Password 3058
Edit Password 3058
Other Password Functions 3059
Operator Passwords – Enable/Disable 3059
Password Time-Out Delay 3059
Passwords – Number Wrong to Disable 3060
Lockout Reset Password 3060
View Password Log 3061
View Versions 3062
VSM Versions 3062
Dash Display Versions 3063
Engine Controller Version 3064
Transmission (Xmsn) Controller Version 3065
Truck Serial Number 3066
Diagnostics 3067
View Fault Log 3067
Set Travel and Braking 3068
Speed Limit 3068
Acceleration Rate 3069
Auto-Deceleration Rate 3069
Set Power Reversal Rate 3070
Set Inching/Brake Overlap 3071
Setup Display Menu 3072
Set Operator Language 3072
Set Units 3073
Set Time Format (12/24 Hour) 3073
Set Daylight Saving Time 3073
Set Time 3076
Set Date Format 3077
Set Date 3077
Setup Hydraulics 3078
Return to Set Tilt Delay/On/Off 3078
Setup General Items 3079
Light Shutdown Time-Out 3079
Impact Sensor – Enable/Disable 3080
Impact Sensor – Soft Impact Settings 3081
Impact Sensor – Hard Impact Settings 3082
Adjust Impact Sensor Settings 3082
Initial Adjustment of Soft and Hard Impact Settings 3084
Readjustment of Soft and Hard Impact Settings 3084
Impact Sensor – Impact Alarm/Shutdown Reset 3085
Impact Sensor – Alarm Time Duration and Deactivation 3086
Impact Sensor – View Impact Event Log 3087
Engine Mode Indicator 3088
Generation 1 (ECO-eLo ONLY) 3088
Generation 2 3089
Operator Checklist 3090
Operator Checklist Off-On Mode 3090
Edit Operator Checklist 3090
Set Operator Checklist Expiration 3091
View Checklist Log 3091
Clear Operator Checklist Log 3092
Clear Operator Checklist Fault 3092
Calibrations 3093
Set Tilt Stop Point 3093
Calibrate Loaded Weight 3093
524223770-2200YRM1130-(05-2021)-US-EN 3095
General 3099
Description 3099
Dash Display Menu Access 3099
Menu Navigation 3100
Standard Display 3100
Main Menu 3100
Passwords Menu 3101
Password Administration 3101
Add Password 3101
Delete Password 3101
Edit Password 3102
Other Password Functions 3103
Operator Passwords – Enable/Disable 3103
Password Time-Out Delay 3103
Passwords – Number Wrong to Disable 3103
Lockout Reset Password 3104
View Password Log 3104
View Versions 3105
VSM Versions 3105
Dash Display Versions 3106
Engine Controller Version 3107
Transmission (Xmsn) Controller Version 3108
Truck Serial Number 3109
Diagnostics 3110
View Fault Log 3110
Set Travel and Braking 3111
Speed Limit 3111
Acceleration Rate 3112
Auto-Deceleration Rate 3112
Set Power Reversal Rate 3113
Set Inching/Brake Overlap 3114
Setup Display Menu 3115
Set Operator Language 3115
Set Units 3116
Set Time Format (12/24 Hour) 3116
Set Daylight Saving Time 3117
Set Time 3120
Set Date Format 3120
Set Date 3121
Setup Hydraulics 3122
Return to Set Tilt Delay/On/Off 3122
Setup General Items 3123
Light Shutdown Time-Out 3123
Impact Sensor – Enable/Disable 3124
Impact Sensor – Soft Impact Settings 3125
Impact Sensor – Hard Impact Settings 3125
Adjust Impact Sensor Settings 3126
Initial Adjustment of Soft and Hard Impact Settings 3128
Readjustment of Soft and Hard Impact Settings 3128
Impact Sensor – Impact Alarm/Shutdown Reset 3129
Impact Sensor – Alarm Time Duration and Deactivation 3130
Impact Sensor – View Impact Event Log 3131
Engine Mode Indicator 3131
Generation 1 (ECO-eLo ONLY) 3131
Generation 2 3132
Operator Checklist 3133
Operator Checklist Off-On Mode 3133
Edit Operator Checklist 3133
Set Operator Checklist Expiration 3133
View Checklist Log 3134
Clear Operator Checklist Log 3135
Clear Operator Checklist Fault 3135
Calibrations 3136
Set Tilt Stop Point 3136
Calibrate Loaded Weight 3136
524223771-2200YRM1131-(03-2020)-US-EN 3139
Series Code / Model Designation Reference Table 3145
General 3147
Description 3147
Dash Display Menu Access 3147
Menu Navigation 3148
Main Menu 3148
Passwords 3149
Adding Passwords 3149
Hourmeters 3151
View Versions 3152
VSM Versions 3152
Dash Display Versions 3153
Engine Controller Version 3154
Transmission (Xmsn) Controller Version 3155
Truck Serial Number 3156
Truck Configuration 3157
Diagnostics 3158
Clear Fault Log 3158
View Fault Log 3159
No-Run Data Display 3160
Engine Accelerator and Throttle Data Display 3160
Engine Speeds and Governor Data Display 3161
Engine Fuel and Emissions Data Display 3162
Engine General Data Display 3164
XMSN/Brake Data Display 3165
Hydraulic Data Display 3168
General Truck Data Display 3170
Set Travel and Braking 3171
Speed Limit 3171
Acceleration Rate 3172
Auto-Deceleration Rate 3173
Set Power Reversal Rate 3173
Set Inching/Brake Overlap 3174
Setup Hydraulics 3174
Lift Maximum Speed 3175
Lower Maximum Speed 3175
Tilt Maximum Speed 3176
Auxiliary Function One, Direction A, Maximum Speed 3178
Auxiliary Function One, Direction B, Maximum Speed 3180
Auxiliary Function Two, Direction A, Maximum Speed 3180
Auxiliary Function Two, Direction B, Maximum Speed 3181
Auxiliary Function Three, Direction A, Maximum Speed 3182
Auxiliary Function Three, Direction B, Maximum Speed 3182
Lift/Lower Ramp Rate 3183
Hydraulic Auxiliary Ramp Rate 3183
Return to Set Tilt Delay/On/Off 3184
Hydraulic Input Device 3185
Auxiliary Solenoid 3185
Dual Function 3186
Setup Display 3187
Set Service Language 3187
Setup General Items 3187
Motion Alarm Activation Type 3188
Light Shutdown Time-Out 3189
Restore Default Settings 3189
Restore Engine Controller Default Calibration 3190
Impact Sensor – Enable/Disable 3190
Impact Sensor – Soft Impact Settings 3191
Impact Sensor – Hard Impact Settings 3192
Adjust Impact Sensor Settings 3193
Initial Adjustment of Soft and Hard Impact Settings 3195
Readjustment of Soft and Hard Impact Settings 3195
Impact Sensor – Impact Alarm/Shutdown Reset 3196
Impact Sensor – Alarm Time Duration and Deactivation 3197
Impact Sensor – View Impact Event Log 3198
Engine Mode Indicator 3198
Generation 1 (ECO-eLo ONLY) 3198
Generation 2 3199
Diesel Particulate Filter (DPF) Display 3200
General Description 3200
Passive Regeneration Only 3200
Regeneration Level 0 3200
Auto/Active Regeneration Inhibited 3201
Auto/Active Regeneration 3201
Regeneration Level 1 3201
Parked Regeneration Request 3202
Regeneration Level 2 3202
Warning Level 3202
Regeneration Level 3 3202
Service Level 3203
Regeneration Level 4 3203
Display, Diesel Particulate Filter (DPF), Revised 3203
Operator Interface 3203
Refer to Operator Manual 3203
CAN Communication Lost 3204
Passive Regeneration Only 3204
Regeneration Level 0 3204
Auto/Active Regeneration Inhibited 3204
Auto/Active Regeneration 3205
Regeneration Level 1 3205
Idle-up Auto/Active Regeneration 3205
Parked Regeneration Request 3205
Regeneration Level 2 3205
Warning Level 3207
Regeneration Level 3 3207
Service Level 3207
Regeneration Level 4 3207
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3207
Display, Diesel Particulate Filter (DPF), Stage V Engine 3207
Operator Interface 3208
Refer to Operator Manual 3208
CAN Communication Lost 3208
Passive Regeneration Only 3208
Regeneration Level 0 3208
Auto/Active Regeneration Inhibited 3209
Auto/Active Regeneration 3209
Regeneration Level 1 3209
Idle-up Auto/Active Regeneration 3210
Parked Regeneration Request 3210
Regeneration Level 2 3210
Warning Level 3211
Regeneration Level 3 3211
Service Level 3212
Regeneration Level 4 3212
Stage V Content 3212
Emissions System Malfunction 3212
Ash Load 3212
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3213
Operator Interface 3213
Refer to Operator Manual 3213
CAN Communication Lost 3214
Passive Regeneration Only 3214
Regeneration Level 0 3214
Auto/Active Regeneration Inhibited 3214
Auto/Active Regeneration 3215
Regeneration Level 1 3215
Idle-up Auto/Active Regeneration 3215
Parked Regeneration Request 3215
Regeneration Level 2 3215
Warning Level 3217
Regeneration Level 3 3217
Service Level 3217
Regeneration Level 4 3217
Calibrations 3218
Calibrate Transmission Valve 3220
Set Tilt Stop Point 3220
Calibrate Loaded Weight 3220
Calibrate Travel Speed Sensor 3221
Calibrate Mazda LP and Gas Accelerator Pedal 3221
524223771-2200YRM1131-(05-2021)-US-EN 3223
Series Code / Model Designation Reference Table 3229
General 3231
Description 3231
Dash Display Menu Access 3231
Menu Navigation 3232
Main Menu 3233
Passwords 3233
Adding Passwords 3233
Hourmeters 3235
View Versions 3236
VSM Versions 3236
Dash Display Versions 3237
Engine Controller Version 3238
Transmission (Xmsn) Controller Version 3239
Truck Serial Number 3240
Truck Configuration 3241
Diagnostics 3242
Clear Fault Log 3242
View Fault Log 3243
No-Run Data Display 3244
Engine Accelerator and Throttle Data Display 3245
Engine Speeds and Governor Data Display 3247
Engine Fuel and Emissions Data Display 3248
Engine General Data Display 3250
XMSN/Brake Data Display 3251
Hydraulic Data Display 3253
General Truck Data Display 3256
Set Travel and Braking 3258
Speed Limit 3258
Acceleration Rate 3259
Auto-Deceleration Rate 3259
Set Power Reversal Rate 3260
Set Inching/Brake Overlap 3260
Setup Hydraulics 3261
Lift Maximum Speed 3261
Lower Maximum Speed 3262
Tilt Maximum Speed 3262
Auxiliary Function One, Direction A, Maximum Speed 3264
Auxiliary Function One, Direction B, Maximum Speed 3267
Auxiliary Function Two, Direction A, Maximum Speed 3267
Auxiliary Function Two, Direction B, Maximum Speed 3268
Auxiliary Function Three, Direction A, Maximum Speed 3269
Auxiliary Function Three, Direction B, Maximum Speed 3269
Lift/Lower Ramp Rate 3270
Hydraulic Auxiliary Ramp Rate 3270
Return to Set Tilt Delay/On/Off 3271
Hydraulic Input Device 3272
Auxiliary Solenoid 3272
Dual Function 3273
Setup Display 3274
Set Service Language 3274
Setup General Items 3274
Motion Alarm Activation Type 3275
Light Shutdown Time-Out 3276
Restore Default Settings 3276
Restore Engine Controller Default Calibration 3277
Impact Sensor – Enable/Disable 3277
Impact Sensor – Soft Impact Settings 3278
Impact Sensor – Hard Impact Settings 3278
Adjust Impact Sensor Settings 3279
Initial Adjustment of Soft and Hard Impact Settings 3281
Readjustment of Soft and Hard Impact Settings 3281
Impact Sensor – Impact Alarm/Shutdown Reset 3282
Impact Sensor – Alarm Time Duration and Deactivation 3283
Impact Sensor – View Impact Event Log 3284
Engine Mode Indicator 3284
Generation 1 (ECO-eLo ONLY) 3284
Generation 2 3285
Diesel Particulate Filter (DPF) Display 3286
General Description 3286
Passive Regeneration Only 3286
Regeneration Level 0 3286
Auto/Active Regeneration Inhibited 3287
Auto/Active Regeneration 3287
Regeneration Level 1 3287
Parked Regeneration Request 3288
Regeneration Level 2 3288
Warning Level 3289
Regeneration Level 3 3289
Service Level 3289
Regeneration Level 4 3289
Display, Diesel Particulate Filter (DPF), Revised 3289
Operator Interface 3290
Refer to Operator Manual 3290
CAN Communication Lost 3290
Passive Regeneration Only 3290
Regeneration Level 0 3290
Auto/Active Regeneration Inhibited 3291
Auto/Active Regeneration 3291
Regeneration Level 1 3291
Idle-up Auto/Active Regeneration 3291
Parked Regeneration Request 3292
Regeneration Level 2 3292
Warning Level 3293
Regeneration Level 3 3293
Service Level 3293
Regeneration Level 4 3293
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3294
Display, Diesel Particulate Filter (DPF), Stage V Engine 3294
Operator Interface 3294
Refer to Operator Manual 3294
CAN Communication Lost 3295
Passive Regeneration Only 3295
Regeneration Level 0 3295
Auto/Active Regeneration Inhibited 3295
Auto/Active Regeneration 3296
Regeneration Level 1 3296
Idle-up Auto/Active Regeneration 3296
Parked Regeneration Request 3296
Regeneration Level 2 3296
Warning Level 3298
Regeneration Level 3 3298
Service Level 3298
Regeneration Level 4 3298
Stage V Content 3298
Emissions System Malfunction 3298
Ash Load 3299
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3300
Operator Interface 3300
Refer to Operator Manual 3300
CAN Communication Lost 3301
Passive Regeneration Only 3301
Regeneration Level 0 3301
Auto/Active Regeneration Inhibited 3301
Auto/Active Regeneration 3302
Regeneration Level 1 3302
Idle-up Auto/Active Regeneration 3302
Parked Regeneration Request 3302
Regeneration Level 2 3302
Warning Level 3304
Regeneration Level 3 3304
Service Level 3304
Regeneration Level 4 3304
Calibrations 3305
Calibrate Transmission Valve 3307
Set Tilt Stop Point 3307
Calibrate Loaded Weight 3308
Calibrate Travel Speed Sensor 3308
Calibrate Mazda LP and Gas Accelerator Pedal 3309
524223772-2200YRM1142-(01-2020)-US-EN 3311
General 3321
Display Switch Cluster 3324
Remove 3324
Install 3327
Direction Control and Turn Signal Levers 3327
Remove 3327
Install 3329
Key Switch 3329
Remove 3329
Install 3330
Display Switch Cluster Panel Bezel and Overlay 3330
Remove 3330
Install 3330
Steering Column Repair 3330
Remove 3330
Disassemble 3333
Assemble 3333
Install 3333
Sensors and Switches 3334
General 3334
Dash and Kick Panel, Remove and Install 3334
Remove 3334
Install 3335
Accelerator Pedal Position Sensor 3336
Remove 3336
Install 3339
Brake Fluid Level Switch 3340
Remove 3340
Install 3342
Service Brake Pedal Position Sensor 3343
Remove 3343
Install 3346
Parking Brake Sensor 3347
Remove 3347
Install 3348
Service Brake Pressure Sensor 3349
Remove 3349
Install 3351
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3352
Remove 3352
Install 3352
Sensor Microswitch (Foot Directional Control Pedal) 3353
Remove 3353
Install 3356
Low Coolant Level Sensor 3357
Remove 3357
Install 3360
Fuel Level Sensor, Gas and Diesel Engines Only 3361
Remove 3361
Install 3362
Armrest Switch 3362
Remove 3362
Install 3364
Seat Sensor (Operator Presence System) 3364
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) 3364
Remove 3364
Install 3365
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3365
Remove 3365
Install 3366
Full Suspension Seats; All Lift Truck Models 3366
Remove 3366
Install 3366
Hood Shut Off Switch 3366
Remove 3366
Install 3369
Remote Key Switch 3370
Remove 3370
Install 3370
Hydraulic Filter Pressure Switch 3371
Remove 3371
Install 3373
Transmission Speed Sensor 3373
Remove 3373
Install 3376
Transmission Pressure Sensors 3377
Remove 3377
Install 3379
Transmission Temperature Sensor 3380
Remove 3380
Install 3382
Engine Speed Sensor 3384
Remove 3384
Install 3384
Intermediate Speed Sensor 3385
Remove 3385
Install 3385
Return to Set Tilt (Tilt Angle) Sensor 3385
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) 3385
Remove 3385
Install 3386
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) 3387
Remove 3387
Install 3388
Rear Horn Button Switch 3388
Remove 3388
Install 3389
Impact Sensor 3390
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) 3390
Remove 3390
Install 3393
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) 3393
Remove 3393
Install 3394
Load Weight Sensor 3395
Remove 3395
Install 3396
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3397
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3397
Crankshaft Position (CKP) Sensor 3397
Camshaft Position (CMP) Sensor 3397
Oil Pressure Sensor 3397
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3397
Engine Coolant Temperature (ECT) Sensor 3398
Air Flow Restriction Switch 3398
Remove for GM 2 4L Gas and LPG Trucks 3398
Install for GM 2 4L Gas and LPG Trucks 3398
Oxygen Sensor 3399
Remove 3399
Install 3402
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3403
Crankshaft Position (CKP) Sensor 3403
Camshaft Position (CMP) Sensor 3403
Oil Pressure Sensor 3403
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3403
Engine Coolant Temperature (ECT) Sensor 3403
Air Flow Restriction Switch 3403
Oxygen Sensor 3403
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3403
Low LPG Pressure Switch 3403
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3404
Air Filter Restriction Switch 3404
Remove 3404
Install 3404
Oil Pressure Sensor 3404
Remove 3404
Install 3404
Engine Speed Sensor 3404
Remove 3404
Install 3404
Engine Coolant Temperature (ECT) Sensor 3404
Remove 3404
Install 3404
Throttle Position Sensor (TPS) 3407
Remove 3407
Install 3408
Fuel/Water Separator Sensor 3408
Remove 3408
Install 3408
Glow Plug Relay 3409
Remove 3409
Install 3411
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3411
Air Filter Restriction Switch 3411
Remove 3411
Install 3411
Engine Oil Pressure Sensor 3416
Remove 3416
Install 3416
Engine Speed Sensor 3416
Remove 3416
Install 3417
Engine Coolant Temperature (ECT) Sensor 3417
Remove 3417
Install 3418
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3419
Remove 3419
Install 3419
Fuel/Water Separator Sensor 3420
Remove 3420
Install 3420
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3421
Intake Air Temperature Sensor 3421
Remove 3421
Install 3422
Intake Air Pressure Sensor 3422
Remove 3422
Install 3422
Air Inlet Heater 3422
Remove 3422
Install 3423
Engine Oil Pressure Sensor 3423
Remove 3423
Install 3423
Engine Coolant Temperature (ECT) Sensor 3423
Remove 3423
Install 3423
Crankshaft Position Sensor 3424
Remove 3424
Install 3424
Adjust Shim Procedure 3425
Camshaft Position Sensor 3426
Remove 3426
Install 3426
Air Flow Restriction Sensor 3427
Remove 3427
Install 3427
Fuel/Water Separator 3427
Remove 3427
Install 3428
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3428
Intake Air Temperature Sensor 3432
Remove 3432
Install 3433
Boost Sensor 3433
Remove 3433
Install 3434
Throttle Valve Assembly and Air Intake Heater 3434
Remove 3434
Install 3434
Engine Coolant Temperature (ECT) Sensor 3435
Remove 3435
Install 3435
Engine Oil Pressure Sensor 3435
Remove 3435
Install 3436
Crankshaft Position Sensor 3436
Remove 3436
Install 3436
Adjust Shim Procedure 3437
Camshaft Position Sensor 3438
Remove 3438
Install 3439
Differential Pressure Sensor 3439
Remove 3439
Install 3439
Mass Air Flow Sensor 3440
Remove 3440
Install 3441
Fuel/Water Separator 3441
Remove 3441
Install 3442
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3442
Engine Coolant Temperature (ECT) Sensor 3443
Remove 3443
Install 3443
Throttle Position Sensor 3444
Engine Oil Pressure Sensor 3444
Remove 3444
Install 3444
Engine Speed Sensor 3444
Remove 3444
Install 3444
Fuel Shut Off Solenoid 3444
Remove 3444
Install 3444
Vehicle System Manager (VSM) 3445
General 3445
VSM Replacement 3445
Remove 3445
Install 3447
Programming a New VSM and/or Display Switch Cluster 3447
General 3447
PC Service Tool Software 3448
Data Transferring 3448
New VSM 3448
New (Blank) Display Switch Cluster 3448
Used (Non-Blank) Display Switch Cluster 3448
Power Distribution Module (PDM) and Component Parts 3450
Remove 3450
PDM as a Unit 3450
Install 3454
PDM as a Unit 3454
Remove and Install 3455
PDM Component Parts 3455
Transmission Control Unit 3455
Remove 3455
Install 3459
Battery 3461
Remove 3461
Install 3461
Lights 3462
Work Lights (Front and Rear) 3462
Remove 3462
Install 3462
Strobe Light 3463
Remove 3463
Install 3463
LED Tail, Backup, and Brake Lights 3464
Remove 3464
Install 3465
Front Marker/Turn Signal Lights 3466
Replacing Whole Front Marker/Turn Signal Light Assembly 3466
Remove 3466
Install 3466
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3467
Remove 3467
Install 3467
Diesel Particulate Filter (DPF) Display 3467
Remove 3467
Clean and Inspect 3468
Install 3468
Electronic-Hydraulic Controls – Generation 1 3469
E-Hydraulic Controls – Test 3469
Mini-Levers 3469
Full Stroke Test 3469
Function Returns to Neutral Test 3469
Push Button Switch 3469
General 3470
Mini-Lever Replacement 3470
Remove 3470
Clean and Inspect 3471
Install 3471
Push Button Switch Replacement 3472
Remove 3472
Install 3474
Mini-Lever Module (MLM) 3474
Remove 3474
Install 3474
Joystick 3475
Remove and Disassemble 3475
Inspect 3475
Assemble and Install 3475
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3476
General 3476
Mini-levers, Remove and Install 3476
Armrest Assembly 3477
Remove 3477
Install 3480
Horn Button 3480
Remove 3480
Install 3480
Direction Control Switch 3481
Remove 3481
Install 3481
push (override) buttons and Toggle Switch 3481
Remove 3482
Install 3483
Joystick 3484
Remove and Disassemble 3484
Inspect 3484
Assemble and Install 3484
Joystick Armrest Slider Assembly 3485
Remove 3485
Install 3486
Electronic-Hydraulic Controls, After January, 2020 3486
E-Hydraulic Controls – TEST 3486
Mini-Levers 3486
Full Stroke Test 3486
Function Returns to Neutral Test 3486
Push (Override) Button 3487
General 3487
Mini-levers, Remove and Install 3487
Armrest Assembly 3488
Remove 3488
Install 3491
Horn Button 3491
Remove 3491
Install 3491
Direction Control Switch 3491
Remove 3491
Install 3492
Push (Override) buttons and Toggle Switch 3492
Remove 3493
Install 3495
Special Tools 3496
524223772-2200YRM1142-(08-2021)-US-EN 3499
General 3509
Display Switch Cluster 3513
Remove 3513
Install 3515
Direction Control and Turn Signal Levers 3515
Remove 3515
Install 3516
Key Switch 3517
Remove 3517
Install 3518
Display Switch Cluster Panel Bezel and Overlay 3518
Remove 3518
Install 3518
Steering Column Repair 3519
Remove 3519
Disassemble 3522
Assemble 3522
Install 3522
Sensors and Switches 3523
General 3523
Dash and Kick Panel, Remove and Install 3523
Remove 3523
Install 3524
Accelerator Pedal Position Sensor 3524
Remove 3524
Install 3528
Brake Fluid Level Switch 3529
Remove 3529
Install 3530
Service Brake Pedal Position Sensor 3532
Remove 3532
Install 3534
Parking Brake Sensor 3535
Remove 3535
Install 3537
Service Brake Pressure Sensor 3537
Remove 3537
Install 3539
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3541
Remove 3541
Install 3541
Sensor Microswitch (Foot Directional Control Pedal) 3541
Remove 3541
Install 3544
Low Coolant Level Sensor 3545
Remove 3545
Install 3548
Fuel Level Sensor, Gas and Diesel Engines Only 3549
Remove 3549
Install 3550
Armrest Switch 3550
Remove 3550
Install 3552
Seat Sensor (Operator Presence System) 3552
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) 3552
Remove 3552
Install 3553
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3553
Remove 3553
Install 3553
Full Suspension Seats; All Lift Truck Models 3554
Remove 3554
Install 3554
Hood Shut Off Switch 3555
Remove 3555
Install 3557
Remote Key Switch 3558
Remove 3558
Install 3558
Hydraulic Filter Pressure Switch 3559
Remove 3559
Install 3561
Transmission Speed Sensor 3561
Remove 3561
Install 3564
Transmission Pressure Sensors 3565
Remove 3565
Install 3567
Transmission Temperature Sensor 3568
Remove 3568
Install 3570
Engine Speed Sensor 3572
Remove 3572
Install 3573
Intermediate Speed Sensor 3573
Remove 3573
Install 3573
Return to Set Tilt (Tilt Angle) Sensor 3574
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) 3574
Remove 3574
Install 3574
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) 3574
Remove 3575
Install 3576
Rear Horn Button Switch 3577
Remove 3577
Install 3577
Impact Sensor 3578
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) 3578
Remove 3578
Install 3580
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) 3580
Remove 3580
Install 3581
Load Weight Sensor 3581
Remove 3581
Install 3583
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3584
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3584
Crankshaft Position (CKP) Sensor 3584
Camshaft Position (CMP) Sensor 3584
Oil Pressure Sensor 3584
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3584
Engine Coolant Temperature (ECT) Sensor 3585
Air Flow Restriction Switch 3585
Remove for GM 2 4L Gas and LPG Trucks 3585
Install for GM 2 4L Gas and LPG Trucks 3585
Oxygen Sensor 3586
Remove 3586
Install 3589
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3590
Crankshaft Position (CKP) Sensor 3590
Camshaft Position (CMP) Sensor 3590
Oil Pressure Sensor 3590
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3590
Engine Coolant Temperature (ECT) Sensor 3590
Air Flow Restriction Switch 3590
Oxygen Sensor 3590
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3590
Low LPG Pressure Switch 3590
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3591
Air Filter Restriction Switch 3591
Remove 3591
Install 3591
Oil Pressure Sensor 3591
Remove 3591
Install 3591
Engine Speed Sensor 3591
Remove 3591
Install 3591
Engine Coolant Temperature (ECT) Sensor 3591
Remove 3591
Install 3591
Throttle Position Sensor (TPS) 3594
Remove 3594
Install 3595
Fuel/Water Separator Sensor 3595
Remove 3595
Install 3595
Glow Plug Relay 3596
Remove 3596
Install 3598
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3598
Air Filter Restriction Switch 3598
Remove 3598
Install 3599
Engine Oil Pressure Sensor 3603
Remove 3603
Install 3603
Engine Speed Sensor 3603
Remove 3603
Install 3604
Engine Coolant Temperature (ECT) Sensor 3604
Remove 3604
Install 3605
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3606
Remove 3606
Install 3606
Fuel/Water Separator Sensor 3607
Remove 3607
Install 3607
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3608
Intake Air Temperature Sensor 3608
Remove 3608
Install 3609
Intake Air Pressure Sensor 3609
Remove 3609
Install 3609
Air Inlet Heater 3609
Remove 3609
Install 3610
Engine Oil Pressure Sensor 3610
Remove 3610
Install 3610
Engine Coolant Temperature (ECT) Sensor 3610
Remove 3610
Install 3610
Crankshaft Position Sensor 3611
Remove 3611
Install 3611
Adjust Shim Procedure 3612
Camshaft Position Sensor 3613
Remove 3613
Install 3613
Air Flow Restriction Sensor 3613
Remove 3613
Install 3614
Fuel/Water Separator 3614
Remove 3614
Install 3615
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3615
Intake Air Temperature Sensor 3619
Remove 3619
Install 3620
Boost Sensor 3620
Remove 3620
Install 3621
Throttle Valve Assembly and Air Intake Heater 3621
Remove 3621
Install 3621
Engine Coolant Temperature (ECT) Sensor 3622
Remove 3622
Install 3622
Engine Oil Pressure Sensor 3623
Remove 3623
Install 3623
Crankshaft Position Sensor 3623
Remove 3623
Install 3623
Adjust Shim Procedure 3624
Camshaft Position Sensor 3626
Remove 3626
Install 3626
Differential Pressure Sensor 3626
Remove 3626
Install 3627
Mass Air Flow Sensor 3627
Remove 3627
Install 3628
Fuel/Water Separator 3629
Remove 3629
Install 3630
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3631
Engine Coolant Temperature (ECT) Sensor 3632
Remove 3632
Install 3632
Throttle Position Sensor 3632
Engine Oil Pressure Sensor 3632
Remove 3632
Install 3632
Engine Speed Sensor 3632
Remove 3632
Install 3632
Fuel Shut Off Solenoid 3633
Remove 3633
Install 3633
Vehicle System Manager (VSM) 3634
General 3634
VSM Replacement 3634
Remove 3634
Install 3636
Programming a New VSM and/or Display Switch Cluster 3636
General 3636
PC Service Tool Software 3637
Data Transferring 3637
New VSM 3637
New (Blank) Display Switch Cluster 3637
Used (Non-Blank) Display Switch Cluster 3637
Power Distribution Module (PDM) and Component Parts 3640
Remove 3640
PDM as a Unit 3640
Install 3643
PDM as a Unit 3643
Remove and Install 3644
PDM Component Parts 3644
Transmission Control Unit (TCU) 3645
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) 3645
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) 3645
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3646
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3646
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 3646
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 3647
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 3648
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 3650
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 3650
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 3650
Battery 3651
Remove 3651
Install 3651
Lights 3652
Work Lights (Front and Rear) 3652
Remove 3652
Install 3652
Strobe Light 3653
Remove 3653
Install 3653
LED Tail, Backup, and Brake Lights 3654
Remove 3654
Install 3655
Front Marker/Turn Signal Lights 3656
Replacing Whole Front Marker/Turn Signal Light Assembly 3656
Remove 3656
Install 3656
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3657
Remove 3657
Install 3657
Diesel Particulate Filter (DPF) Display 3658
Remove 3658
Clean and Inspect 3659
Install 3659
Electronic-Hydraulic Controls – Generation 1 3660
E-Hydraulic Controls – Test 3660
Mini-Levers 3660
Full Stroke Test 3660
Function Returns to Neutral Test 3660
Push Button Switch 3660
General 3661
Mini-Lever Replacement 3661
Remove 3661
Clean and Inspect 3662
Install 3662
Push Button Switch Replacement 3663
Remove 3663
Install 3665
Mini-Lever Module (MLM) 3665
Remove 3665
Install 3665
Joystick 3666
Remove and Disassemble 3666
Inspect 3666
Assemble and Install 3666
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 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 3672
Remove 3672
Install 3672
push (override) buttons and Toggle Switch 3672
Remove 3673
Install 3674
Joystick 3675
Remove and Disassemble 3675
Inspect 3675
Assemble and Install 3675
Joystick Armrest Slider Assembly 3676
Remove 3676
Install 3677
Electronic-Hydraulic Controls, After January, 2020 3678
E-Hydraulic Controls – TEST 3678
Mini-Levers 3678
Full Stroke Test 3678
Function Returns to Neutral Test 3678
Push (Override) Button 3678
General 3679
Mini-levers, Remove and Install 3679
Armrest Assembly 3680
Remove 3680
Install 3683
Horn Button 3683
Remove 3683
Install 3683
Direction Control Switch 3683
Remove 3683
Install 3684
Push (Override) buttons and Toggle Switch 3684
Remove 3685
Install 3687
Special Tools 3688
524223780-8000YRM1134-(03-2020)-US-EN 3691
Series Code / Model Designation Reference Table 3697
Description 3699
Proc_Cal_001: Service Password Entry 3701
When to Perform 3701
Why Perform 3701
How to Perform 3701
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3702
When to Perform 3702
Calibration Order 3702
Why Perform 3702
How to Perform 3703
Proc_Cal_003: Save and Exit 3704
When to Perform 3704
Why Perform 3704
How to Perform 3704
Proc_Cal_004: Lift Valve Output Threshold 3705
When to Perform 3705
Calibration Order 3705
Why Perform 3705
How to Perform 3706
Proc_Cal_005: Lower Valve Output Threshold 3708
When to Perform 3708
Calibration Order 3708
Why Perform 3708
How to Perform 3708
Proc_Cal_006: Tilt Back Valve Output Threshold 3711
When to Perform 3711
Calibration Order 3711
Why Perform 3711
How to Perform 3711
Proc_Cal_007: Tilt Forward Valve Output Threshold 3714
When to Perform 3714
Calibration Order 3714
Why Perform 3714
How to Perform 3714
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3717
When to Perform 3717
Calibration Order 3717
Why Perform 3717
How to Perform 3717
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3720
When to Perform 3720
Calibration Order 3720
Why Perform 3720
How to Perform 3720
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3723
When to Perform 3723
Calibration Order 3723
Why Perform 3723
How to Perform 3723
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3726
When to Perform 3726
Calibration Order 3726
Why Perform 3726
How to Perform 3726
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3729
When to Perform 3729
Calibration Order 3729
Why Perform 3729
How to Perform 3729
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3732
When to Perform 3732
Calibration Order 3732
Why Perform 3732
How to Perform 3732
Proc_Cal_014: Load Weight Zero Point 3736
When to Perform 3736
Calibration Order 3736
Why Perform 3736
How to Perform 3736
Proc_Cal_015: Loaded Weight Calibration 3738
When to Perform 3738
Calibration Order 3738
Why Perform 3738
How to Perform 3738
Proc_Cal_016: Transmission Valve Calibration 3741
Applicable System/Option 3741
When to Perform 3741
Calibration Order 3741
Why Perform 3741
How to Perform 3741
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3743
Applicable System/Option 3743
When to Perform 3743
Calibration Order 3743
Why Perform 3743
How to Perform 3743
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3745
Applicable System/Option 3745
When to Perform 3745
Calibration Order 3745
Why Perform 3745
How to Perform 3746
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3747
Required Tools 3747
When to Perform 3747
Calibration Order 3747
Why Perform 3748
How to Perform 3748
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3749
When to Perform 3749
Why Perform 3749
How to Perform 3749
Proc_Cal_026: Travel Speed Calibration 3751
When to Perform 3751
Calibration Order 3751
Why Perform 3751
How to Perform 3751
524223780-8000YRM1134-(05-2022)-US-EN 3755
Series Code / Model Designation Reference Table 3761
Description 3764
Proc_Cal_001: Service Password Entry 3766
When to Perform 3766
Why Perform 3766
How to Perform 3766
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3767
When to Perform 3767
Calibration Order 3767
Why Perform 3767
How to Perform 3767
Proc_Cal_003: Save and Exit 3769
When to Perform 3769
Why Perform 3769
How to Perform 3769
Proc_Cal_004: Lift Valve Output Threshold 3770
When to Perform 3770
Calibration Order 3770
Why Perform 3770
How to Perform 3770
Proc_Cal_005: Lower Valve Output Threshold 3773
When to Perform 3773
Calibration Order 3773
Why Perform 3773
How to Perform 3773
Proc_Cal_006: Tilt Back Valve Output Threshold 3776
When to Perform 3776
Calibration Order 3776
Why Perform 3776
How to Perform 3776
Proc_Cal_007: Tilt Forward Valve Output Threshold 3779
When to Perform 3779
Calibration Order 3779
Why Perform 3779
How to Perform 3779
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3782
When to Perform 3782
Calibration Order 3782
Why Perform 3782
How to Perform 3782
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3785
When to Perform 3785
Calibration Order 3785
Why Perform 3785
How to Perform 3785
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3788
When to Perform 3788
Calibration Order 3788
Why Perform 3788
How to Perform 3788
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3791
When to Perform 3791
Calibration Order 3791
Why Perform 3791
How to Perform 3791
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3794
When to Perform 3794
Calibration Order 3794
Why Perform 3794
How to Perform 3794
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3797
When to Perform 3797
Calibration Order 3797
Why Perform 3797
How to Perform 3797
Proc_Cal_014: Load Weight Zero Point 3800
When to Perform 3800
Calibration Order 3800
Why Perform 3800
How to Perform 3800
Proc_Cal_015: Loaded Weight Calibration 3802
When to Perform 3802
Calibration Order 3802
Why Perform 3802
How to Perform 3802
Proc_Cal_016: Transmission Valve Calibration 3805
Applicable System/Option 3805
When to Perform 3805
Calibration Order 3805
Why Perform 3805
How to Perform 3805
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3807
Applicable System/Option 3807
When to Perform 3807
Calibration Order 3807
Why Perform 3807
How to Perform 3807
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3810
Applicable System/Option 3810
When to Perform 3810
Calibration Order 3810
Why Perform 3810
How to Perform 3810
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3813
Required Tools 3813
When to Perform 3813
Calibration Order 3813
Why Perform 3813
How to Perform 3813
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3815
When to Perform 3815
Why Perform 3815
How to Perform 3815
Proc_Cal_026: Travel Speed Calibration 3817
When to Perform 3817
Calibration Order 3817
Why Perform 3817
How to Perform 3817
524262279-1800YRM1247-(06-2021)-US-EN 3821
General 3825
Dry Brake System 3825
Wet Brake System 3825
Service Brakes Repair (Dry Brake) 3829
Remove and Disassemble 3829
Clean 3831
Inspect 3832
Assemble and Install 3833
Adjust 3836
Parking Brake Repair 3837
Dry Brake System 3837
Remove and Disassembly 3837
Assemble and Install 3839
Wet Brake System 3839
Remove and Install 3839
Assemble and Install 3846
Adjust 3846
Dry Brake System 3846
Wet Brake System 3847
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3847
Master Cylinder Repair 3849
Remove 3849
Disassemble 3853
Clean and Inspect 3854
Assemble 3855
Install and Adjust 3855
Accumulator 3858
Pre-Charge Check 3858
Remove 3859
Install 3861
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3862
Remove 3862
Modulating Brake Valve 3864
Disassemble 3864
Clean and Inspect 3865
Assemble 3865
Accumulator Charge Valve 3866
Disassemble 3866
Clean and Inspect 3868
Assemble 3868
Install 3869
Pressure Checks 3870
Accumulator Charge Valve Check 3870
Accumulator Check 3870
Service Brakes Adjustment (Dry Brake) 3871
Service Brakes Adjustment 3871
Brake System Air Removal 3873
Using Pressure Bleed System 3873
Using Brake Pedal Pressure 3873
Lift Truck Models with Master Cylinder 3873
Lift Truck Models with Modulating Brake Valve 3874
Brake Pedal Adjustment 3875
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) 3875
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3876
Free Pedal Adjustment 3878
Torque Specifications 3879
524262279-1800YRM1247-(09-2018)-US-EN 3881
General 3885
Dry Brake System 3885
Wet Brake System 3886
Service Brakes Repair (Dry Brake) 3890
Remove and Disassemble 3890
Clean 3892
Inspect 3893
Assemble and Install 3893
Adjust 3897
Parking Brake Repair 3897
Dry Brake System 3898
Remove and Disassembly 3898
Assemble and Install 3900
Wet Brake System 3900
Remove and Install 3901
Assemble and Install 3907
Adjust 3907
Dry Brake System 3907
Wet Brake System 3908
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3908
Master Cylinder Repair 3909
Remove 3909
Disassemble 3914
Clean and Inspect 3915
Assemble 3916
Install and Adjust 3916
Accumulator 3918
Pre-Charge Check 3919
Remove 3920
Install 3922
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3922
Remove 3923
Modulating Brake Valve 3924
Disassemble 3924
Clean and Inspect 3926
Assemble 3926
Accumulator Charge Valve 3927
Disassemble 3927
Clean and Inspect 3929
Assemble 3929
Install 3930
Pressure Checks 3931
Accumulator Charge Valve Check 3931
Accumulator Check 3931
Service Brakes Adjustment (Dry Brake) 3932
Service Brakes Adjustment 3932
Brake System Air Removal 3933
Using Pressure Bleed System 3933
Using Brake Pedal Pressure 3934
Lift Truck Models with Master Cylinder 3934
Lift Truck Models with Modulating Brake Valve 3934
Brake Pedal Adjustment 3935
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) 3935
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3936
Free Pedal Adjustment 3938
Torque Specifications 3939
524265337-0600YRM1251-(09-2015)-US-EN 3943
General 3949
Engine Removal and Installation 3949
Cylinder Head Repair 3949
Remove and Disassemble 3949
Clean and Inspect 3951
Valve Oil Seals 3954
Remove and Disassemble 3954
Cylinder Leak Down Test 3954
Clean and Inspect 3955
Assemble and Install 3955
Valve Guides and Seats, Repairs 3957
Valves, Repair 3957
Valve Seats, Repair 3958
Valve Springs 3959
Assemble and Install 3960
Engine Block Cleaning and Inspection 3963
Clean and Inspect 3964
Piston Bore Preparation 3966
Engine Mounts Installation 3966
Remove 3966
Clean and Inspect 3967
Install 3967
Lubrication System Repair 3968
Oil Pump, Remove and Disassemble 3968
Clean and Inspect 3969
Oil Pump, Assemble and Install 3970
Oil Pan, Install 3972
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 3974
Timing Cover 3974
Remove 3974
Install 3976
Timing Sprockets 3976
Remove 3976
Install 3976
Camshaft 3976
Remove 3976
Inspect 3977
Install 3977
Balance Shaft 3978
Remove 3978
Install 3979
Valve Lifters 3980
Remove 3980
Clean and Inspect 3980
Install 3981
Crankshaft Repair 3981
Remove 3982
Inspect and Repair 3982
How to Check Clearance Between Main Bearings and Their Journals 3983
Install 3984
Piston and Connecting Rod Assemblies Repair 3986
Connecting Rod Bearings, Replace 3986
Piston and Connecting Rod Assemblies, Remove 3987
Disassemble 3987
Piston, Clean and Inspect 3988
Cylinder Bores, Inspect and Repair 3988
Piston Rings 3989
Assemble 3990
Piston and Connecting Rod Assemblies, Install 3990
Flywheel and Flywheel Housing Repair 3990
Flywheel, Remove 3991
Clean 3991
Inspect 3991
Flywheel, Install 3992
Coolant Pump Repair 3992
Remove 3992
Clean and Inspect 3993
Install 3993
Thermostat Replacement 3993
Remove 3994
Thermostat Operation Check 3994
Install 3994
Starter Replacement 3995
3995
Remove 3995
Install 3998
Fan Assembly Replacement 3999
Remove 3999
Inspect 4001
Install 4001
Drive Belt Installation 4002
Remove 4002
Clean 4002
Inspect 4002
Installation 4003
Compression Check 4004
Engine Specifications 4004
Engine Data 4004
Cylinder Head 4004
Hydraulic Valve Lifter 4005
Camshaft 4005
Pistons 4005
Crankshaft 4006
Connecting Rods 4006
Balance Shaft 4007
Cooling System 4007
Lubrication System 4007
Torque Specifications 4008
524265342-4000YRM1250-(06-2021)-US-EN 4013
Safety Procedures When Working Near Mast 4019
Fork Replacement 4022
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4022
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4023
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) 4025
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4026
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4027
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) 4028
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4028
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) 4029
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4030
Fixed Carriage Replacement 4032
Remove, Carriage With Hook Forks 4032
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4040
Install, Carriage With Hook Forks 4041
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4041
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4042
Connecting Attachment Hydraulic Quick Disconnect Hoses 4042
Integral Sideshift Carriage Repair 4043
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) 4043
Disassemble 4043
Clean and Inspect 4046
Assemble 4046
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) 4047
Hang On Sideshift Carriage Repair 4048
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) 4048
Disassemble 4060
Clean and Inspect 4069
Assemble 4070
Install 4071
Hang-On Sideshift Carriage Repair 4073
Remove 4073
Disassemble Carriage 4075
Clean and Inspect 4078
Assemble 4078
Install 4081
Fork Positioner 4084
Two-Stage Mast With Limited Free-Lift Repair 4085
Remove 4085
Disassemble 4088
Clean and Inspect 4091
Assemble 4109
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) 4111
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) 4113
Header Hose Alignment 4124
Two-Stage Mast With Full Free-Lift Repair 4135
Remove 4135
Disassemble 4137
Clean and Inspect 4148
Assemble 4149
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) 4151
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) 4154
Header Hose Installation and Adjustment 4158
Installation 4158
Adjustment 4159
Three-Stage Mast With Full Free-Lift Repair 4160
Remove 4160
Disassemble 4162
Clean and Inspect 4192
Assemble 4194
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) 4197
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) 4202
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) 4209
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) 4216
Mast Operation Check 4220
Tilt Cylinder Adjustment 4221
Lift Chains Adjustment 4221
Mast Adjustments 4223
Load Roller Adjustment 4223
Mast Side Kicking Adjustment 4225
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4226
Carriage Adjustments 4228
Series Code / Model Designation Reference Table 4229
524265342-4000YRM1250-(09-2018)-US-EN 4233
Safety Procedures When Working Near Mast 4239
Fork Replacement 4241
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4241
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4243
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) 4244
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4245
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4246
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) 4247
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4247
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) 4249
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4249
Fixed Carriage Replacement 4251
Remove, Carriage With Hook Forks 4251
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4260
Install, Carriage With Hook Forks 4261
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4261
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4262
Connecting Attachment Hydraulic Quick Disconnect Hoses 4262
Integral Sideshift Carriage Repair 4263
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) 4263
Disassemble 4263
Clean and Inspect 4266
Assemble 4266
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) 4267
Hang On Sideshift Carriage Repair 4267
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) 4267
Disassemble 4279
Clean and Inspect 4288
Assemble 4289
Install 4290
Bolzoni Hang-On Sideshift Carriage Repair 4292
Remove 4292
Disassemble Carriage 4294
Clean and Inspect 4297
Assemble 4297
Install 4300
Fork Positioner 4302
Two-Stage Mast With Limited Free-Lift Repair 4303
Remove 4303
Disassemble 4307
Clean and Inspect 4310
Assemble 4327
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) 4329
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) 4330
Header Hose Alignment 4342
Two-Stage Mast With Full Free-Lift Repair 4352
Remove 4352
Disassemble 4354
Clean and Inspect 4366
Assemble 4367
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) 4369
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) 4372
Header Hose Installation and Adjustment 4376
Installation 4376
Adjustment 4376
Three-Stage Mast With Full Free-Lift Repair 4377
Remove 4377
Disassemble 4379
Clean and Inspect 4409
Assemble 4410
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) 4414
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) 4419
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) 4426
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) 4432
Mast Operation Check 4436
Tilt Cylinder Adjustment 4436
Lift Chains Adjustment 4437
Mast Adjustments 4438
Load Roller Adjustment 4438
Mast Side Kicking Adjustment 4440
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4441
Carriage Adjustments 4444
524288189-0100YRM1316-(01-2022)-US-EN 4447
General 4451
Description 4452
Hood, Seat, Dash, and Side Covers Replacement 4454
Remove 4454
Install 4460
Steering Column 4464
Description 4464
Steering Column Repair 4464
Remove 4464
Disassemble 4465
Clean 4467
Inspect 4467
Assemble 4467
Install 4467
LPG Tank and Bracket Replacement 4467
Counterweight Replacement 4468
Remove 4468
Install 4469
Tow Pin, Remove and Install 4471
Overhead Guard Replacement 4472
Remove 4472
Install 4473
LED Tail, Backup, and Brake Lights, Replace 4474
Operator Restraint System Replacement 4475
Description 4475
Engine Replacement 4477
Remove Engine Only 4477
Install Engine only 4503
Remove Engine and Transmission 4506
Install Engine and Transmission 4508
Electronic Throttle Replacement 4512
Cummins 4 5L Diesel Engine With Electronic Throttle 4512
Remove 4512
Install 4516
Pull Actuator Linkage Adjustment 4518
Low Idle Adjustment 4518
Throttle Pedal and Cable Adjustment 4519
Cummins 4 5L Diesel Engine 4519
Exhaust System Repair 4521
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4521
PSI 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4521
Cummins QSB 3 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4521
Remove 4521
Inspect 4521
Install 4524
Cummins 4 5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4524
Remove 4524
Inspect 4526
Install 4526
Kubota 3 8L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 4526
Remove 4526
Inspect 4529
Install 4529
Kubota 3 8L Diesel Engine w/DPF for Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) 4529
Remove 4529
Inspect 4532
Install 4532
Kubota 3 8L Diesel Engine w/DOC for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) 4532
Remove 4532
Inspect 4535
Install 4535
Cooling System 4536
Description 4536
Hydraulic Filter Assembly Repair 4537
Remove 4537
Disassemble 4537
Clean 4538
Inspect 4538
Assemble 4538
Install 4538
Fuel and Hydraulic Tanks Repair 4539
Inspect 4539
Clean 4539
Steam Method of Cleaning 4539
Chemical Solution Method of Cleaning 4540
Additional Preparations for Repair 4541
Small Leaks, Repair 4541
Large Leaks, Repair 4541
Preparations for Use After Repair 4541
Safety Labels 4542
524288189-0100YRM1316-(11-2017)-US-EN 4549
General 4553
Description 4553
Hood, Seat, Dash, and Side Covers Replacement 4554
Remove 4555
Install 4560
Steering Column 4563
Description 4563
Steering Column Repair 4563
Remove 4563
Disassemble 4565
Clean 4566
Inspect 4566
Assemble 4566
Install 4566
LPG Tank and Bracket Replacement 4566
Counterweight Replacement 4566
Remove 4567
Install 4568
Tow Pin, Remove and Install 4570
Overhead Guard Replacement 4570
Remove 4570
Install 4571
LED Tail, Backup, and Brake Lights, Replace 4572
Operator Restraint System Replacement 4572
Description 4573
Engine Replacement 4574
Remove Engine Only 4574
Install Engine only 4596
Remove Engine and Transmission 4600
Install Engine and Transmission 4603
Electronic Throttle Replacement 4605
Cummins 4 5L Diesel Engine With Electronic Throttle 4605
Remove 4605
Install 4609
Pull Actuator Linkage Adjustment 4611
Low Idle Adjustment 4611
Throttle Pedal and Cable Adjustment 4611
Cummins 4 5L Diesel Engine 4612
Exhaust System Repair 4613
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4614
PSI 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4614
Cummins QSB 3 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4614
Remove 4614
Inspect 4614
Install 4616
Cummins 4 5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4616
Remove 4616
Inspect 4617
Install 4617
Kubota 3 8L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 4619
Remove 4619
Inspect 4619
Install 4620
Kubota 3 8L Diesel Engine w/DPF for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4621
Remove 4621
Inspect 4623
Install 4623
Kubota 3 8L Diesel Engine w/DOC for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4623
Remove 4623
Inspect 4624
Install 4624
Cooling System 4627
Description 4628
Hydraulic Filter Assembly Repair 4628
Remove 4628
Disassemble 4628
Clean 4628
Inspect 4629
Assemble 4629
Install 4629
Fuel and Hydraulic Tanks Repair 4629
Inspect 4630
Clean 4630
Steam Method of Cleaning 4630
Chemical Solution Method of Cleaning 4631
Additional Preparations for Repair 4632
Small Leaks, Repair 4632
Large Leaks, Repair 4632
Preparations for Use After Repair 4632
Safety Labels 4632
524288194-1300YRM1317-(03-2020)-US-EN 4639
Transmission Repair 4643
Remove 4643
Torque Converter, Remove 4643
Disassemble 4644
Clean and Inspect 4693
Housings 4693
Oil Seals and Gaskets 4693
Bearings 4693
Gears and Shafts 4694
Assemble 4694
Torque Converter, Install 4735
Install 4736
Control Valve Repair 4737
Remove 4737
Disassemble 4737
Clean 4739
Inspect 4739
Assemble 4739
Install 4740
Torque Specification 4741
524288194-1300YRM1317-(06-2021)-US-EN 4743
Transmission Repair 4747
Remove 4747
Torque Converter, Remove 4747
Disassemble 4748
Clean and Inspect 4799
Housings 4799
Oil Seals and Gaskets 4799
Bearings 4799
Gears and Shafts 4800
Assemble 4800
Torque Converter, Install 4842
Install 4843
Control Valve Repair 4844
Remove 4844
Disassemble 4844
Clean 4846
Inspect 4846
Assemble 4846
Install 4847
Torque Specification 4848
524288199-1400YRM1318-(06-2021)-US-EN 4851
General 4855
Identification Plate 4855
Drive Axle Removal 4855
Planetary Reduction Gear Repair 4863
Clean and Inspect 4870
Brake Repair 4878
Clean and Inspect 4885
Wet Brake Noise Reduction 4896
General 4896
Adding Additive To Transmission 4896
Differential Repair 4898
Clean and Inspect 4907
Bevel Pinion 4919
Clean and Inspect 4923
Drive Axle Installation 4934
Special Tools 4942
Torque Specifications 4943
524288199-1400YRM1318-(09-2018)-US-EN 4945
General 4949
Identification Plate 4949
Drive Axle Removal 4949
Planetary Reduction Gear Repair 4956
Clean and Inspect 4964
Brake Repair 4971
Clean and Inspect 4979
Wet Brake Noise Reduction 4989
General 4989
Adding Additive To Transmission 4989
Differential Repair 4990
Clean and Inspect 5000
Bevel Pinion 5012
Clean and Inspect 5016
Drive Axle Installation 5026
Special Tools 5033
Torque Specifications 5033
524294873-1300YRM1343-(06-2021)-US-EN 5037
Transmission Repair 5041
Remove 5041
Torque Converter, Remove 5041
Disassemble 5043
Clean and Inspect 5084
Housings 5084
Oil Seals and Gaskets 5084
Bearings 5084
Gears and Shafts 5085
Assemble 5085
Torque Converter, Install 5123
Install 5124
Control Valve Repair 5125
Remove 5125
Disassemble 5125
Control Valve Assembly 5125
Control Valve Body 5125
Clean 5128
Inspect 5128
Assemble 5128
Control Valve Body 5128
Control Valve Assembly 5129
Install 5129
Torque Specification 5131
524294873-1300YRM1343-(11-2019)-US-EN 5133
Transmission Repair 5137
Remove 5137
Torque Converter, Remove 5137
Disassemble 5138
Clean and Inspect 5178
Housings 5178
Oil Seals and Gaskets 5178
Bearings 5179
Gears and Shafts 5179
Assemble 5179
Torque Converter, Install 5217
Install 5218
Control Valve Repair 5219
Remove 5219
Disassemble 5219
Control Valve Assembly 5219
Control Valve Body 5219
Clean 5222
Inspect 5222
Assemble 5222
Control Valve Body 5222
Control Valve Assembly 5222
Install 5223
Torque Specification 5225
524294878-2100YRM1328-(06-2021)-US-EN 5227
General 5231
Safety Procedures When Working Near Mast 5231
Tilt Cylinder Repair 5234
Remove 5234
Disassemble 5238
Clean 5240
Inspect 5240
Assemble 5240
Install 5242
Tilt Cylinders, Adjust 5244
Tilt Cylinder Leak Check 5246
Lift Cylinder Repair 5247
Remove 5247
Disassemble 5256
Clean 5259
Inspect 5259
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 5259
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5259
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 5260
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5260
Free-Lift Cylinder Repair 5262
Remove 5262
Disassemble 5268
Clean 5270
Inspect 5270
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 5271
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5271
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 5271
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5272
Sideshift Cylinder Repair 5273
Remove 5273
Disassemble 5274
Clean 5277
Inspect 5277
Assemble 5278
Install 5279
Bolzoni Sideshift Cylinder Repair 5280
Remove 5280
Disassemble 5280
Clean 5281
Inspect 5281
Assemble 5282
Install 5282
Fork Positioner Cylinder Repair 5283
Remove 5283
Disassemble 5286
Clean 5290
Inspect 5290
Assemble 5291
Install 5292
Lift Cylinder Leak Check 5294
Seal Kit Installation 5295
External Installation (Seal and Back-Up Ring) 5295
Internal Installation (Piston Rod Assembly) 5295
Special Tools 5296
Torque Specifications 5297
For Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5297
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5297
524294878-2100YRM1328-(09-2018)-US-EN 5299
General 5303
Safety Procedures When Working Near Mast 5303
Tilt Cylinder Repair 5305
Remove 5305
Disassemble 5310
Clean 5312
Inspect 5312
Assemble 5312
Install 5314
Tilt Cylinders, Adjust 5316
Tilt Cylinder Leak Check 5317
Lift Cylinder Repair 5318
Remove 5318
Disassemble 5328
Clean 5331
Inspect 5331
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 5331
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5331
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 5332
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5332
Free-Lift Cylinder Repair 5333
Remove 5333
Disassemble 5339
Clean 5341
Inspect 5341
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 5342
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5342
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 5342
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5343
Sideshift Cylinder Repair 5344
Remove 5344
Disassemble 5345
Clean 5348
Inspect 5348
Assemble 5349
Install 5350
Bolzoni Sideshift Cylinder Repair 5351
Remove 5351
Disassemble 5351
Clean 5352
Inspect 5352
Assemble 5353
Install 5353
Fork Positioner Cylinder Repair 5353
Remove 5354
Disassemble 5357
Clean 5361
Inspect 5361
Assemble 5362
Install 5363
Lift Cylinder Leak Check 5364
Seal Kit Installation 5364
External Installation (Seal and Back-Up Ring) 5364
Internal Installation (Piston Rod Assembly) 5365
Special Tools 5366
Torque Specifications 5367
For Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5367
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5367
550043871-0900YRM1556-(04-2018)-US-EN 5371
General 5375
LPG Tank and Bracket 5375
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) 5375
Remove 5375
Install 5383
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) 5384
Remove 5384
Install 5386
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 5386
Remove 5386
Install 5388
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 5388
Remove 5388
Install 5388
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) 5389
Remove 5389
Install 5391
Fuel Filter Unit 5391
Fuel Filter Element 5392
Remove 5392
Clean and Inspect 5392
Install 5393
Fuel Filter Housing with LP Vapor Sensor 5393
Remove 5393
Disassemble 5395
Clean and Inspect 5396
Assemble 5396
Install 5397
Throttle Body 5398
Remove 5398
Clean 5402
Install 5402
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 5403
Remove 5403
Install 5404
Control System 5404
Engine Control Unit (ECU) 5405
Remove 5405
Install 5406
Low Pressure Switch 5406
Remove 5406
Install 5406
Low Fuel Sensor 5407
Remove 5407
Install 5407
LP Converter 5408
Remove and Disassemble 5408
Assemble and Install 5409
LPG Lock-Off 5409
Remove 5410
Install 5411
Exhaust System 5412
Counterweight Exhaust 5412
Remove and Disassemble 5412
Inspect 5414
Assemble and Install 5414
Overhead Exhaust 5415
Remove and Disassemble 5415
Inspect 5417
Assemble and Install 5417
Exhaust Manifold 5417
Remove 5417
Install 5419
Oxygen (HEGO) Sensor 5419
Remove 5419
Install 5419
LPG Fuel Testing 5420
General 5420
Available Fuel Tests 5420
Composition Test (ASTM D-2163) 5420
Ammonia Test (ASTM D-4490) 5420
Basic Nitrogen Test (ASTM UOP269-90) 5420
Residues Test (ASTM D-2158) 5420
Vapor Pressure Test (ASTM D-2598) 5420
Sulfur Compounds Test (ASTM D-5623) 5420
Methanol Test (ASTM D-4864) 5421
Copper Corrosion (ASTM D-1838) 5421
Where To Send LPG Fuel Samples For Testing 5421
550048401-0900YRM1570-(03-2015)-US-EN 5425
550048607-0600YRM1557-(07-2019)-US-EN 5455
General 5461
Engine Identification 5461
Major Engine Component Identification 5461
Location of Labels 5461
Crankcase Description 5462
Engine Removal and Installation 5463
Cylinder Head Assembly Repair 5464
Valve Covers and Fuel Injectors 5464
Remove 5464
Clean and Inspect 5470
Install 5470
Rocker Arm Assembly 5471
Remove 5471
Disassemble 5472
Clean and Inspect 5473
Push Rods 5473
Rocker Arm Assembly 5473
Assemble 5473
Install 5474
Valve Clearance Adjustments 5474
Cylinder Head Assembly 5475
Remove 5475
Disassemble 5487
Valves and Valve Springs, Remove 5487
Valve Guides, Remove 5488
Clean and Inspect 5488
Cylinder Head 5489
Valve Guides 5489
Valves 5489
Valve Sink 5489
Valve Seat 5490
Valve Springs 5490
Assemble 5491
Valve Guides, Install 5491
Valves and Valve Springs, Install 5492
Install 5493
Timing Gear Case and Timing Gears Repair 5497
Timing Gear Case Cover 5497
Remove 5497
Clean and Inspect 5498
Install 5498
Timing Gears 5499
Crankshaft Gear 5500
Remove 5500
Install 5500
Idler Gear 5500
Remove 5500
Inspect 5501
Install 5501
Camshaft Gear 5501
Remove 5501
Install 5502
Timing Gear Case 5502
Remove 5502
Clean and Inspect 5503
Install 5503
Drive Train, Camshaft, and Cylinder Block Repair 5504
Remove 5504
Disassemble 5504
Pistons and Connecting Rods 5504
Crankshaft 5505
Camshaft 5507
Clean and Inspect 5509
Cylinder Block 5509
Honing and Boring 5511
Cylinder Correction (Oversize) 5512
Pistons 5512
Piston Pin 5513
Connecting Rod 5513
Tappets 5514
Crankshaft 5514
Camshaft 5516
Camshaft Bushing 5517
Assemble 5517
Camshaft 5517
Crankshaft 5517
Pistons and Connecting Rods 5518
Install 5520
Angular Deviation Procedure 5520
Lubrication System Repair 5523
Engine Oil and Oil Filter Change 5523
Oil Pan 5524
Remove 5524
Install 5525
Oil Suction Tube 5525
Remove 5525
Clean 5526
Install 5526
Oil Pump 5526
Remove 5526
Clean and Inspect 5527
Outer Rotor Outside Clearance 5527
Outer Rotor to Inner Rotor Tip Clearance 5527
Outer Rotor Side Clearance 5528
Rotor Shaft Clearance 5528
Install 5528
Fuel System Repair 5529
Fuel Injectors 5529
Remove 5529
Inspect 5529
Clean 5529
Replace 5529
Install 5530
Test 5530
Fuel Injection Pump 5530
Remove 5530
Clean and Inspect 5535
Install 5535
Cooling System Repair 5536
Serpentine Belt 5536
Remove 5536
Inspect 5536
Install 5536
Serpentine Belt, Adjustment 5537
Water Pump 5537
Remove 5537
Install 5540
Thermostat 5542
Remove 5542
Inspect 5542
Install 5543
Flywheel and Flywheel Housing 5544
Flywheel 5544
Remove 5544
Install 5544
Flywheel Housing 5544
Remove 5544
Install 5544
Electrical Equipment Repair 5545
Alternator 5545
Remove 5545
Install 5546
Starter 5547
Remove 5547
Install 5547
Engine Specifications 5548
Engine Data For Lift Truck Models and GLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (H813)GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (E879) 5548
Engine Data For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (J813, K813) 5549
Engine Data For Lift Truck Models GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (F879) 5550
Engine Tuning 5551
Cylinder Head 5551
Intake/Exhaust Valve and Guide 5552
Valve Spring 5552
Rocker Arm and Shaft 5552
Push Rod 5552
Gear Train and Camshaft 5553
Camshaft 5553
Idle Gear Shaft and Bushing 5553
Backlash of Each Gear 5553
Cylinder Block 5553
Crankshaft 5553
Piston 5554
Piston Ring 5554
Connecting Rod 5554
Rod Small End 5554
Tappet 5555
Oil Pump 5555
Engine Oil Pressure 5555
Outer Rotor Outside Clearance 5555
Outer Rotor Side Clearance 5555
Inner Rotor to Cover 5555
Standard Torque Specifications 5556
Standard Torque Chart 5556
Special Torque Specifications 5556
Special Tools 5558
550048607-0600YRM1557-(11-2021)-US-EN 5571
General 5577
Engine Identification 5577
Major Engine Component Identification 5577
Location of Labels 5578
Crankcase Description 5579
Engine Removal and Installation 5580
Cylinder Head Assembly Repair 5580
Valve Covers and Fuel Injectors 5580
Remove 5580
Clean and Inspect 5587
Install 5587
Rocker Arm Assembly 5589
Remove 5589
Disassemble 5589
Clean and Inspect 5590
Push Rods 5590
Rocker Arm Assembly 5590
Assemble 5591
Install 5591
Valve Clearance Adjustments 5591
Cylinder Head Assembly 5592
Remove 5592
Disassemble 5603
Valves and Valve Springs, Remove 5603
Valve Guides, Remove 5604
Clean and Inspect 5604
Cylinder Head 5605
Valve Guides 5605
Valves 5605
Valve Sink 5605
Valve Seat 5606
Valve Springs 5606
Assemble 5607
Valve Guides, Install 5607
Valves and Valve Springs, Install 5608
Install 5608
Timing Gear Case and Timing Gears Repair 5612
Timing Gear Case Cover 5612
Remove 5612
Clean and Inspect 5613
Install 5613
Timing Gears 5614
Crankshaft Gear 5614
Remove 5614
Install 5614
Idler Gear 5615
Remove 5615
Inspect 5615
Install 5615
Camshaft Gear 5615
Remove 5615
Install 5616
Timing Gear Case 5616
Remove 5616
Clean and Inspect 5617
Install 5617
Drive Train, Camshaft, and Cylinder Block Repair 5618
Remove 5618
Disassemble 5618
Pistons and Connecting Rods 5618
Crankshaft 5619
Camshaft 5621
Clean and Inspect 5623
Cylinder Block 5623
Honing and Boring 5625
Cylinder Correction (Oversize) 5626
Pistons 5626
Piston Pin 5627
Connecting Rod 5627
Tappets 5628
Crankshaft 5628
Camshaft 5630
Camshaft Bushing 5631
Assemble 5631
Camshaft 5631
Crankshaft 5632
Pistons and Connecting Rods 5632
Install 5634
Angular Deviation Procedure 5634
Lubrication System Repair 5638
Engine Oil and Oil Filter Change 5638
Oil Pan 5639
Remove 5639
Install 5640
Oil Suction Tube 5640
Remove 5640
Clean 5641
Install 5641
Oil Pump 5641
Remove 5641
Clean and Inspect 5642
Outer Rotor Outside Clearance 5642
Outer Rotor to Inner Rotor Tip Clearance 5642
Outer Rotor Side Clearance 5643
Rotor Shaft Clearance 5643
Install 5643
Fuel System Repair 5645
Fuel Injectors 5645
Remove 5645
Inspect 5645
Clean 5645
Replace 5645
Install 5645
Test 5645
Fuel Injection Pump 5645
Remove 5645
Clean and Inspect 5650
Install 5650
Cooling System Repair 5652
Serpentine Belt 5652
Remove 5652
Inspect 5652
Install 5652
Serpentine Belt, Adjustment 5652
Water Pump 5653
Remove 5653
Install 5656
Thermostat 5658
Remove 5658
Inspect 5658
Install 5659
Flywheel and Flywheel Housing 5661
Flywheel 5661
Remove 5661
Install 5661
Flywheel Housing 5661
Remove 5661
Install 5661
Electrical Equipment Repair 5662
Alternator 5662
Remove 5662
Install 5663
Starter 5664
Remove 5664
Install 5664
Engine Specifications 5665
Engine Data For Lift Truck Models and GLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (H813)GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (E879) 5665
Engine Data For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (J813, K813) 5666
Engine Data For Lift Truck Models GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (F879, G879) 5667
Engine Tuning 5668
Cylinder Head 5668
Intake/Exhaust Valve and Guide 5669
Valve Spring 5669
Rocker Arm and Shaft 5669
Push Rod 5669
Gear Train and Camshaft 5670
Camshaft 5670
Idle Gear Shaft and Bushing 5670
Backlash of Each Gear 5670
Cylinder Block 5670
Crankshaft 5670
Piston 5671
Piston Ring 5671
Connecting Rod 5671
Rod Small End 5671
Tappet 5672
Oil Pump 5672
Engine Oil Pressure 5672
Outer Rotor Outside Clearance 5672
Outer Rotor Side Clearance 5672
Inner Rotor to Cover 5672
Standard Torque Specifications 5673
Standard Torque Chart 5673
Special Torque Specifications 5674
Special Tools 5675
550048608-8000YRM1571-(12-2018)-US-EN 5689
General 5695
Serial Number Data 5695
How to Move Disabled Lift Truck 5696
How to Tow Lift Truck 5696
How to Put Lift Truck on Blocks 5697
How to Raise Drive Tires 5697
How to Raise Steering Tires 5697
How to Clean a Lift Truck 5698
Maintenance Schedule 5699
Maintenance Procedures Every 8 Hours or Daily 5713
How to Make Checks With Engine Stopped 5713
Tires and Wheels 5713
Safety Labels 5713
Mast, Carriage, Lift Chains, Header Hoses, Attachment 5714
Operator Restraint System 5714
Emergency Locking Retractor (ELR) 5714
Adjust Seat – Full Suspension 5715
Adjust Seat – Internal Suspension 5716
Hood and Seat Latches 5717
Engine Compartment 5717
Paper Application 5717
Fuel, Oil, and Coolant Leaks, Check 5718
Hydraulic Hoses 5718
Coolant Hoses 5719
Steering Column Gas Cylinder 5719
Transmission 5719
Hydraulic System Oil 5719
Engine Oil 5720
Air Filter 5723
Forks 5723
Remove 5723
Inspect 5724
Install 5724
Adjust 5725
Hang On Sideshift Carriage 5725
How to Make Checks With Engine Running 5726
Indicator Lights, Horn, Fuses, and Relays 5726
Service Brakes 5728
Brake Oil Level 5728
Operation, Check 5729
Parking Brake 5729
Engine Oil Pressure 5729
Cooling System 5729
Steering System 5730
Control Levers and Pedals 5730
Lift System, Operate 5731
Air Filter 5731
Fuel/Water Separator Filter, Kubota 3 8L Diesel Engine 5731
First Service After First 100 Hours of Operation 5731
GM 4 3L Engine Oil and Oil Filter 5732
Kubota 3 8L Engine Oil and Oil Filter 5732
Maintenance Procedures Every 250 Hours or 6 Months 5732
GM 4 3L Engine Oil and Oil Filter Change 5732
Drive Belt 5733
GM 4 3L Engine 5733
Fan and Alternator Drive Belt 5733
Drain Tar From LPG Converter 5734
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine With PSI 5735
Maintenance Procedures Every 500 Hours or 6 Months 5737
Hydraulic System Oil 5738
Hydraulic Tank Breather 5739
Inspect 5739
Battery 5740
Kubota 3 8L Engine Oil and Oil Filter 5740
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 5741
Remove 5741
Install 5741
Priming the Fuel System (Kubota 3 8L Engine) 5742
Drive Belt 5743
Kubota 3 8L Diesel Engine 5743
Fan and Alternator Drive Belt 5743
Clean Debris From Radiator Core 5743
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 5744
Wet Brake Center Body Oil Level Check 5744
Forks 5747
Mast Lubrication 5748
Header Hose Checks 5752
Lift Chain Lubrication 5752
Tilt Cylinder Lubrication 5752
Master Brake Cylinder Rod End Pin Lubrication 5753
Manual Hydraulic Levers Lubrication 5754
Brake Oil 5754
Tie Rod Lubrication 5755
Parking Brake Adjustment 5755
Maintenance Procedures Every 1000 Hours or 6 Months 5756
Valve Clearance, Check and Adjust 5756
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 5756
Ignition System 5756
GM 4 3L Engine 5756
Gasoline Fuel Filter, GM 4 3L Engine 5756
Remove and Replace 5756
In-Line Strainer Replacement, Kubota 3 8L Engine 5757
Remove 5757
Install 5757
Lift Chains Wear Check 5759
Lift Chain Lubrication 5759
Hang On Sideshift Carriage, Check Sliding Surfaces 5759
Steering Axle Spindle Bearings 5762
Control Levers and Pedals 5763
Inspect Engine Electrical System, Connectors 5763
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 5764
Parking Brake Lever Lubrication, Dana Wet Brake Axle 5767
Normal Operating Environment 5767
Heavy Duty or Contaminated Environment 5767
Remove 5767
Clean and Inspect 5768
Install 5769
Crankcase Breather Element 5769
Remove 5769
Clean and Inspect 5770
Install 5770
Maintenance Procedures Every 2000 Hours or Annually 5770
Hydraulic System 5770
Hydraulic Filter Assembly, Replace 5770
Hydraulic Tank Breather, Replace 5771
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 5772
Cooling System Check 5772
Air Filter 5774
LPG Fuel Filter Element Replace, GM 4 3L With PSI Engine 5775
Remove 5775
Install 5776
Fuel Injector, Kubota 3 8L Engine 5776
Forks 5776
Brake Oil (Master Cylinder), Change 5776
Check Throttle Shaft for Sticking 5777
Inspect Exhaust Manifold and Piping for Leaks 5777
Transmission Automatic Clutch Calibration 5778
Brake System Accumulator 5778
Wheel Bearings 5778
Steer Wheels, Lubrication 5778
Maintenance Procedures Every 4000 Hours or 2 Years 5778
Hydraulic Oil, Replace 5778
Safety Procedures When Working Near Mast 5780
Fuel Filter Water Removal 5782
Kubota Diesel Engine 5782
3 8L Diesel Engine 5782
Hood Latch Check 5783
Lift Chain Adjustments 5784
Jump-Starting the Lift Truck 5786
Jump-Starting Using a Battery Charger 5786
Jump-Starting a Lift Truck Using Another Lift Truck 5786
Welding Repairs 5787
Overhead Guard Changes 5787
Wheel and Tire Replacement 5788
General 5788
Solid Rubber Tire, Change 5788
Remove and Install Tire on Wheel 5788
Adhesives and Sealants 5790
550048609-8000YRM1572-(04-2018)-US-EN 5793
Lift Truck Lifting Capacity 5797
Counterweight Weights 5797
Tire Sizes 5797
Capacities 5797
Electrical System 5801
Transmission Oil Pressures 5802
Hydraulic System Relief Pressures 5803
Steering System 5804
Stall Speeds (in RPM ±100 rpm) 5804
GM 4 3L Gas 5804
GM/PSI 4 3L LPG 5804
Kubota Diesel 5804
Tilt Angles 5804
Front End Equipment – Mast Creep 5805
Mast Creep 5805
Engine Specifications 5806
Diesel Fuel Cleanliness Levels 5807
Torque Specifications 5808
Frame 5808
Mast 5808
Hang On Sideshift Carriage With Fork Positioner, Lift Truck Models Manufactured After August, 2012GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 5808
Steering System 5808
Transmission 5808
Engine – GM 4 3L 5809
Engine – Kubota 3 8L Diesel 5810
550055283-8000YRM1585-(06-2021)-US-EN 5813
General Information About Diagrams and Schematics 5817
Symbol Definitions 5817
Diagrams Manual Applications 5818
Diagrams and Schematics 5820
550055283-8000YRM1585-(07-2020)-US-EN 5909
General Information About Diagrams and Schematics 5913
Symbol Definitions 5913
Diagrams Manual Applications 5914
Diagrams and Schematics 5916
550073240-1900YRM1620-(01-2023)-US-EN 6005
Proper Flushing after Major Hydraulic Repairs 6011
Introduction 6011
The Phases of Wear 6011
Causes of Hydraulic System Failure 6011
Progression of Contaminant Caused Hydraulic System Failure 6012
Hydraulic System Flushing Techniques 6012
Double Oil and Filter Change 6012
Mechanical Cleaning 6013
Cleaning of Components 6013
How to Clean Tubes and Hoses 6013
Filter Caddy 6013
Start-Up Procedure for Cleaned System 6014
Contaminated Oil Coolers 6014
Additional Filter Caddy Functions 6015
How to Handle Different Fluids 6015
Water Removal Filters 6015
Fluid Conditioning and System Flushing Procedures 6016
Operation of the Filter Caddy 6016
Filter Caddy operation 6016
Fluid Conditioning Procedure 6016
Filter Caddy Start-Up 6017
System Flushing Procedure 6017
Component Cleaning Procedure 6018
Reservoir Cleaning Procedure 6018
Cylinder Cleaning Procedure 6018
Hose and Tube Cleaning Procedure 6018
Valve Cleaning Procedure 6019
Front-End Attachment Cleaning Procedure 6020
System Flushing Procedure 6020
Filter Caddy Start-Up 6021
System Start-Up and Flushing 6021
Reservoir Fluid Cleaning Times 6022
Dealing With Different Fluid Types 6023
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 6023
Filter Caddy Maintenance 6023
Servicing the Strainer 6023
DC Motor 6023
Hydraulic Oil Sampling Method and Procedure 6024
Hydraulic Oil Sampling Method 6024
Objective 6024
General Guidelines 6024
Synopsis 6025
Hydraulic Oil Analysis Report Guidelines 6026
Sampling Conditions 6026
Equipment 6026
Sampling Procedure 6027
Hydraulic Oil Sampling 6027
Sample Labeling 6027
Results Documentation 6027
550073240-1900YRM1620-(03-2020)-US-EN 6029
Proper Flushing after Major Hydraulic Repairs 6033
Introduction 6033
The Phases of Wear 6033
Causes of Hydraulic System Failure 6033
Progression of Contaminant Caused Hydraulic System Failure 6034
Hydraulic System Flushing Techniques 6034
Double Oil and Filter Change 6034
Mechanical Cleaning 6035
Cleaning of Components 6035
How to Clean Tubes and Hoses 6035
Filter Caddy 6035
Start-Up Procedure for Cleaned System 6036
Contaminated Oil Coolers 6036
Additional Filter Caddy Functions 6036
How to Handle Different Fluids 6036
Water Removal Filters 6037
Fluid Conditioning and System Flushing Procedures 6037
Operation of the Filter Caddy 6037
Filter Caddy operation 6037
Fluid Conditioning Procedure 6038
Filter Caddy Start-Up 6038
System Flushing Procedure 6039
Component Cleaning Procedure 6039
Reservoir Cleaning Procedure 6039
Cylinder Cleaning Procedure 6039
Hose and Tube Cleaning Procedure 6040
Valve Cleaning Procedure 6040
Front-End Attachment Cleaning Procedure 6041
System Flushing Procedure 6041
Filter Caddy Start-Up 6042
System Start-Up and Flushing 6042
Reservoir Fluid Cleaning Times 6043
Dealing With Different Fluid Types 6043
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 6043
Filter Caddy Maintenance 6044
Servicing the Strainer 6044
DC Motor 6044
Hydraulic Oil Sampling Method and Procedure 6044
Hydraulic Oil Sampling Method 6044
Objective 6044
General Guidelines 6044
Synopsis 6045
Hydraulic Oil Analysis Report Guidelines 6046
Sampling Conditions 6047
Equipment 6047
Sampling Procedure 6047
Hydraulic Oil Sampling 6047
Sample Labeling 6048
Results Documentation 6048

S.V 06/24