Yale Forklift F818 (GC_GLC080-120 VX, GC_GLC080-100VXBCS, GC_GLC120SVX, GC_GLC120VXPRS) Service Manual PDF

Description

Yale Forklift F818 (GC_GLC080-120 VX, GC_GLC080-100VXBCS, GC_GLC120SVX, GC_GLC120VXPRS) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift F818 (GC_GLC080-120 VX, GC_GLC080-100VXBCS, GC_GLC120SVX, GC_GLC120VXPRS) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5582
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift F818 (GC_GLC080-120 VX, GC_GLC080-100VXBCS, GC_GLC120SVX, GC_GLC120VXPRS) 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
524223768-2100YRM1139-(02-2014)-US-EN 2727
524223769-2200YRM1128-(01-2023)-US-EN 2775
Series Code / Model Designation Reference Table 2783
General 2785
Deutsch Crimping Tool 2786
How to Strip a Wire for Use With Deutsch Crimping Tool 2786
How to Crimp With the Deutsch Crimping Tool 2787
Calibration Test for the Deutsch Crimping Tool 2789
Deutsch Connectors 2791
DT, DTM, and DTP Series Connectors 2791
HD Series Connectors 2834
Metri-Pack Connectors 2856
Remove and Install 2856
Micro-Pack Connectors 2859
Weather-Pack Connectors 2860
AMPSEAL Crimping Tools 2862
AMP Hand Crimping Tool With Certi-Crimp 2862
Description 2862
Stripping Wire for Use with AMP Hand Crimping Tool 2863
Insulation Crimp Adjustment 2864
Maintenance and Inspection for AMP Hand Crimping Tool 2864
AMP Hand Crimping Tool 2864
Crimp Height Inspection 2864
How to use AMP Hand Crimping Tool 2865
AMP Pro-Crimper II Tool 2865
Description 2865
Remove and Install Die Set and Locator Assembly 2866
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2866
Contact Support Adjustment 2867
Crimp Height Adjustment 2868
Maintenance and Inspection Procedures 2868
PRO-CRIMPER II Tool 2868
Crimp Height Inspection 2868
How to Use AMP PRO-CRIMPER II Tool 2869
AMPSEAL Connector Assemblies 2870
Description for Plug Connector Assembly 2870
Seal Plug 2871
Contact Crimping 2871
Description for Plug Connector and Header Assembly 2876
Voltage Reading 2879
Seal Plug 2879
Contact Crimping 2879
AMP Superseal 1 5 Crimping Tools 2886
Mini Mic Receptacle and Tab Contacts 2886
Description 2886
Crimping Conditions and Measurements 2886
Insertion of Rubber Seal on Cable 2888
AMP Hand Application Tool 2893
Description 2893
Maintenance and Inspection 2893
Crimp Height Inspection 2893
Crimp Height Adjustment 2894
How to Use AMP Hand Application Tool 2894
AMP Pro-Crimper II Tool 2895
Description 2895
Remove and Install Die Set and Locator Assembly 2895
Adjustments 2896
Contact Support 2896
Crimp Height 2897
Inspections and Maintenance 2898
Crimp Height Inspection 2898
Visual Inspection 2898
Maintenance 2899
How to Use Pro-Crimper II Tool 2899
AMP Superseal 1 5 Connector Assemblies 2900
Description 2900
Repair and Maintenance 2907
Panel Mount Option 2907
AMP Fastin-Faston Hand Tools 2908
Description – AMP Double Action Hand Tool 2908
Maintenance and Inspection Procedures 2908
Daily Maintenance 2908
Periodic Tool Inspection 2909
Lubrication 2909
Visual Inspection 2909
Crimp Height Inspection 2909
Certi-Crimp Ratchet Inspection 2910
How to Use AMP Double Action Hand Tool 2911
Description – AMP Extraction Tool 2912
Maintenance and Inspection 2913
How to Use AMP Extraction Tool 2913
AMP Fastin-Faston Receptacles and Housings 2915
Description 2915
Wire Repair 2923
Wire Splicing Requirements 2923
Deutsch Jiffy Splice 2924
Twisted/Shielded Cable and Leads Repair 2930
Special Tools 2932
524223769-2200YRM1128-(07-2020)-US-EN 2941
Series Code / Model Designation Reference Table 2947
General 2950
Deutsch Crimping Tool 2950
How to Strip a Wire for Use With Deutsch Crimping Tool 2950
How to Crimp With the Deutsch Crimping Tool 2951
Calibration Test for the Deutsch Crimping Tool 2953
Deutsch Connectors 2955
DT, DTM, and DTP Series Connectors 2955
HD Series Connectors 2997
Metri-Pack Connectors 3020
Remove and Install 3020
Micro-Pack Connectors 3022
Weather-Pack Connectors 3023
AMPSEAL Crimping Tools 3025
AMP Hand Crimping Tool With Certi-Crimp 3025
Description 3025
Stripping Wire for Use with AMP Hand Crimping Tool 3025
Insulation Crimp Adjustment 3026
Maintenance and Inspection for AMP Hand Crimping Tool 3026
AMP Hand Crimping Tool 3026
Crimp Height Inspection 3026
How to use AMP Hand Crimping Tool 3027
AMP Pro-Crimper II Tool 3027
Description 3027
Remove and Install Die Set and Locator Assembly 3028
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3029
Contact Support Adjustment 3029
Crimp Height Adjustment 3030
Maintenance and Inspection Procedures 3030
PRO-CRIMPER II Tool 3030
Crimp Height Inspection 3030
How to Use AMP PRO-CRIMPER II Tool 3031
AMPSEAL Connector Assemblies 3032
Description for Plug Connector Assembly 3032
Seal Plug 3033
Contact Crimping 3033
Description for Plug Connector and Header Assembly 3038
Voltage Reading 3040
Seal Plug 3040
Contact Crimping 3040
AMP Superseal 1 5 Crimping Tools 3047
Mini Mic Receptacle and Tab Contacts 3047
Description 3047
Crimping Conditions and Measurements 3047
Insertion of Rubber Seal on Cable 3049
AMP Hand Application Tool 3054
Description 3054
Maintenance and Inspection 3054
Crimp Height Inspection 3054
Crimp Height Adjustment 3055
How to Use AMP Hand Application Tool 3055
AMP Pro-Crimper II Tool 3056
Description 3056
Remove and Install Die Set and Locator Assembly 3057
Adjustments 3057
Contact Support 3057
Crimp Height 3058
Inspections and Maintenance 3059
Crimp Height Inspection 3059
Visual Inspection 3059
Maintenance 3060
How to Use Pro-Crimper II Tool 3060
AMP Superseal 1 5 Connector Assemblies 3061
Description 3061
Repair and Maintenance 3068
Panel Mount Option 3068
AMP Fastin-Faston Hand Tools 3069
Description – AMP Double Action Hand Tool 3069
Maintenance and Inspection Procedures 3069
Daily Maintenance 3069
Periodic Tool Inspection 3070
Lubrication 3070
Visual Inspection 3070
Crimp Height Inspection 3070
Certi-Crimp Ratchet Inspection 3071
How to Use AMP Double Action Hand Tool 3072
Description – AMP Extraction Tool 3073
Maintenance and Inspection 3073
How to Use AMP Extraction Tool 3074
AMP Fastin-Faston Receptacles and Housings 3075
Description 3075
Wire Repair 3082
Wire Splicing Requirements 3082
Deutsch Jiffy Splice 3083
Twisted/Shielded Cable and Leads Repair 3088
Special Tools 3091
524223770-2200YRM1130-(03-2020)-US-EN 3099
General 3103
Description 3103
Dash Display Menu Access 3103
Menu Navigation 3104
Standard Display 3104
Main Menu 3104
Passwords Menu 3105
Password Administration 3105
Add Password 3105
Delete Password 3106
Edit Password 3106
Other Password Functions 3107
Operator Passwords – Enable/Disable 3107
Password Time-Out Delay 3107
Passwords – Number Wrong to Disable 3108
Lockout Reset Password 3108
View Password Log 3109
View Versions 3110
VSM Versions 3110
Dash Display Versions 3111
Engine Controller Version 3112
Transmission (Xmsn) Controller Version 3113
Truck Serial Number 3114
Diagnostics 3115
View Fault Log 3115
Set Travel and Braking 3116
Speed Limit 3116
Acceleration Rate 3117
Auto-Deceleration Rate 3117
Set Power Reversal Rate 3118
Set Inching/Brake Overlap 3119
Setup Display Menu 3120
Set Operator Language 3120
Set Units 3121
Set Time Format (12/24 Hour) 3121
Set Daylight Saving Time 3121
Set Time 3124
Set Date Format 3125
Set Date 3125
Setup Hydraulics 3126
Return to Set Tilt Delay/On/Off 3126
Setup General Items 3127
Light Shutdown Time-Out 3127
Impact Sensor – Enable/Disable 3128
Impact Sensor – Soft Impact Settings 3129
Impact Sensor – Hard Impact Settings 3130
Adjust Impact Sensor Settings 3130
Initial Adjustment of Soft and Hard Impact Settings 3132
Readjustment of Soft and Hard Impact Settings 3132
Impact Sensor – Impact Alarm/Shutdown Reset 3133
Impact Sensor – Alarm Time Duration and Deactivation 3134
Impact Sensor – View Impact Event Log 3135
Engine Mode Indicator 3136
Generation 1 (ECO-eLo ONLY) 3136
Generation 2 3137
Operator Checklist 3138
Operator Checklist Off-On Mode 3138
Edit Operator Checklist 3138
Set Operator Checklist Expiration 3139
View Checklist Log 3139
Clear Operator Checklist Log 3140
Clear Operator Checklist Fault 3140
Calibrations 3141
Set Tilt Stop Point 3141
Calibrate Loaded Weight 3141
524223770-2200YRM1130-(05-2021)-US-EN 3143
General 3147
Description 3147
Dash Display Menu Access 3147
Menu Navigation 3148
Standard Display 3148
Main Menu 3148
Passwords Menu 3149
Password Administration 3149
Add Password 3149
Delete Password 3149
Edit Password 3150
Other Password Functions 3151
Operator Passwords – Enable/Disable 3151
Password Time-Out Delay 3151
Passwords – Number Wrong to Disable 3151
Lockout Reset Password 3152
View Password Log 3152
View Versions 3153
VSM Versions 3153
Dash Display Versions 3154
Engine Controller Version 3155
Transmission (Xmsn) Controller Version 3156
Truck Serial Number 3157
Diagnostics 3158
View Fault Log 3158
Set Travel and Braking 3159
Speed Limit 3159
Acceleration Rate 3160
Auto-Deceleration Rate 3160
Set Power Reversal Rate 3161
Set Inching/Brake Overlap 3162
Setup Display Menu 3163
Set Operator Language 3163
Set Units 3164
Set Time Format (12/24 Hour) 3164
Set Daylight Saving Time 3165
Set Time 3168
Set Date Format 3168
Set Date 3169
Setup Hydraulics 3170
Return to Set Tilt Delay/On/Off 3170
Setup General Items 3171
Light Shutdown Time-Out 3171
Impact Sensor – Enable/Disable 3172
Impact Sensor – Soft Impact Settings 3173
Impact Sensor – Hard Impact Settings 3173
Adjust Impact Sensor Settings 3174
Initial Adjustment of Soft and Hard Impact Settings 3176
Readjustment of Soft and Hard Impact Settings 3176
Impact Sensor – Impact Alarm/Shutdown Reset 3177
Impact Sensor – Alarm Time Duration and Deactivation 3178
Impact Sensor – View Impact Event Log 3179
Engine Mode Indicator 3179
Generation 1 (ECO-eLo ONLY) 3179
Generation 2 3180
Operator Checklist 3181
Operator Checklist Off-On Mode 3181
Edit Operator Checklist 3181
Set Operator Checklist Expiration 3181
View Checklist Log 3182
Clear Operator Checklist Log 3183
Clear Operator Checklist Fault 3183
Calibrations 3184
Set Tilt Stop Point 3184
Calibrate Loaded Weight 3184
524223771-2200YRM1131-(03-2020)-US-EN 3187
Series Code / Model Designation Reference Table 3193
General 3195
Description 3195
Dash Display Menu Access 3195
Menu Navigation 3196
Main Menu 3196
Passwords 3197
Adding Passwords 3197
Hourmeters 3199
View Versions 3200
VSM Versions 3200
Dash Display Versions 3201
Engine Controller Version 3202
Transmission (Xmsn) Controller Version 3203
Truck Serial Number 3204
Truck Configuration 3205
Diagnostics 3206
Clear Fault Log 3206
View Fault Log 3207
No-Run Data Display 3208
Engine Accelerator and Throttle Data Display 3208
Engine Speeds and Governor Data Display 3209
Engine Fuel and Emissions Data Display 3210
Engine General Data Display 3212
XMSN/Brake Data Display 3213
Hydraulic Data Display 3216
General Truck Data Display 3218
Set Travel and Braking 3219
Speed Limit 3219
Acceleration Rate 3220
Auto-Deceleration Rate 3221
Set Power Reversal Rate 3221
Set Inching/Brake Overlap 3222
Setup Hydraulics 3222
Lift Maximum Speed 3223
Lower Maximum Speed 3223
Tilt Maximum Speed 3224
Auxiliary Function One, Direction A, Maximum Speed 3226
Auxiliary Function One, Direction B, Maximum Speed 3228
Auxiliary Function Two, Direction A, Maximum Speed 3228
Auxiliary Function Two, Direction B, Maximum Speed 3229
Auxiliary Function Three, Direction A, Maximum Speed 3230
Auxiliary Function Three, Direction B, Maximum Speed 3230
Lift/Lower Ramp Rate 3231
Hydraulic Auxiliary Ramp Rate 3231
Return to Set Tilt Delay/On/Off 3232
Hydraulic Input Device 3233
Auxiliary Solenoid 3233
Dual Function 3234
Setup Display 3235
Set Service Language 3235
Setup General Items 3235
Motion Alarm Activation Type 3236
Light Shutdown Time-Out 3237
Restore Default Settings 3237
Restore Engine Controller Default Calibration 3238
Impact Sensor – Enable/Disable 3238
Impact Sensor – Soft Impact Settings 3239
Impact Sensor – Hard Impact Settings 3240
Adjust Impact Sensor Settings 3241
Initial Adjustment of Soft and Hard Impact Settings 3243
Readjustment of Soft and Hard Impact Settings 3243
Impact Sensor – Impact Alarm/Shutdown Reset 3244
Impact Sensor – Alarm Time Duration and Deactivation 3245
Impact Sensor – View Impact Event Log 3246
Engine Mode Indicator 3246
Generation 1 (ECO-eLo ONLY) 3246
Generation 2 3247
Diesel Particulate Filter (DPF) Display 3248
General Description 3248
Passive Regeneration Only 3248
Regeneration Level 0 3248
Auto/Active Regeneration Inhibited 3249
Auto/Active Regeneration 3249
Regeneration Level 1 3249
Parked Regeneration Request 3250
Regeneration Level 2 3250
Warning Level 3250
Regeneration Level 3 3250
Service Level 3251
Regeneration Level 4 3251
Display, Diesel Particulate Filter (DPF), Revised 3251
Operator Interface 3251
Refer to Operator Manual 3251
CAN Communication Lost 3252
Passive Regeneration Only 3252
Regeneration Level 0 3252
Auto/Active Regeneration Inhibited 3252
Auto/Active Regeneration 3253
Regeneration Level 1 3253
Idle-up Auto/Active Regeneration 3253
Parked Regeneration Request 3253
Regeneration Level 2 3253
Warning Level 3255
Regeneration Level 3 3255
Service Level 3255
Regeneration Level 4 3255
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3255
Display, Diesel Particulate Filter (DPF), Stage V Engine 3255
Operator Interface 3256
Refer to Operator Manual 3256
CAN Communication Lost 3256
Passive Regeneration Only 3256
Regeneration Level 0 3256
Auto/Active Regeneration Inhibited 3257
Auto/Active Regeneration 3257
Regeneration Level 1 3257
Idle-up Auto/Active Regeneration 3258
Parked Regeneration Request 3258
Regeneration Level 2 3258
Warning Level 3259
Regeneration Level 3 3259
Service Level 3260
Regeneration Level 4 3260
Stage V Content 3260
Emissions System Malfunction 3260
Ash Load 3260
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3261
Operator Interface 3261
Refer to Operator Manual 3261
CAN Communication Lost 3262
Passive Regeneration Only 3262
Regeneration Level 0 3262
Auto/Active Regeneration Inhibited 3262
Auto/Active Regeneration 3263
Regeneration Level 1 3263
Idle-up Auto/Active Regeneration 3263
Parked Regeneration Request 3263
Regeneration Level 2 3263
Warning Level 3265
Regeneration Level 3 3265
Service Level 3265
Regeneration Level 4 3265
Calibrations 3266
Calibrate Transmission Valve 3268
Set Tilt Stop Point 3268
Calibrate Loaded Weight 3268
Calibrate Travel Speed Sensor 3269
Calibrate Mazda LP and Gas Accelerator Pedal 3269
524223771-2200YRM1131-(05-2021)-US-EN 3271
Series Code / Model Designation Reference Table 3277
General 3279
Description 3279
Dash Display Menu Access 3279
Menu Navigation 3280
Main Menu 3281
Passwords 3281
Adding Passwords 3281
Hourmeters 3283
View Versions 3284
VSM Versions 3284
Dash Display Versions 3285
Engine Controller Version 3286
Transmission (Xmsn) Controller Version 3287
Truck Serial Number 3288
Truck Configuration 3289
Diagnostics 3290
Clear Fault Log 3290
View Fault Log 3291
No-Run Data Display 3292
Engine Accelerator and Throttle Data Display 3293
Engine Speeds and Governor Data Display 3295
Engine Fuel and Emissions Data Display 3296
Engine General Data Display 3298
XMSN/Brake Data Display 3299
Hydraulic Data Display 3301
General Truck Data Display 3304
Set Travel and Braking 3306
Speed Limit 3306
Acceleration Rate 3307
Auto-Deceleration Rate 3307
Set Power Reversal Rate 3308
Set Inching/Brake Overlap 3308
Setup Hydraulics 3309
Lift Maximum Speed 3309
Lower Maximum Speed 3310
Tilt Maximum Speed 3310
Auxiliary Function One, Direction A, Maximum Speed 3312
Auxiliary Function One, Direction B, Maximum Speed 3315
Auxiliary Function Two, Direction A, Maximum Speed 3315
Auxiliary Function Two, Direction B, Maximum Speed 3316
Auxiliary Function Three, Direction A, Maximum Speed 3317
Auxiliary Function Three, Direction B, Maximum Speed 3317
Lift/Lower Ramp Rate 3318
Hydraulic Auxiliary Ramp Rate 3318
Return to Set Tilt Delay/On/Off 3319
Hydraulic Input Device 3320
Auxiliary Solenoid 3320
Dual Function 3321
Setup Display 3322
Set Service Language 3322
Setup General Items 3322
Motion Alarm Activation Type 3323
Light Shutdown Time-Out 3324
Restore Default Settings 3324
Restore Engine Controller Default Calibration 3325
Impact Sensor – Enable/Disable 3325
Impact Sensor – Soft Impact Settings 3326
Impact Sensor – Hard Impact Settings 3326
Adjust Impact Sensor Settings 3327
Initial Adjustment of Soft and Hard Impact Settings 3329
Readjustment of Soft and Hard Impact Settings 3329
Impact Sensor – Impact Alarm/Shutdown Reset 3330
Impact Sensor – Alarm Time Duration and Deactivation 3331
Impact Sensor – View Impact Event Log 3332
Engine Mode Indicator 3332
Generation 1 (ECO-eLo ONLY) 3332
Generation 2 3333
Diesel Particulate Filter (DPF) Display 3334
General Description 3334
Passive Regeneration Only 3334
Regeneration Level 0 3334
Auto/Active Regeneration Inhibited 3335
Auto/Active Regeneration 3335
Regeneration Level 1 3335
Parked Regeneration Request 3336
Regeneration Level 2 3336
Warning Level 3337
Regeneration Level 3 3337
Service Level 3337
Regeneration Level 4 3337
Display, Diesel Particulate Filter (DPF), Revised 3337
Operator Interface 3338
Refer to Operator Manual 3338
CAN Communication Lost 3338
Passive Regeneration Only 3338
Regeneration Level 0 3338
Auto/Active Regeneration Inhibited 3339
Auto/Active Regeneration 3339
Regeneration Level 1 3339
Idle-up Auto/Active Regeneration 3339
Parked Regeneration Request 3340
Regeneration Level 2 3340
Warning Level 3341
Regeneration Level 3 3341
Service Level 3341
Regeneration Level 4 3341
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3342
Display, Diesel Particulate Filter (DPF), Stage V Engine 3342
Operator Interface 3342
Refer to Operator Manual 3342
CAN Communication Lost 3343
Passive Regeneration Only 3343
Regeneration Level 0 3343
Auto/Active Regeneration Inhibited 3343
Auto/Active Regeneration 3344
Regeneration Level 1 3344
Idle-up Auto/Active Regeneration 3344
Parked Regeneration Request 3344
Regeneration Level 2 3344
Warning Level 3346
Regeneration Level 3 3346
Service Level 3346
Regeneration Level 4 3346
Stage V Content 3346
Emissions System Malfunction 3346
Ash Load 3347
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3348
Operator Interface 3348
Refer to Operator Manual 3348
CAN Communication Lost 3349
Passive Regeneration Only 3349
Regeneration Level 0 3349
Auto/Active Regeneration Inhibited 3349
Auto/Active Regeneration 3350
Regeneration Level 1 3350
Idle-up Auto/Active Regeneration 3350
Parked Regeneration Request 3350
Regeneration Level 2 3350
Warning Level 3352
Regeneration Level 3 3352
Service Level 3352
Regeneration Level 4 3352
Calibrations 3353
Calibrate Transmission Valve 3355
Set Tilt Stop Point 3355
Calibrate Loaded Weight 3356
Calibrate Travel Speed Sensor 3356
Calibrate Mazda LP and Gas Accelerator Pedal 3357
524223772-2200YRM1142-(01-2020)-US-EN 3359
General 3369
Display Switch Cluster 3372
Remove 3372
Install 3375
Direction Control and Turn Signal Levers 3375
Remove 3375
Install 3377
Key Switch 3377
Remove 3377
Install 3378
Display Switch Cluster Panel Bezel and Overlay 3378
Remove 3378
Install 3378
Steering Column Repair 3378
Remove 3378
Disassemble 3381
Assemble 3381
Install 3381
Sensors and Switches 3382
General 3382
Dash and Kick Panel, Remove and Install 3382
Remove 3382
Install 3383
Accelerator Pedal Position Sensor 3384
Remove 3384
Install 3387
Brake Fluid Level Switch 3388
Remove 3388
Install 3390
Service Brake Pedal Position Sensor 3391
Remove 3391
Install 3394
Parking Brake Sensor 3395
Remove 3395
Install 3396
Service Brake Pressure Sensor 3397
Remove 3397
Install 3399
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3400
Remove 3400
Install 3400
Sensor Microswitch (Foot Directional Control Pedal) 3401
Remove 3401
Install 3404
Low Coolant Level Sensor 3405
Remove 3405
Install 3408
Fuel Level Sensor, Gas and Diesel Engines Only 3409
Remove 3409
Install 3410
Armrest Switch 3410
Remove 3410
Install 3412
Seat Sensor (Operator Presence System) 3412
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) 3412
Remove 3412
Install 3413
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3413
Remove 3413
Install 3414
Full Suspension Seats; All Lift Truck Models 3414
Remove 3414
Install 3414
Hood Shut Off Switch 3414
Remove 3414
Install 3417
Remote Key Switch 3418
Remove 3418
Install 3418
Hydraulic Filter Pressure Switch 3419
Remove 3419
Install 3421
Transmission Speed Sensor 3421
Remove 3421
Install 3424
Transmission Pressure Sensors 3425
Remove 3425
Install 3427
Transmission Temperature Sensor 3428
Remove 3428
Install 3430
Engine Speed Sensor 3432
Remove 3432
Install 3432
Intermediate Speed Sensor 3433
Remove 3433
Install 3433
Return to Set Tilt (Tilt Angle) Sensor 3433
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) 3433
Remove 3433
Install 3434
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) 3435
Remove 3435
Install 3436
Rear Horn Button Switch 3436
Remove 3436
Install 3437
Impact Sensor 3438
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) 3438
Remove 3438
Install 3441
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) 3441
Remove 3441
Install 3442
Load Weight Sensor 3443
Remove 3443
Install 3444
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3445
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3445
Crankshaft Position (CKP) Sensor 3445
Camshaft Position (CMP) Sensor 3445
Oil Pressure Sensor 3445
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3445
Engine Coolant Temperature (ECT) Sensor 3446
Air Flow Restriction Switch 3446
Remove for GM 2 4L Gas and LPG Trucks 3446
Install for GM 2 4L Gas and LPG Trucks 3446
Oxygen Sensor 3447
Remove 3447
Install 3450
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3451
Crankshaft Position (CKP) Sensor 3451
Camshaft Position (CMP) Sensor 3451
Oil Pressure Sensor 3451
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3451
Engine Coolant Temperature (ECT) Sensor 3451
Air Flow Restriction Switch 3451
Oxygen Sensor 3451
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3451
Low LPG Pressure Switch 3451
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3452
Air Filter Restriction Switch 3452
Remove 3452
Install 3452
Oil Pressure Sensor 3452
Remove 3452
Install 3452
Engine Speed Sensor 3452
Remove 3452
Install 3452
Engine Coolant Temperature (ECT) Sensor 3452
Remove 3452
Install 3452
Throttle Position Sensor (TPS) 3455
Remove 3455
Install 3456
Fuel/Water Separator Sensor 3456
Remove 3456
Install 3456
Glow Plug Relay 3457
Remove 3457
Install 3459
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3459
Air Filter Restriction Switch 3459
Remove 3459
Install 3459
Engine Oil Pressure Sensor 3464
Remove 3464
Install 3464
Engine Speed Sensor 3464
Remove 3464
Install 3465
Engine Coolant Temperature (ECT) Sensor 3465
Remove 3465
Install 3466
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3467
Remove 3467
Install 3467
Fuel/Water Separator Sensor 3468
Remove 3468
Install 3468
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3469
Intake Air Temperature Sensor 3469
Remove 3469
Install 3470
Intake Air Pressure Sensor 3470
Remove 3470
Install 3470
Air Inlet Heater 3470
Remove 3470
Install 3471
Engine Oil Pressure Sensor 3471
Remove 3471
Install 3471
Engine Coolant Temperature (ECT) Sensor 3471
Remove 3471
Install 3471
Crankshaft Position Sensor 3472
Remove 3472
Install 3472
Adjust Shim Procedure 3473
Camshaft Position Sensor 3474
Remove 3474
Install 3474
Air Flow Restriction Sensor 3475
Remove 3475
Install 3475
Fuel/Water Separator 3475
Remove 3475
Install 3476
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3476
Intake Air Temperature Sensor 3480
Remove 3480
Install 3481
Boost Sensor 3481
Remove 3481
Install 3482
Throttle Valve Assembly and Air Intake Heater 3482
Remove 3482
Install 3482
Engine Coolant Temperature (ECT) Sensor 3483
Remove 3483
Install 3483
Engine Oil Pressure Sensor 3483
Remove 3483
Install 3484
Crankshaft Position Sensor 3484
Remove 3484
Install 3484
Adjust Shim Procedure 3485
Camshaft Position Sensor 3486
Remove 3486
Install 3487
Differential Pressure Sensor 3487
Remove 3487
Install 3487
Mass Air Flow Sensor 3488
Remove 3488
Install 3489
Fuel/Water Separator 3489
Remove 3489
Install 3490
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3490
Engine Coolant Temperature (ECT) Sensor 3491
Remove 3491
Install 3491
Throttle Position Sensor 3492
Engine Oil Pressure Sensor 3492
Remove 3492
Install 3492
Engine Speed Sensor 3492
Remove 3492
Install 3492
Fuel Shut Off Solenoid 3492
Remove 3492
Install 3492
Vehicle System Manager (VSM) 3493
General 3493
VSM Replacement 3493
Remove 3493
Install 3495
Programming a New VSM and/or Display Switch Cluster 3495
General 3495
PC Service Tool Software 3496
Data Transferring 3496
New VSM 3496
New (Blank) Display Switch Cluster 3496
Used (Non-Blank) Display Switch Cluster 3496
Power Distribution Module (PDM) and Component Parts 3498
Remove 3498
PDM as a Unit 3498
Install 3502
PDM as a Unit 3502
Remove and Install 3503
PDM Component Parts 3503
Transmission Control Unit 3503
Remove 3503
Install 3507
Battery 3509
Remove 3509
Install 3509
Lights 3510
Work Lights (Front and Rear) 3510
Remove 3510
Install 3510
Strobe Light 3511
Remove 3511
Install 3511
LED Tail, Backup, and Brake Lights 3512
Remove 3512
Install 3513
Front Marker/Turn Signal Lights 3514
Replacing Whole Front Marker/Turn Signal Light Assembly 3514
Remove 3514
Install 3514
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3515
Remove 3515
Install 3515
Diesel Particulate Filter (DPF) Display 3515
Remove 3515
Clean and Inspect 3516
Install 3516
Electronic-Hydraulic Controls – Generation 1 3517
E-Hydraulic Controls – Test 3517
Mini-Levers 3517
Full Stroke Test 3517
Function Returns to Neutral Test 3517
Push Button Switch 3517
General 3518
Mini-Lever Replacement 3518
Remove 3518
Clean and Inspect 3519
Install 3519
Push Button Switch Replacement 3520
Remove 3520
Install 3522
Mini-Lever Module (MLM) 3522
Remove 3522
Install 3522
Joystick 3523
Remove and Disassemble 3523
Inspect 3523
Assemble and Install 3523
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3524
General 3524
Mini-levers, Remove and Install 3524
Armrest Assembly 3525
Remove 3525
Install 3528
Horn Button 3528
Remove 3528
Install 3528
Direction Control Switch 3529
Remove 3529
Install 3529
push (override) buttons and Toggle Switch 3529
Remove 3530
Install 3531
Joystick 3532
Remove and Disassemble 3532
Inspect 3532
Assemble and Install 3532
Joystick Armrest Slider Assembly 3533
Remove 3533
Install 3534
Electronic-Hydraulic Controls, After January, 2020 3534
E-Hydraulic Controls – TEST 3534
Mini-Levers 3534
Full Stroke Test 3534
Function Returns to Neutral Test 3534
Push (Override) Button 3535
General 3535
Mini-levers, Remove and Install 3535
Armrest Assembly 3536
Remove 3536
Install 3539
Horn Button 3539
Remove 3539
Install 3539
Direction Control Switch 3539
Remove 3539
Install 3540
Push (Override) buttons and Toggle Switch 3540
Remove 3541
Install 3543
Special Tools 3544
524223772-2200YRM1142-(08-2021)-US-EN 3547
General 3557
Display Switch Cluster 3561
Remove 3561
Install 3563
Direction Control and Turn Signal Levers 3563
Remove 3563
Install 3564
Key Switch 3565
Remove 3565
Install 3566
Display Switch Cluster Panel Bezel and Overlay 3566
Remove 3566
Install 3566
Steering Column Repair 3567
Remove 3567
Disassemble 3570
Assemble 3570
Install 3570
Sensors and Switches 3571
General 3571
Dash and Kick Panel, Remove and Install 3571
Remove 3571
Install 3572
Accelerator Pedal Position Sensor 3572
Remove 3572
Install 3576
Brake Fluid Level Switch 3577
Remove 3577
Install 3578
Service Brake Pedal Position Sensor 3580
Remove 3580
Install 3582
Parking Brake Sensor 3583
Remove 3583
Install 3585
Service Brake Pressure Sensor 3585
Remove 3585
Install 3587
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3589
Remove 3589
Install 3589
Sensor Microswitch (Foot Directional Control Pedal) 3589
Remove 3589
Install 3592
Low Coolant Level Sensor 3593
Remove 3593
Install 3596
Fuel Level Sensor, Gas and Diesel Engines Only 3597
Remove 3597
Install 3598
Armrest Switch 3598
Remove 3598
Install 3600
Seat Sensor (Operator Presence System) 3600
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) 3600
Remove 3600
Install 3601
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3601
Remove 3601
Install 3601
Full Suspension Seats; All Lift Truck Models 3602
Remove 3602
Install 3602
Hood Shut Off Switch 3603
Remove 3603
Install 3605
Remote Key Switch 3606
Remove 3606
Install 3606
Hydraulic Filter Pressure Switch 3607
Remove 3607
Install 3609
Transmission Speed Sensor 3609
Remove 3609
Install 3612
Transmission Pressure Sensors 3613
Remove 3613
Install 3615
Transmission Temperature Sensor 3616
Remove 3616
Install 3618
Engine Speed Sensor 3620
Remove 3620
Install 3621
Intermediate Speed Sensor 3621
Remove 3621
Install 3621
Return to Set Tilt (Tilt Angle) Sensor 3622
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) 3622
Remove 3622
Install 3622
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) 3622
Remove 3623
Install 3624
Rear Horn Button Switch 3625
Remove 3625
Install 3625
Impact Sensor 3626
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) 3626
Remove 3626
Install 3628
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) 3628
Remove 3628
Install 3629
Load Weight Sensor 3629
Remove 3629
Install 3631
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3632
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3632
Crankshaft Position (CKP) Sensor 3632
Camshaft Position (CMP) Sensor 3632
Oil Pressure Sensor 3632
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3632
Engine Coolant Temperature (ECT) Sensor 3633
Air Flow Restriction Switch 3633
Remove for GM 2 4L Gas and LPG Trucks 3633
Install for GM 2 4L Gas and LPG Trucks 3633
Oxygen Sensor 3634
Remove 3634
Install 3637
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3638
Crankshaft Position (CKP) Sensor 3638
Camshaft Position (CMP) Sensor 3638
Oil Pressure Sensor 3638
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3638
Engine Coolant Temperature (ECT) Sensor 3638
Air Flow Restriction Switch 3638
Oxygen Sensor 3638
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3638
Low LPG Pressure Switch 3638
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3639
Air Filter Restriction Switch 3639
Remove 3639
Install 3639
Oil Pressure Sensor 3639
Remove 3639
Install 3639
Engine Speed Sensor 3639
Remove 3639
Install 3639
Engine Coolant Temperature (ECT) Sensor 3639
Remove 3639
Install 3639
Throttle Position Sensor (TPS) 3642
Remove 3642
Install 3643
Fuel/Water Separator Sensor 3643
Remove 3643
Install 3643
Glow Plug Relay 3644
Remove 3644
Install 3646
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3646
Air Filter Restriction Switch 3646
Remove 3646
Install 3647
Engine Oil Pressure Sensor 3651
Remove 3651
Install 3651
Engine Speed Sensor 3651
Remove 3651
Install 3652
Engine Coolant Temperature (ECT) Sensor 3652
Remove 3652
Install 3653
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3654
Remove 3654
Install 3654
Fuel/Water Separator Sensor 3655
Remove 3655
Install 3655
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3656
Intake Air Temperature Sensor 3656
Remove 3656
Install 3657
Intake Air Pressure Sensor 3657
Remove 3657
Install 3657
Air Inlet Heater 3657
Remove 3657
Install 3658
Engine Oil Pressure Sensor 3658
Remove 3658
Install 3658
Engine Coolant Temperature (ECT) Sensor 3658
Remove 3658
Install 3658
Crankshaft Position Sensor 3659
Remove 3659
Install 3659
Adjust Shim Procedure 3660
Camshaft Position Sensor 3661
Remove 3661
Install 3661
Air Flow Restriction Sensor 3661
Remove 3661
Install 3662
Fuel/Water Separator 3662
Remove 3662
Install 3663
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3663
Intake Air Temperature Sensor 3667
Remove 3667
Install 3668
Boost Sensor 3668
Remove 3668
Install 3669
Throttle Valve Assembly and Air Intake Heater 3669
Remove 3669
Install 3669
Engine Coolant Temperature (ECT) Sensor 3670
Remove 3670
Install 3670
Engine Oil Pressure Sensor 3671
Remove 3671
Install 3671
Crankshaft Position Sensor 3671
Remove 3671
Install 3671
Adjust Shim Procedure 3672
Camshaft Position Sensor 3674
Remove 3674
Install 3674
Differential Pressure Sensor 3674
Remove 3674
Install 3675
Mass Air Flow Sensor 3675
Remove 3675
Install 3676
Fuel/Water Separator 3677
Remove 3677
Install 3678
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3679
Engine Coolant Temperature (ECT) Sensor 3680
Remove 3680
Install 3680
Throttle Position Sensor 3680
Engine Oil Pressure Sensor 3680
Remove 3680
Install 3680
Engine Speed Sensor 3680
Remove 3680
Install 3680
Fuel Shut Off Solenoid 3681
Remove 3681
Install 3681
Vehicle System Manager (VSM) 3682
General 3682
VSM Replacement 3682
Remove 3682
Install 3684
Programming a New VSM and/or Display Switch Cluster 3684
General 3684
PC Service Tool Software 3685
Data Transferring 3685
New VSM 3685
New (Blank) Display Switch Cluster 3685
Used (Non-Blank) Display Switch Cluster 3685
Power Distribution Module (PDM) and Component Parts 3688
Remove 3688
PDM as a Unit 3688
Install 3691
PDM as a Unit 3691
Remove and Install 3692
PDM Component Parts 3692
Transmission Control Unit (TCU) 3693
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) 3693
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) 3693
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3694
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3694
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 3694
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 3695
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 3696
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 3698
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 3698
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 3698
Battery 3699
Remove 3699
Install 3699
Lights 3700
Work Lights (Front and Rear) 3700
Remove 3700
Install 3700
Strobe Light 3701
Remove 3701
Install 3701
LED Tail, Backup, and Brake Lights 3702
Remove 3702
Install 3703
Front Marker/Turn Signal Lights 3704
Replacing Whole Front Marker/Turn Signal Light Assembly 3704
Remove 3704
Install 3704
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3705
Remove 3705
Install 3705
Diesel Particulate Filter (DPF) Display 3706
Remove 3706
Clean and Inspect 3707
Install 3707
Electronic-Hydraulic Controls – Generation 1 3708
E-Hydraulic Controls – Test 3708
Mini-Levers 3708
Full Stroke Test 3708
Function Returns to Neutral Test 3708
Push Button Switch 3708
General 3709
Mini-Lever Replacement 3709
Remove 3709
Clean and Inspect 3710
Install 3710
Push Button Switch Replacement 3711
Remove 3711
Install 3713
Mini-Lever Module (MLM) 3713
Remove 3713
Install 3713
Joystick 3714
Remove and Disassemble 3714
Inspect 3714
Assemble and Install 3714
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3715
General 3715
Mini-levers, Remove and Install 3715
Armrest Assembly 3716
Remove 3716
Install 3719
Horn Button 3719
Remove 3719
Install 3719
Direction Control Switch 3720
Remove 3720
Install 3720
push (override) buttons and Toggle Switch 3720
Remove 3721
Install 3722
Joystick 3723
Remove and Disassemble 3723
Inspect 3723
Assemble and Install 3723
Joystick Armrest Slider Assembly 3724
Remove 3724
Install 3725
Electronic-Hydraulic Controls, After January, 2020 3726
E-Hydraulic Controls – TEST 3726
Mini-Levers 3726
Full Stroke Test 3726
Function Returns to Neutral Test 3726
Push (Override) Button 3726
General 3727
Mini-levers, Remove and Install 3727
Armrest Assembly 3728
Remove 3728
Install 3731
Horn Button 3731
Remove 3731
Install 3731
Direction Control Switch 3731
Remove 3731
Install 3732
Push (Override) buttons and Toggle Switch 3732
Remove 3733
Install 3735
Special Tools 3736
524223780-8000YRM1134-(03-2020)-US-EN 3739
Series Code / Model Designation Reference Table 3745
Description 3747
Proc_Cal_001: Service Password Entry 3749
When to Perform 3749
Why Perform 3749
How to Perform 3749
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3750
When to Perform 3750
Calibration Order 3750
Why Perform 3750
How to Perform 3751
Proc_Cal_003: Save and Exit 3752
When to Perform 3752
Why Perform 3752
How to Perform 3752
Proc_Cal_004: Lift Valve Output Threshold 3753
When to Perform 3753
Calibration Order 3753
Why Perform 3753
How to Perform 3754
Proc_Cal_005: Lower Valve Output Threshold 3756
When to Perform 3756
Calibration Order 3756
Why Perform 3756
How to Perform 3756
Proc_Cal_006: Tilt Back Valve Output Threshold 3759
When to Perform 3759
Calibration Order 3759
Why Perform 3759
How to Perform 3759
Proc_Cal_007: Tilt Forward Valve Output Threshold 3762
When to Perform 3762
Calibration Order 3762
Why Perform 3762
How to Perform 3762
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3765
When to Perform 3765
Calibration Order 3765
Why Perform 3765
How to Perform 3765
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3768
When to Perform 3768
Calibration Order 3768
Why Perform 3768
How to Perform 3768
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3771
When to Perform 3771
Calibration Order 3771
Why Perform 3771
How to Perform 3771
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3774
When to Perform 3774
Calibration Order 3774
Why Perform 3774
How to Perform 3774
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3777
When to Perform 3777
Calibration Order 3777
Why Perform 3777
How to Perform 3777
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3780
When to Perform 3780
Calibration Order 3780
Why Perform 3780
How to Perform 3780
Proc_Cal_014: Load Weight Zero Point 3784
When to Perform 3784
Calibration Order 3784
Why Perform 3784
How to Perform 3784
Proc_Cal_015: Loaded Weight Calibration 3786
When to Perform 3786
Calibration Order 3786
Why Perform 3786
How to Perform 3786
Proc_Cal_016: Transmission Valve Calibration 3789
Applicable System/Option 3789
When to Perform 3789
Calibration Order 3789
Why Perform 3789
How to Perform 3789
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3791
Applicable System/Option 3791
When to Perform 3791
Calibration Order 3791
Why Perform 3791
How to Perform 3791
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3793
Applicable System/Option 3793
When to Perform 3793
Calibration Order 3793
Why Perform 3793
How to Perform 3794
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3795
Required Tools 3795
When to Perform 3795
Calibration Order 3795
Why Perform 3796
How to Perform 3796
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3797
When to Perform 3797
Why Perform 3797
How to Perform 3797
Proc_Cal_026: Travel Speed Calibration 3799
When to Perform 3799
Calibration Order 3799
Why Perform 3799
How to Perform 3799
524223780-8000YRM1134-(05-2022)-US-EN 3803
Series Code / Model Designation Reference Table 3809
Description 3812
Proc_Cal_001: Service Password Entry 3814
When to Perform 3814
Why Perform 3814
How to Perform 3814
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3815
When to Perform 3815
Calibration Order 3815
Why Perform 3815
How to Perform 3815
Proc_Cal_003: Save and Exit 3817
When to Perform 3817
Why Perform 3817
How to Perform 3817
Proc_Cal_004: Lift Valve Output Threshold 3818
When to Perform 3818
Calibration Order 3818
Why Perform 3818
How to Perform 3818
Proc_Cal_005: Lower Valve Output Threshold 3821
When to Perform 3821
Calibration Order 3821
Why Perform 3821
How to Perform 3821
Proc_Cal_006: Tilt Back Valve Output Threshold 3824
When to Perform 3824
Calibration Order 3824
Why Perform 3824
How to Perform 3824
Proc_Cal_007: Tilt Forward Valve Output Threshold 3827
When to Perform 3827
Calibration Order 3827
Why Perform 3827
How to Perform 3827
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3830
When to Perform 3830
Calibration Order 3830
Why Perform 3830
How to Perform 3830
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3833
When to Perform 3833
Calibration Order 3833
Why Perform 3833
How to Perform 3833
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3836
When to Perform 3836
Calibration Order 3836
Why Perform 3836
How to Perform 3836
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3839
When to Perform 3839
Calibration Order 3839
Why Perform 3839
How to Perform 3839
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3842
When to Perform 3842
Calibration Order 3842
Why Perform 3842
How to Perform 3842
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3845
When to Perform 3845
Calibration Order 3845
Why Perform 3845
How to Perform 3845
Proc_Cal_014: Load Weight Zero Point 3848
When to Perform 3848
Calibration Order 3848
Why Perform 3848
How to Perform 3848
Proc_Cal_015: Loaded Weight Calibration 3850
When to Perform 3850
Calibration Order 3850
Why Perform 3850
How to Perform 3850
Proc_Cal_016: Transmission Valve Calibration 3853
Applicable System/Option 3853
When to Perform 3853
Calibration Order 3853
Why Perform 3853
How to Perform 3853
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3855
Applicable System/Option 3855
When to Perform 3855
Calibration Order 3855
Why Perform 3855
How to Perform 3855
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3858
Applicable System/Option 3858
When to Perform 3858
Calibration Order 3858
Why Perform 3858
How to Perform 3858
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3861
Required Tools 3861
When to Perform 3861
Calibration Order 3861
Why Perform 3861
How to Perform 3861
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3863
When to Perform 3863
Why Perform 3863
How to Perform 3863
Proc_Cal_026: Travel Speed Calibration 3865
When to Perform 3865
Calibration Order 3865
Why Perform 3865
How to Perform 3865
524262274-0100YRM1243-(11-2016)-US-EN 3869
General 3873
Description 3874
Hood, Seat, and Side Covers Replacement 3876
Remove 3876
Install 3876
Steering Column 3883
Description 3884
Steering Column Repair 3884
Remove 3884
Disassemble 3886
Clean 3889
Inspect 3889
Assemble 3889
Install 3889
LPG Tank and Bracket Replacement 3890
Counterweight Replacement 3890
Remove 3890
Install 3893
Tow Pin 3897
Remove and Install For Lift Truck
Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813) 3897
Remove and Install For Lift Truck
Models GLC55SVX (GC/GLC80XVBCS,
GC/GLC100VXBCS; GC/GLC120SVX; and
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(J813) 3897
Overhead Guard Replacement 3898
Remove 3898
Install 3899
LED Tail, Backup, and Brake Lights, Replace 3899
Operator Restraint System Replacement 3900
Description 3900
Engine Replacement 3901
Remove Engine Only 3901
Install Engine only 3928
Remove Engine and Transmission 3931
Install Engine and Transmission 3935
Electronic Throttle Replacement 3939
Cummins 4 5L Diesel Engine With Electronic Throttle 3939
Remove 3939
Install 3942
Pull Actuator Linkage Adjustment 3944
Low Idle Adjustment 3944
Throttle Pedal and Cable Adjustment 3945
Cummins 4 5L Diesel Engine with Basic Power Shift Transmission 3945
Kubota 3 6L Diesel Engine 3945
Exhaust System Repair 3948
GM 4 3L Engine for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) 3948
Cummins 4 5L Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813) 3948
Remove 3948
Inspect 3948
Install 3950
Cummins QSB 3 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) 3950
Remove 3950
Inspect 3952
Install 3952
Kubota Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) Equipped with Kubota 3 6L Diesel Engine 3952
Remove 3952
Inspect 3954
Install 3954
Kubota Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) 3954
Remove 3954
Inspect 3957
Diesel Particulate Filter 3959
Disassemble 3959
CLEAN AND INSPECT 3960
Assembly 3960
Install 3961
Cooling System 3962
Description 3962
Hydraulic Filter Assembly Repair 3963
Remove 3963
Disassemble 3963
Clean 3964
Inspect 3964
Assemble 3964
Install 3964
Fuel and Hydraulic Tanks Repair 3964
Inspect 3964
Clean 3965
Steam Method of Cleaning 3965
Chemical Solution Method of Cleaning 3966
Additional Preparations for Repair 3966
Small Leaks, Repair 3966
Large Leaks, Repair 3966
Preparations for Use After Repair 3966
Safety Labels 3966
524262278-1400YRM1246-(02-2018)-US-EN 3977
General 3981
Identification Plate 3982
Drive Axle Removal 3982
Hub Seal Replacement 3994
Planetary Reduction Repair 4003
Clean and Inspect 4012
Brake Repair 4025
Clean and Inspect 4041
Wet Brake Noise Reduction 4057
General 4057
Adding Additive To Transmission 4058
Bevel Pinion 4059
Clean and Inspect 4064
Differential Unit 4076
Disassemble 4087
Clean and Inspect 4093
Assemble 4094
Drive Axle Installation 4117
Special Tools 4127
Torque Specifications 4127
524262279-1800YRM1247-(06-2021)-US-EN 4131
General 4135
Dry Brake System 4135
Wet Brake System 4135
Service Brakes Repair (Dry Brake) 4139
Remove and Disassemble 4139
Clean 4141
Inspect 4142
Assemble and Install 4143
Adjust 4146
Parking Brake Repair 4147
Dry Brake System 4147
Remove and Disassembly 4147
Assemble and Install 4149
Wet Brake System 4149
Remove and Install 4149
Assemble and Install 4156
Adjust 4156
Dry Brake System 4156
Wet Brake System 4157
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 4157
Master Cylinder Repair 4159
Remove 4159
Disassemble 4163
Clean and Inspect 4164
Assemble 4165
Install and Adjust 4165
Accumulator 4168
Pre-Charge Check 4168
Remove 4169
Install 4171
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 4172
Remove 4172
Modulating Brake Valve 4174
Disassemble 4174
Clean and Inspect 4175
Assemble 4175
Accumulator Charge Valve 4176
Disassemble 4176
Clean and Inspect 4178
Assemble 4178
Install 4179
Pressure Checks 4180
Accumulator Charge Valve Check 4180
Accumulator Check 4180
Service Brakes Adjustment (Dry Brake) 4181
Service Brakes Adjustment 4181
Brake System Air Removal 4183
Using Pressure Bleed System 4183
Using Brake Pedal Pressure 4183
Lift Truck Models with Master Cylinder 4183
Lift Truck Models with Modulating Brake Valve 4184
Brake Pedal Adjustment 4185
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) 4185
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4186
Free Pedal Adjustment 4188
Torque Specifications 4189
524262279-1800YRM1247-(09-2018)-US-EN 4191
General 4195
Dry Brake System 4195
Wet Brake System 4196
Service Brakes Repair (Dry Brake) 4200
Remove and Disassemble 4200
Clean 4202
Inspect 4203
Assemble and Install 4203
Adjust 4207
Parking Brake Repair 4207
Dry Brake System 4208
Remove and Disassembly 4208
Assemble and Install 4210
Wet Brake System 4210
Remove and Install 4211
Assemble and Install 4217
Adjust 4217
Dry Brake System 4217
Wet Brake System 4218
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 4218
Master Cylinder Repair 4219
Remove 4219
Disassemble 4224
Clean and Inspect 4225
Assemble 4226
Install and Adjust 4226
Accumulator 4228
Pre-Charge Check 4229
Remove 4230
Install 4232
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 4232
Remove 4233
Modulating Brake Valve 4234
Disassemble 4234
Clean and Inspect 4236
Assemble 4236
Accumulator Charge Valve 4237
Disassemble 4237
Clean and Inspect 4239
Assemble 4239
Install 4240
Pressure Checks 4241
Accumulator Charge Valve Check 4241
Accumulator Check 4241
Service Brakes Adjustment (Dry Brake) 4242
Service Brakes Adjustment 4242
Brake System Air Removal 4243
Using Pressure Bleed System 4243
Using Brake Pedal Pressure 4244
Lift Truck Models with Master Cylinder 4244
Lift Truck Models with Modulating Brake Valve 4244
Brake Pedal Adjustment 4245
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) 4245
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4246
Free Pedal Adjustment 4248
Torque Specifications 4249
524265337-0600YRM1251-(09-2015)-US-EN 4253
General 4259
Engine Removal and Installation 4259
Cylinder Head Repair 4259
Remove and Disassemble 4259
Clean and Inspect 4261
Valve Oil Seals 4264
Remove and Disassemble 4264
Cylinder Leak Down Test 4264
Clean and Inspect 4265
Assemble and Install 4265
Valve Guides and Seats, Repairs 4267
Valves, Repair 4267
Valve Seats, Repair 4268
Valve Springs 4269
Assemble and Install 4270
Engine Block Cleaning and Inspection 4273
Clean and Inspect 4274
Piston Bore Preparation 4276
Engine Mounts Installation 4276
Remove 4276
Clean and Inspect 4277
Install 4277
Lubrication System Repair 4278
Oil Pump, Remove and Disassemble 4278
Clean and Inspect 4279
Oil Pump, Assemble and Install 4280
Oil Pan, Install 4282
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4284
Timing Cover 4284
Remove 4284
Install 4286
Timing Sprockets 4286
Remove 4286
Install 4286
Camshaft 4286
Remove 4286
Inspect 4287
Install 4287
Balance Shaft 4288
Remove 4288
Install 4289
Valve Lifters 4290
Remove 4290
Clean and Inspect 4290
Install 4291
Crankshaft Repair 4291
Remove 4292
Inspect and Repair 4292
How to Check Clearance Between Main Bearings and Their Journals 4293
Install 4294
Piston and Connecting Rod Assemblies Repair 4296
Connecting Rod Bearings, Replace 4296
Piston and Connecting Rod Assemblies, Remove 4297
Disassemble 4297
Piston, Clean and Inspect 4298
Cylinder Bores, Inspect and Repair 4298
Piston Rings 4299
Assemble 4300
Piston and Connecting Rod Assemblies, Install 4300
Flywheel and Flywheel Housing Repair 4300
Flywheel, Remove 4301
Clean 4301
Inspect 4301
Flywheel, Install 4302
Coolant Pump Repair 4302
Remove 4302
Clean and Inspect 4303
Install 4303
Thermostat Replacement 4303
Remove 4304
Thermostat Operation Check 4304
Install 4304
Starter Replacement 4305
4305
Remove 4305
Install 4308
Fan Assembly Replacement 4309
Remove 4309
Inspect 4311
Install 4311
Drive Belt Installation 4312
Remove 4312
Clean 4312
Inspect 4312
Installation 4313
Compression Check 4314
Engine Specifications 4314
Engine Data 4314
Cylinder Head 4314
Hydraulic Valve Lifter 4315
Camshaft 4315
Pistons 4315
Crankshaft 4316
Connecting Rods 4316
Balance Shaft 4317
Cooling System 4317
Lubrication System 4317
Torque Specifications 4318
524265342-4000YRM1250-(06-2021)-US-EN 4323
Safety Procedures When Working Near Mast 4329
Fork Replacement 4332
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4332
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4333
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) 4335
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4336
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4337
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) 4338
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4338
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) 4339
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4340
Fixed Carriage Replacement 4342
Remove, Carriage With Hook Forks 4342
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4350
Install, Carriage With Hook Forks 4351
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4351
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4352
Connecting Attachment Hydraulic Quick Disconnect Hoses 4352
Integral Sideshift Carriage Repair 4353
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) 4353
Disassemble 4353
Clean and Inspect 4356
Assemble 4356
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) 4357
Hang On Sideshift Carriage Repair 4358
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) 4358
Disassemble 4370
Clean and Inspect 4379
Assemble 4380
Install 4381
Hang-On Sideshift Carriage Repair 4383
Remove 4383
Disassemble Carriage 4385
Clean and Inspect 4388
Assemble 4388
Install 4391
Fork Positioner 4394
Two-Stage Mast With Limited Free-Lift Repair 4395
Remove 4395
Disassemble 4398
Clean and Inspect 4401
Assemble 4419
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) 4421
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) 4423
Header Hose Alignment 4434
Two-Stage Mast With Full Free-Lift Repair 4445
Remove 4445
Disassemble 4447
Clean and Inspect 4458
Assemble 4459
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) 4461
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) 4464
Header Hose Installation and Adjustment 4468
Installation 4468
Adjustment 4469
Three-Stage Mast With Full Free-Lift Repair 4470
Remove 4470
Disassemble 4472
Clean and Inspect 4502
Assemble 4504
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) 4507
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) 4512
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) 4519
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) 4526
Mast Operation Check 4530
Tilt Cylinder Adjustment 4531
Lift Chains Adjustment 4531
Mast Adjustments 4533
Load Roller Adjustment 4533
Mast Side Kicking Adjustment 4535
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4536
Carriage Adjustments 4538
Series Code / Model Designation Reference Table 4539
524265342-4000YRM1250-(09-2018)-US-EN 4543
Safety Procedures When Working Near Mast 4549
Fork Replacement 4551
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4551
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4553
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) 4554
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4555
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4556
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) 4557
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4557
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) 4559
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4559
Fixed Carriage Replacement 4561
Remove, Carriage With Hook Forks 4561
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4570
Install, Carriage With Hook Forks 4571
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4571
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4572
Connecting Attachment Hydraulic Quick Disconnect Hoses 4572
Integral Sideshift Carriage Repair 4573
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) 4573
Disassemble 4573
Clean and Inspect 4576
Assemble 4576
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) 4577
Hang On Sideshift Carriage Repair 4577
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) 4577
Disassemble 4589
Clean and Inspect 4598
Assemble 4599
Install 4600
Bolzoni Hang-On Sideshift Carriage Repair 4602
Remove 4602
Disassemble Carriage 4604
Clean and Inspect 4607
Assemble 4607
Install 4610
Fork Positioner 4612
Two-Stage Mast With Limited Free-Lift Repair 4613
Remove 4613
Disassemble 4617
Clean and Inspect 4620
Assemble 4637
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) 4639
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) 4640
Header Hose Alignment 4652
Two-Stage Mast With Full Free-Lift Repair 4662
Remove 4662
Disassemble 4664
Clean and Inspect 4676
Assemble 4677
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) 4679
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) 4682
Header Hose Installation and Adjustment 4686
Installation 4686
Adjustment 4686
Three-Stage Mast With Full Free-Lift Repair 4687
Remove 4687
Disassemble 4689
Clean and Inspect 4719
Assemble 4720
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) 4724
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) 4729
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) 4736
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) 4742
Mast Operation Check 4746
Tilt Cylinder Adjustment 4746
Lift Chains Adjustment 4747
Mast Adjustments 4748
Load Roller Adjustment 4748
Mast Side Kicking Adjustment 4750
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4751
Carriage Adjustments 4754
550043871-0900YRM1556-(04-2018)-US-EN 4757
General 4761
LPG Tank and Bracket 4761
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) 4761
Remove 4761
Install 4769
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) 4770
Remove 4770
Install 4772
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4772
Remove 4772
Install 4774
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4774
Remove 4774
Install 4774
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) 4775
Remove 4775
Install 4777
Fuel Filter Unit 4777
Fuel Filter Element 4778
Remove 4778
Clean and Inspect 4778
Install 4779
Fuel Filter Housing with LP Vapor Sensor 4779
Remove 4779
Disassemble 4781
Clean and Inspect 4782
Assemble 4782
Install 4783
Throttle Body 4784
Remove 4784
Clean 4788
Install 4788
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 4789
Remove 4789
Install 4790
Control System 4790
Engine Control Unit (ECU) 4791
Remove 4791
Install 4792
Low Pressure Switch 4792
Remove 4792
Install 4792
Low Fuel Sensor 4793
Remove 4793
Install 4793
LP Converter 4794
Remove and Disassemble 4794
Assemble and Install 4795
LPG Lock-Off 4795
Remove 4796
Install 4797
Exhaust System 4798
Counterweight Exhaust 4798
Remove and Disassemble 4798
Inspect 4800
Assemble and Install 4800
Overhead Exhaust 4801
Remove and Disassemble 4801
Inspect 4803
Assemble and Install 4803
Exhaust Manifold 4803
Remove 4803
Install 4805
Oxygen (HEGO) Sensor 4805
Remove 4805
Install 4805
LPG Fuel Testing 4806
General 4806
Available Fuel Tests 4806
Composition Test (ASTM D-2163) 4806
Ammonia Test (ASTM D-4490) 4806
Basic Nitrogen Test (ASTM UOP269-90) 4806
Residues Test (ASTM D-2158) 4806
Vapor Pressure Test (ASTM D-2598) 4806
Sulfur Compounds Test (ASTM D-5623) 4806
Methanol Test (ASTM D-4864) 4807
Copper Corrosion (ASTM D-1838) 4807
Where To Send LPG Fuel Samples For Testing 4807
550048401-0900YRM1570-(03-2015)-US-EN 4811
550048681-1300YRM1569-(11-2018)-US-EN 4841
General 4845
Serial Number 4845
Charge Pump Repair 4845
Lift Trucks Manufactured Before July, 2013 4845
Remove 4845
Inspect 4846
Install 4846
Lift Trucks Manufactured After July, 2013 4846
Remove 4846
Inspect 4847
Install 4847
Torque Converter Replace 4847
Remove 4847
Install 4853
Housings and Chain Drive Repair 4858
Remove 4859
Clean 4867
Inspect 4867
Install 4867
Clutch Packs Repair- 1 Speed Transmission 4873
Remove and Disassemble 4873
Transmission, Remove and Disassemble 4873
Clean 4885
Inspect 4885
Assemble and Install 4886
Transmission, Assemble and Install 4894
Clutch Packs Repair- 2 Speed Transmission 4897
Remove and Disassemble 4898
Transmission, Remove and Disassemble 4898
Clean 4912
Inspect 4912
Assemble and Install 4913
Transmission, Assemble and Install 4922
Control Valve Repair 4924
Remove and Disassemble 4925
Clean 4928
Inspect 4928
Assemble and Install 4928
Foot Directional Control Pedal Repair 4929
Remove and Disassemble 4929
Assemble and Install 4933
Direction Control Lever 4934
Remove 4934
Install 4934
550055280-1400YRM1582-(01-2019)-US-EN 4939
General 4943
Identification Plate 4943
Drive Axle Removal 4944
Reduction Gear Assembly 4949
Remove 4949
Disassemble 4952
Clean and Inspect 4956
Assemble 4956
Install 4965
Wet Disc Brake Repair 4968
General 4968
Remove 4969
Clean and Inspect 4972
Install 4973
Initial Steps For Install 4973
Final Steps For Install 4980
Wet Brake Noise Reduction 4983
General 4983
Adding Additive To Transmission 4983
Piston Housing 4985
Remove 4985
Disassemble 4986
Clean and Inspect 4987
Assemble 4987
Install 4988
Parking Brake Control Lever 4989
Remove 4989
Clean and Inspect 4990
Install 4990
Differential Repair 4992
Initial Removal Steps for Differential Housing and drive axle trumpet arm (right side) 4992
Input Pinion Carrier 4992
Remove 4993
Disassemble 4993
Clean and Inspect 4994
Assemble 4994
Preload Pinion Bearings 4996
Differential Housing and Drive Axle Trumpet Arm (Right Side) 4996
Remove 4998
Disassemble 4998
Clean and Inspect 4999
Assemble 4999
Install 5001
Ring Gear Backlash 5001
Final Installation Steps for Differential Housing and drive axle trumpet arm (right side) 5002
Pinion and Motor Carrier 5003
Install 5003
Drive Axle Installation 5006
Special Tools 5011
Special Tools 5011
Torque specifications 5013
550055283-8000YRM1585-(06-2021)-US-EN 5017
General Information About Diagrams and Schematics 5021
Symbol Definitions 5021
Diagrams Manual Applications 5022
Diagrams and Schematics 5024
550055283-8000YRM1585-(07-2020)-US-EN 5113
General Information About Diagrams and Schematics 5117
Symbol Definitions 5117
Diagrams Manual Applications 5118
Diagrams and Schematics 5120
550064329-1800YRM1597-(03-2017)-US-EN 5209
Wet Brake System 5213
Service Brake Repair 5214
Parking Brake Repair 5214
Remove and Disassemble 5214
Assemble and Install 5215
Adjust 5216
Lift Trucks With a Foot Directional Control Pedal or Forward Reverse Lever 5216
Master Cylinder and Booster 5216
Remove 5216
Disassemble 5218
Clean and Inspect 5219
Assemble 5219
Install and Adjust 5219
Brake System Air Removal 5221
Using Pressure Bleed System 5221
Using Brake Pedal Pressure 5222
Lift Truck Models with Master Cylinder 5222
Brake Pedal Adjustment 5223
Free Pedal Adjustment 5224
Torque Specifications 5224
550064334-8000YRM1598-(10-2016)-US-EN 5227
General 5233
Serial Number Data 5233
How to Move Disabled Lift Truck 5234
How to Tow Lift Truck 5234
How to Put Lift Truck on Blocks 5234
How to Raise Drive Tires 5234
How to Raise Steering Tires 5236
How to Clean a Lift Truck 5236
Maintenance Schedule 5237
Maintenance Procedures Every 8 Hours or Daily 5251
How to Make Checks With Engine Stopped 5252
Tires and Wheels 5252
Safety Labels 5252
Mast, Carriage, Lift Chains, Header Hoses, Attachment 5253
Operator Restraint System 5254
Emergency Locking Retractor (ELR) 5254
Adjust Seat – Full Suspension 5254
Adjust Seat – Internal Suspension 5255
Hood and Seat Latches 5256
Engine Compartment 5256
Paper Application 5256
Fuel, Oil, and Coolant Leaks, Check 5257
Hydraulic Hoses 5258
Coolant Hoses 5258
Steering Column Gas Cylinder 5258
Transmission 5258
Hydraulic System Oil 5258
Engine Oil 5258
Air Filter 5260
Forks 5260
Remove 5260
Inspect 5261
Install 5261
Adjust 5262
Integral Sideshift Carriage 5262
How to Make Checks With Engine Running 5263
Indicator Lights, Horn, Fuses, and Relays 5263
Service Brakes 5263
Brake Oil Level 5263
Operation, Check 5263
Parking Brake 5266
Engine Oil Pressure 5266
Cooling System 5266
Steering System 5267
Control Levers and Pedals 5267
Lift System, Operate 5267
First Service After First 100 Hours of Operation 5268
Engine Oil and Oil Filter 5268
Maintenance Procedures Every 250 Hours or 6 Months 5269
Engine Oil and Oil Filter 5269
Drive Belt 5269
GM 4 3L Engine 5269
Fan and Alternator Drive Belt 5269
Drain Tar From LPG Converter 5270
Maintenance Procedures Every 500 Hours or 6 Months 5271
Hydraulic System Oil 5271
Hydraulic Tank Breather 5271
Inspect 5271
Battery 5272
Clean Debris From Radiator Core 5272
Transmission Oil Level 5273
Wet Brake Center Body Oil Level Check 5274
Forks 5274
Mast Lubrication 5276
Header Hose Checks 5278
Lift Chain Lubrication 5278
Tilt Cylinder Lubrication 5279
Master Brake Cylinder Rod End Pin Lubrication 5280
Manual Hydraulic Levers Lubrication 5280
Brake Oil 5281
Tie Rod Lubrication 5282
Parking Brake Adjustment 5282
Maintenance Procedures Every 1000 Hours or 6 Months 5282
Valve Clearance, Check and Adjust 5283
Ignition System 5283
GM 4 3L Engine 5283
LPG Fuel Filter Element Replace, GM 4 3L Engine 5283
Remove 5283
Install 5283
Lift Chains Wear Check 5284
Lift Chain Lubrication 5284
Integral Sideshift Carriage, Check Sliding Surfaces 5285
Steering Axle (Spindle Bearings) 5285
Control Levers and Pedals 5285
Parking Brake Lever Lubrication, Dana Wet Brake Axle 5286
Normal Operating Environment 5286
Heavy Duty or Contaminated Environment 5286
Remove 5286
Clean and Inspect 5288
Install 5288
Inspect Engine Electrical System, Connectors 5288
Maintenance Procedures Every 2000 Hours or Annually 5289
Hydraulic System 5289
Hydraulic Filter, Replace 5289
Hydraulic Tank Breather, Replace 5290
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 5291
Cooling System 5291
Air Filter 5292
Gasoline Fuel Filter 5293
Remove and Replace for Lift Trucks Equipped with PSI 5293
LPG Fuel Injector, GM Engines 5294
Gasoline Fuel Injector, GM Engines 5294
Forks 5294
Transmission and Wet Brake Planetary Carrier Housing Oil Change (Dana Drive Axle) 5295
Wet Brake Center Section Oil Change (Dana Drive Axle) 5297
Remove 5297
Install 5297
Wet Brake Oil Change (NMHG Drive Axle) 5297
Brake Oil (Master Cylinder), Change 5300
Test LPG/GAS Regulator Pressure 5300
Check Throttle Shaft for Sticking 5300
Inspect Exhaust Manifold and Piping for Leaks 5300
Wheel Bearings 5301
Steer Wheels, Lubrication 5301
Maintenance Procedures Every 4000 Hours or 2 Years 5301
Hydraulic Oil, Replace 5301
Weld Inspection 5304
Safety Procedures When Working Near Mast 5305
Hood Latch Check 5308
Lift Chain Adjustments 5308
Jump-Starting the Lift Truck 5310
Jump-Starting Using a Battery Charger 5310
Jump-Starting a Lift Truck Using Another Lift Truck 5310
Welding Repairs 5310
Overhead Guard Changes 5311
Wheel and Tire Replacement 5312
General 5312
Solid Rubber Tire, Change (GC/GLCSeries) 5312
Remove and Install Tire on Wheel 5312
Adhesives and Sealants 5313
550064342-8000YRM1599-(10-2016)-US-EN 5317
Lift Truck Lifting Capacity 5321
Counterweight Weights 5321
Tire Sizes 5321
Capacities 5321
Electrical System 5324
Transmission Oil Pressures 5324
Hydraulic System Relief Pressures 5327
Steering System 5327
Stall Speeds (in RPM ±100 rpm) 5327
GM 4 3L Gas/LPG 5327
Mast Speeds 5328
Tilt Angles 5328
Front End Equipment 5328
Mast Creep 5329
Engine Specifications 5329
GM 4 3L Gas/LPG 5329
Torque Specifications 5330
Frame 5330
Mast 5330
Steering Axle 5330
Drive Axle – (Dana Spicer) 5330
Drive Axle – (NMHG) 5330
Transmission 5331
Engine – GM 4 3L 5331
550073240-1900YRM1620-(01-2023)-US-EN 5335
Proper Flushing after Major Hydraulic Repairs 5341
Introduction 5341
The Phases of Wear 5341
Causes of Hydraulic System Failure 5341
Progression of Contaminant Caused Hydraulic System Failure 5342
Hydraulic System Flushing Techniques 5342
Double Oil and Filter Change 5342
Mechanical Cleaning 5343
Cleaning of Components 5343
How to Clean Tubes and Hoses 5343
Filter Caddy 5343
Start-Up Procedure for Cleaned System 5344
Contaminated Oil Coolers 5344
Additional Filter Caddy Functions 5345
How to Handle Different Fluids 5345
Water Removal Filters 5345
Fluid Conditioning and System Flushing Procedures 5346
Operation of the Filter Caddy 5346
Filter Caddy operation 5346
Fluid Conditioning Procedure 5346
Filter Caddy Start-Up 5347
System Flushing Procedure 5347
Component Cleaning Procedure 5348
Reservoir Cleaning Procedure 5348
Cylinder Cleaning Procedure 5348
Hose and Tube Cleaning Procedure 5348
Valve Cleaning Procedure 5349
Front-End Attachment Cleaning Procedure 5350
System Flushing Procedure 5350
Filter Caddy Start-Up 5351
System Start-Up and Flushing 5351
Reservoir Fluid Cleaning Times 5352
Dealing With Different Fluid Types 5353
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5353
Filter Caddy Maintenance 5353
Servicing the Strainer 5353
DC Motor 5353
Hydraulic Oil Sampling Method and Procedure 5354
Hydraulic Oil Sampling Method 5354
Objective 5354
General Guidelines 5354
Synopsis 5355
Hydraulic Oil Analysis Report Guidelines 5356
Sampling Conditions 5356
Equipment 5356
Sampling Procedure 5357
Hydraulic Oil Sampling 5357
Sample Labeling 5357
Results Documentation 5357
550073240-1900YRM1620-(03-2020)-US-EN 5359
Proper Flushing after Major Hydraulic Repairs 5363
Introduction 5363
The Phases of Wear 5363
Causes of Hydraulic System Failure 5363
Progression of Contaminant Caused Hydraulic System Failure 5364
Hydraulic System Flushing Techniques 5364
Double Oil and Filter Change 5364
Mechanical Cleaning 5365
Cleaning of Components 5365
How to Clean Tubes and Hoses 5365
Filter Caddy 5365
Start-Up Procedure for Cleaned System 5366
Contaminated Oil Coolers 5366
Additional Filter Caddy Functions 5366
How to Handle Different Fluids 5366
Water Removal Filters 5367
Fluid Conditioning and System Flushing Procedures 5367
Operation of the Filter Caddy 5367
Filter Caddy operation 5367
Fluid Conditioning Procedure 5368
Filter Caddy Start-Up 5368
System Flushing Procedure 5369
Component Cleaning Procedure 5369
Reservoir Cleaning Procedure 5369
Cylinder Cleaning Procedure 5369
Hose and Tube Cleaning Procedure 5370
Valve Cleaning Procedure 5370
Front-End Attachment Cleaning Procedure 5371
System Flushing Procedure 5371
Filter Caddy Start-Up 5372
System Start-Up and Flushing 5372
Reservoir Fluid Cleaning Times 5373
Dealing With Different Fluid Types 5373
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5373
Filter Caddy Maintenance 5374
Servicing the Strainer 5374
DC Motor 5374
Hydraulic Oil Sampling Method and Procedure 5374
Hydraulic Oil Sampling Method 5374
Objective 5374
General Guidelines 5374
Synopsis 5375
Hydraulic Oil Analysis Report Guidelines 5376
Sampling Conditions 5377
Equipment 5377
Sampling Procedure 5377
Hydraulic Oil Sampling 5377
Sample Labeling 5378
Results Documentation 5378
550096331-8000YRM1689-(03-2020)-US-EN 5381
General Information About Diagrams and Schematics 5385
Symbol Definitions 5385
Diagrams Manual Applications 5386
Diagrams and Schematics 5388
550096331-8000YRM1689-(06-2021)-US-EN 5491
General Information About Diagrams and Schematics 5495
Symbol Definitions 5495
Diagrams Manual Applications 5496
Diagrams and Schematics 5498

S.V 06/24