Yale Forklift F818 (GLC40-55VX, GLC55SVX) Service Manual – PDF DOWNLOAD

Description

Yale Forklift F818 (GLC40-55VX, GLC55SVX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift F818 (GLC40-55VX, GLC55SVX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5720
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift F818 (GLC40-55VX, GLC55SVX) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-UK-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524208014-2200YRM1097-(03-2020)-US-EN 43
Series Code / Model Designation Reference Table 47
Description 48
Distributor Ignition (DI) System 48
Crankshaft Position (CKP) Sensor 48
Camshaft Position (CMP) Sensor 48
Ignition Coil and Ignition Control Module (ICM) 48
Secondary Ignition Components 48
Spark Plugs and Wires 49
Spark Plug Wire Inspection 49
Spark Plug Wire Replacement 49
Remove 49
Install 50
Spark Plug Inspection 50
Usage 50
Inspection 50
Visual Inspection 52
Spark Plug Replacement 52
Remove 52
Install 52
Distributor Repair 53
Inspect 53
Overhaul 53
Disassemble 53
Assemble 56
Replace 57
Remove 57
Install Procedure 1 59
Install Procedure 2 60
Ignition Coil Replacement 61
Remove 61
Install 61
Ignition Control Module Replacement 62
Remove 62
Install 62
Starter Replacement 63
Remove 63
Install 66
Sensors and Switches 67
Gas and LPG Trucks 67
Crankshaft Position (CKP) Sensor 67
Remove 67
Install 67
Camshaft Position (CMP) Sensor 68
Remove 68
Install 70
Oil Pressure Sensor 70
Remove 70
Install 71
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 72
Remove 72
Install 72
Engine Coolant Temperature (ECT) Sensor 73
Remove 73
Install 74
Air Flow Restriction Switch 74
Remove 74
Install 75
Specifications and Special Tools 76
524221866-9000YRM1112-(10-2020)-US-EN 81
SECTION 9010 Operational Diagnostic Procedures 97
Group 05 – Operational Checkout 99
SECTION 9020 Engine 117
Group 10 – Principles of Operation 127
Group 30 – Observed Symptoms 325
Group 40 – Tests and Adjustments 427
SECTION 9030 Electrical System 459
Group 03 – General Maintenance and Diagnostic Data 483
Group 10 – Principles of Operation 577
Group 20 – Diagnostic Trouble Codes 601
Group 30 – Observed Symptoms 1573
SECTION 9040 Drive Train 1629
Group 10 – Principles of Operation 1633
Group 30 – Observed Symptoms 1689
Group 40 – Tests and Adjustments 1739
SECTION 9050 Hydraulic Systems 1749
Group 10 – Principles of Operation 1753
Group 30 – Observed Symptoms 1811
Group 33 – Observed Symptoms-Gear Pump 1813
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1901
Group 40 – Tests and Adjustments 1945
Group 43 – Tests and Adjustments-Gear Pump 1947
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1971
SECTION 9060 Operators Station 1989
Group 10 – Principles of Operation 1991
SECTION 9070 Front End (Mast) and Chassis 2027
Group 10 – Principles of Operation 2029
Group 30 – Observed Symptoms 2051
SECTION 9080 Supplementary Data 2109
Group 50 – Abbreviations and Acronyms 2111
Group 60 – Special Tools List 2119
Group 70 – Fault Mode Indicator Reference 2129
Group 80 – Supplier Specification Data 2131
524223757-0700YRM1123-(06-2016)-UK-EN 2135
General 2139
Cooling System Checks 2139
Exhaust Leaks Into Cooling System 2139
Water Flow Restrictions in Radiator 2139
Radiator Hoses 2139
Water Pump 2140
Flushing the Cooling System 2140
Cooling System, Clean 2140
Radiator Replacement 2141
Radiator, Remove GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2142
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2157
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2160
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 2163
Radiator, Install for Lift Truck Models GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2170
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2175
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2177
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2180
Fan Assembly Replacement 2192
Fan Removal 2192
Inspect 2207
Fan Installation 2207
524223757-0700YRM1123-(06-2021)-US-EN 2213
General 2217
Cooling System Checks 2217
Exhaust Leaks Into Cooling System 2217
Water Flow Restrictions in Radiator 2217
Radiator Hoses 2217
Water Pump 2217
Flushing the Cooling System 2219
Cooling System, Clean 2219
Radiator Replacement 2221
Radiator, Remove GC/GLC030VX,GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX (GP/GLP/GDP030VX,GP/GLP/GDP035VX, GP/GLP/GDP040SVX)(C810); GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910); GLC050LX(A967); GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875);GLP/GDP20-25LX (GLP/GDP050LX)(A974); GLC40, 45, 55VX, GLC55SVX,(GC/GLC080, 100, 120VX, GC/GLC080,100VXBCS, GC/GLC120SVX,GC/GLC120VXPRS) (E818, F818) ANDGLP/GDP40VX5/VX6, GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) 2221
Radiator, Remove for Lift Trucks Models Equipped with Oil CoolerGC/GLC030VX, GC/GLC035VX,GC/GLC040SVX (C809); GLP/GDP16VX,GLP/GDP18VX, GLP/GDP20SVX(GP/GLP/GDP030VX, GP/GLP/GDP035VX,GP/GLP/GDP040SVX) (C810); GLC050LX(A967) AND GLP/GDP20-25LX(GLP/GDP050LX) (A974) 2236
Radiator, Remove for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2239
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX(GP/GLP/GDP135VX, GP/GLP/GDP155VX)(C878, D878, E878) and GLP/GDP80VX,GLP/GDP80VX9, GLP/GDP90VX(GLP/GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (A909, B909) 2242
Radiator, Install for Lift Truck Models GC/GLC030VX,GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX (GP/GLP/GDP030VX,GP/GLP/GDP035VX, GP/GLP/GDP040SVX)(C810); GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910); GLC050LX(A967); GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875);GLP/GDP20-25LX (GLP/GDP050LX)(A974); GLC40, 45, 55VX; GLC55SVX;(GC/GLC080, 100, 120VX; GC/GLC080,100VXBCS; GC/GLC120SVX;GC/GLC120VXPRS) (E818, F818) andGLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) 2248
Radiator, Install for Lift Truck Models Equipped with Oil CoolerGC/GLC030VX, GC/GLC035VX,GC/GLC040SVX (C809); GLP/GDP16VX,GLP/GDP18VX, GLP/GDP20SVX(GP/GLP/GDP030VX, GP/GLP/GDP035VX,GP/GLP/GDP040SVX) (C810); GLC050LX(A967) and GLP/GDP20-25LX(GLP/GDP050LX) (A974) 2252
Radiator, Install for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 2253
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2256
Fan Assembly Replacement 2267
Fan Removal 2267
Inspect 2281
Fan Installation 2282
524223764-1600YRM1133-(07-2013)-UK-EN 2287
toc 2287
Steering Axle 2287
Safety Precautions Maintenance and Repair 2288
General 2291
Steering Axle Assembly Repair 2293
Remove 2293
Disassemble 2294
Clean 2302
Inspect 2302
Assemble 2302
Install 2308
Spindles, Bearings, and Tie Rods Repair 2310
Spindles and Bearings 2310
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2310
Remove 2310
Disassemble 2312
Clean 2313
Inspect 2313
Assemble 2313
Install 2314
Spindles and Bearings 2317
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2317
Remove and Disassemble 2317
Assemble and Install 2318
Tie Rods 2318
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2318
Remove 2318
Install 2319
Tie Rods 2320
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2320
Remove 2320
Install 2326
Steering Cylinder Repair 2326
Remove and Disassemble 2326
Clean and Inspect 2327
Assemble and Install 2327
Torque Specifications 2328
524223764-1600YRM1133-(07-2013)-US-EN 2333
toc 2333
Steering Axle 2333
Safety Precautions Maintenance and Repair 2334
General 2337
Steering Axle Assembly Repair 2339
Remove 2339
Disassemble 2340
Clean 2348
Inspect 2348
Assemble 2348
Install 2354
Spindles, Bearings, and Tie Rods Repair 2356
Spindles and Bearings 2356
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2356
Remove 2356
Disassemble 2358
Clean 2359
Inspect 2359
Assemble 2359
Install 2360
Spindles and Bearings 2363
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2363
Remove and Disassemble 2363
Assemble and Install 2364
Tie Rods 2364
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2364
Remove 2364
Install 2365
Tie Rods 2366
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2366
Remove 2366
Install 2372
Steering Cylinder Repair 2372
Remove and Disassemble 2372
Clean and Inspect 2373
Assemble and Install 2373
Torque Specifications 2374
524223766-1900YRM1136-(01-2022)-US-EN 2379
General 2383
Hydraulic Gear Pump Assembly 2384
Variable Displacement Pump Assembly 2385
Single Gear Pump Assembly Repair 2386
Remove 2386
Disassemble 2392
Clean 2394
Inspect 2394
Assemble 2394
Install 2394
Tandem Gear Pump Assembly 2399
Remove 2399
Disassemble 2400
Clean 2403
Inspect 2403
Assemble 2403
Install 2404
Gear Pump Specifications 2405
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2411
Remove 2411
Disassemble 2421
Clean 2424
Inspect 2425
Assemble 2425
Install 2425
63 0 cc/rev – Variable Displacement Pump Repair 2430
Remove 2430
Disassemble 2433
Clean 2435
Inspect 2435
Assemble 2435
Install 2435
Variable Displacement Pump Checks and Adjustments (Single Pump) 2439
Margin Pressure Check 2439
Flow Compensator Adjustment 2440
Pressure Compensator Adjustment 2440
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2442
Variable Displacement Pump Specifications 2445
Torque Specifications 2447
Hydraulic Gear Pump 2447
Variable Displacement Pump 2448
Special Tools 2449
524223766-1900YRM1136-(11-2017)-UK-EN 2451
General 2455
Hydraulic Gear Pump Assembly 2456
Variable Displacement Pump Assembly 2457
Single Gear Pump Assembly Repair 2457
Remove 2457
Disassemble 2464
Clean 2464
Inspect 2466
Assemble 2466
Install 2466
Tandem Gear Pump Assembly 2470
Remove 2471
Disassemble 2473
Clean 2475
Inspect 2475
Assemble 2475
Install 2476
Gear Pump Specifications 2476
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2482
Remove 2482
Disassemble 2492
Clean 2495
Inspect 2495
Assemble 2495
Install 2496
63 0 cc/rev – Variable Displacement Pump Repair 2499
Remove 2499
Disassemble 2502
Clean 2502
Inspect 2502
Assemble 2504
Install 2504
Variable Displacement Pump Checks and Adjustments (Single Pump) 2506
Margin Pressure Check 2506
Flow Compensator Adjustment 2507
Pressure Compensator Adjustment 2507
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2508
Variable Displacement Pump Specifications 2511
Torque Specifications 2512
Hydraulic Gear Pump 2513
Variable Displacement Pump 2514
Special Tools 2514
524223767-2000YRM1137-(01-2017)-UK-EN 2519
General 2525
Electro-Hydraulic Main Control Valve 2526
Description 2526
Remove 2534
Electro-Hydraulic Control Valve Sections 2539
General 2539
Outlet Control Valve Section 2539
Remove 2539
Disassemble 2540
Clean 2542
Inspect 2542
Assemble 2542
Install 2543
Auxiliary Control Valve Sections 2543
Remove 2543
Disassemble 2550
Clean 2551
Inspect 2552
Assemble 2552
Install 2554
Tilt Control Valve Section 2555
Remove 2555
Disassemble 2555
Clean 2561
Inspect 2561
Assemble 2561
Install 2562
Lift/Lower Control Valve Section 2563
Remove 2563
Disassemble 2563
Clean 2572
Inspect 2572
Assemble 2572
Install 2573
Mid-Inlet Section 2573
Remove 2573
Clean 2574
Inspect 2574
Install 2574
Install 2574
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2579
Lift Pilot Pin 2579
Lower Pilot Pin 2583
Abnormal/Erroneous EHPV Adjustment 2585
Manual Main Control Valve 2586
Description 2586
Remove 2590
OPS Solenoid Assembly 2598
General 2598
Remove 2599
Clean and Inspect 2602
Install 2602
Manual Control Valve Sections 2603
General 2603
Outlet Control Valve Section 2603
Remove 2603
Disassemble 2603
Clean 2606
Inspect 2606
Assemble 2606
Install 2607
Auxiliary Control Valve Sections 2607
Remove 2607
Disassemble 2607
Clean 2610
Inspect 2610
Assemble 2610
Install 2611
Lift/Tilt Control Valve Section 2611
Remove 2611
Disassemble 2611
Clean 2618
Inspect 2618
Assemble 2619
Install 2620
Mid-Inlet Section 2621
Remove 2621
Clean 2621
Inspect 2621
Install 2621
Install 2622
Pressure Relief Valve Check and Adjustment 2628
Primary Relief Valve 2629
Secondary Relief Valve 2633
Steering Control Unit Repair 2640
Steering Control Unit, Remove 2640
Steering Control Unit, Disassemble 2644
Steering Control Unit, Clean 2646
Steering Control Unit, Inspect 2646
Steering Control Unit, Assemble 2646
Relief Valve, Disassemble 2647
Relief Valve, Clean 2647
Relief Valve, Inspect 2648
Relief Valve, Assemble 2648
Steering Control Unit, Install 2648
524223767-2000YRM1137-(06-2021)-US-EN 2653
General 2657
Electro-Hydraulic Main Control Valve 2658
Description 2658
Remove 2666
Electro-Hydraulic Control Valve Sections 2671
General 2671
Outlet Control Valve Section 2671
Remove 2671
Disassemble 2671
Clean 2674
Inspect 2674
Assemble 2675
Install 2675
Auxiliary Control Valve Sections 2675
Remove 2676
Disassemble 2681
Clean 2683
Inspect 2683
Assemble 2683
Install 2685
Tilt Control Valve Section 2686
Remove 2686
Disassemble 2687
Clean 2691
Inspect 2691
Assemble 2692
Install 2693
Lift/Lower Control Valve Section 2693
Remove 2693
Disassemble 2693
Clean 2699
Inspect 2699
Assemble 2699
Install 2700
Mid-Inlet Section 2700
Remove 2700
Clean 2701
Inspect 2701
Install 2701
Install 2701
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2706
Lift Pilot Pin 2706
Lower Pilot Pin 2709
Abnormal/Erroneous EHPV Adjustment 2711
Manual Main Control Valve 2712
Description 2712
Remove 2716
OPS Solenoid Assembly 2724
General 2724
Remove 2725
Clean and Inspect 2727
Install 2727
Manual Control Valve Sections 2728
General 2728
Outlet Control Valve Section 2728
Remove 2728
Disassemble 2728
Clean 2731
Inspect 2731
Assemble 2731
Install 2731
Auxiliary Control Valve Sections 2732
Remove 2732
Disassemble 2732
Clean 2735
Inspect 2735
Assemble 2735
Install 2735
Lift/Tilt Control Valve Section 2736
Remove 2736
Disassemble 2736
Clean 2742
Inspect 2742
Assemble 2742
Install 2744
Mid-Inlet Section 2744
Remove 2744
Clean 2745
Inspect 2745
Install 2745
Install 2745
Pressure Relief Valve Check and Adjustment 2753
Primary Relief Valve 2753
Secondary Relief Valve 2756
Steering Control Unit Repair 2761
Steering Control Unit, Remove 2761
Steering Control Unit, Disassemble 2765
Steering Control Unit, Clean 2767
Steering Control Unit, Inspect 2767
Steering Control Unit, Assemble 2767
Relief Valve, Disassemble 2768
Relief Valve, Clean 2768
Relief Valve, Inspect 2769
Relief Valve, Assemble 2769
Steering Control Unit, Install 2769
524223768-2100YRM1139-(02-2014)-US-EN 2773
524223769-2200YRM1128-(01-2023)-US-EN 2821
Series Code / Model Designation Reference Table 2829
General 2831
Deutsch Crimping Tool 2832
How to Strip a Wire for Use With Deutsch Crimping Tool 2832
How to Crimp With the Deutsch Crimping Tool 2833
Calibration Test for the Deutsch Crimping Tool 2835
Deutsch Connectors 2837
DT, DTM, and DTP Series Connectors 2837
HD Series Connectors 2880
Metri-Pack Connectors 2902
Remove and Install 2902
Micro-Pack Connectors 2905
Weather-Pack Connectors 2906
AMPSEAL Crimping Tools 2908
AMP Hand Crimping Tool With Certi-Crimp 2908
Description 2908
Stripping Wire for Use with AMP Hand Crimping Tool 2909
Insulation Crimp Adjustment 2910
Maintenance and Inspection for AMP Hand Crimping Tool 2910
AMP Hand Crimping Tool 2910
Crimp Height Inspection 2910
How to use AMP Hand Crimping Tool 2911
AMP Pro-Crimper II Tool 2911
Description 2911
Remove and Install Die Set and Locator Assembly 2912
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2912
Contact Support Adjustment 2913
Crimp Height Adjustment 2914
Maintenance and Inspection Procedures 2914
PRO-CRIMPER II Tool 2914
Crimp Height Inspection 2914
How to Use AMP PRO-CRIMPER II Tool 2915
AMPSEAL Connector Assemblies 2916
Description for Plug Connector Assembly 2916
Seal Plug 2917
Contact Crimping 2917
Description for Plug Connector and Header Assembly 2922
Voltage Reading 2925
Seal Plug 2925
Contact Crimping 2925
AMP Superseal 1 5 Crimping Tools 2932
Mini Mic Receptacle and Tab Contacts 2932
Description 2932
Crimping Conditions and Measurements 2932
Insertion of Rubber Seal on Cable 2934
AMP Hand Application Tool 2939
Description 2939
Maintenance and Inspection 2939
Crimp Height Inspection 2939
Crimp Height Adjustment 2940
How to Use AMP Hand Application Tool 2940
AMP Pro-Crimper II Tool 2941
Description 2941
Remove and Install Die Set and Locator Assembly 2941
Adjustments 2942
Contact Support 2942
Crimp Height 2943
Inspections and Maintenance 2944
Crimp Height Inspection 2944
Visual Inspection 2944
Maintenance 2945
How to Use Pro-Crimper II Tool 2945
AMP Superseal 1 5 Connector Assemblies 2946
Description 2946
Repair and Maintenance 2953
Panel Mount Option 2953
AMP Fastin-Faston Hand Tools 2954
Description – AMP Double Action Hand Tool 2954
Maintenance and Inspection Procedures 2954
Daily Maintenance 2954
Periodic Tool Inspection 2955
Lubrication 2955
Visual Inspection 2955
Crimp Height Inspection 2955
Certi-Crimp Ratchet Inspection 2956
How to Use AMP Double Action Hand Tool 2957
Description – AMP Extraction Tool 2958
Maintenance and Inspection 2959
How to Use AMP Extraction Tool 2959
AMP Fastin-Faston Receptacles and Housings 2961
Description 2961
Wire Repair 2969
Wire Splicing Requirements 2969
Deutsch Jiffy Splice 2970
Twisted/Shielded Cable and Leads Repair 2976
Special Tools 2978
524223769-2200YRM1128-(07-2020)-UK-EN 2987
Series Code / Model Designation Reference Table 2993
General 2996
Deutsch Crimping Tool 2996
How to Strip a Wire for Use With Deutsch Crimping Tool 2996
How to Crimp With the Deutsch Crimping Tool 2997
Calibration Test for the Deutsch Crimping Tool 2999
Deutsch Connectors 3001
DT, DTM, and DTP Series Connectors 3001
HD Series Connectors 3043
Metri-Pack Connectors 3066
Remove and Install 3066
Micro-Pack Connectors 3068
Weather-Pack Connectors 3069
AMPSEAL Crimping Tools 3071
AMP Hand Crimping Tool With Certi-Crimp 3071
Description 3071
Stripping Wire for Use with AMP Hand Crimping Tool 3071
Insulation Crimp Adjustment 3072
Maintenance and Inspection for AMP Hand Crimping Tool 3072
AMP Hand Crimping Tool 3072
Crimp Height Inspection 3072
How to use AMP Hand Crimping Tool 3073
AMP Pro-Crimper II Tool 3073
Description 3073
Remove and Install Die Set and Locator Assembly 3074
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3075
Contact Support Adjustment 3075
Crimp Height Adjustment 3076
Maintenance and Inspection Procedures 3076
PRO-CRIMPER II Tool 3076
Crimp Height Inspection 3076
How to Use AMP PRO-CRIMPER II Tool 3077
AMPSEAL Connector Assemblies 3078
Description for Plug Connector Assembly 3078
Seal Plug 3079
Contact Crimping 3079
Description for Plug Connector and Header Assembly 3084
Voltage Reading 3086
Seal Plug 3086
Contact Crimping 3086
AMP Superseal 1 5 Crimping Tools 3093
Mini Mic Receptacle and Tab Contacts 3093
Description 3093
Crimping Conditions and Measurements 3093
Insertion of Rubber Seal on Cable 3095
AMP Hand Application Tool 3100
Description 3100
Maintenance and Inspection 3100
Crimp Height Inspection 3100
Crimp Height Adjustment 3101
How to Use AMP Hand Application Tool 3101
AMP Pro-Crimper II Tool 3102
Description 3102
Remove and Install Die Set and Locator Assembly 3103
Adjustments 3103
Contact Support 3103
Crimp Height 3104
Inspections and Maintenance 3105
Crimp Height Inspection 3105
Visual Inspection 3105
Maintenance 3106
How to Use Pro-Crimper II Tool 3106
AMP Superseal 1 5 Connector Assemblies 3107
Description 3107
Repair and Maintenance 3114
Panel Mount Option 3114
AMP Fastin-Faston Hand Tools 3115
Description – AMP Double Action Hand Tool 3115
Maintenance and Inspection Procedures 3115
Daily Maintenance 3115
Periodic Tool Inspection 3116
Lubrication 3116
Visual Inspection 3116
Crimp Height Inspection 3116
Certi-Crimp Ratchet Inspection 3117
How to Use AMP Double Action Hand Tool 3118
Description – AMP Extraction Tool 3119
Maintenance and Inspection 3119
How to Use AMP Extraction Tool 3120
AMP Fastin-Faston Receptacles and Housings 3121
Description 3121
Wire Repair 3128
Wire Splicing Requirements 3128
Deutsch Jiffy Splice 3129
Twisted/Shielded Cable and Leads Repair 3134
Special Tools 3137
524223770-2200YRM1130-(03-2020)-UK-EN 3145
General 3149
Description 3149
Dash Display Menu Access 3149
Menu Navigation 3150
Standard Display 3150
Main Menu 3150
Passwords Menu 3151
Password Administration 3151
Add Password 3151
Delete Password 3152
Edit Password 3152
Other Password Functions 3153
Operator Passwords – Enable/Disable 3153
Password Time-Out Delay 3153
Passwords – Number Wrong to Disable 3154
Lockout Reset Password 3154
View Password Log 3155
View Versions 3156
VSM Versions 3156
Dash Display Versions 3157
Engine Controller Version 3158
Transmission (Xmsn) Controller Version 3159
Truck Serial Number 3160
Diagnostics 3161
View Fault Log 3161
Set Travel and Braking 3162
Speed Limit 3162
Acceleration Rate 3163
Auto-Deceleration Rate 3163
Set Power Reversal Rate 3164
Set Inching/Brake Overlap 3165
Setup Display Menu 3166
Set Operator Language 3166
Set Units 3167
Set Time Format (12/24 Hour) 3167
Set Daylight Saving Time 3167
Set Time 3170
Set Date Format 3171
Set Date 3171
Setup Hydraulics 3172
Return to Set Tilt Delay/On/Off 3172
Setup General Items 3173
Light Shutdown Time-Out 3173
Impact Sensor – Enable/Disable 3174
Impact Sensor – Soft Impact Settings 3175
Impact Sensor – Hard Impact Settings 3176
Adjust Impact Sensor Settings 3176
Initial Adjustment of Soft and Hard Impact Settings 3178
Readjustment of Soft and Hard Impact Settings 3178
Impact Sensor – Impact Alarm/Shutdown Reset 3179
Impact Sensor – Alarm Time Duration and Deactivation 3180
Impact Sensor – View Impact Event Log 3181
Engine Mode Indicator 3182
Generation 1 (ECO-eLo ONLY) 3182
Generation 2 3183
Operator Checklist 3184
Operator Checklist Off-On Mode 3184
Edit Operator Checklist 3184
Set Operator Checklist Expiration 3185
View Checklist Log 3185
Clear Operator Checklist Log 3186
Clear Operator Checklist Fault 3186
Calibrations 3187
Set Tilt Stop Point 3187
Calibrate Loaded Weight 3187
524223770-2200YRM1130-(05-2021)-US-EN 3189
General 3193
Description 3193
Dash Display Menu Access 3193
Menu Navigation 3194
Standard Display 3194
Main Menu 3194
Passwords Menu 3195
Password Administration 3195
Add Password 3195
Delete Password 3195
Edit Password 3196
Other Password Functions 3197
Operator Passwords – Enable/Disable 3197
Password Time-Out Delay 3197
Passwords – Number Wrong to Disable 3197
Lockout Reset Password 3198
View Password Log 3198
View Versions 3199
VSM Versions 3199
Dash Display Versions 3200
Engine Controller Version 3201
Transmission (Xmsn) Controller Version 3202
Truck Serial Number 3203
Diagnostics 3204
View Fault Log 3204
Set Travel and Braking 3205
Speed Limit 3205
Acceleration Rate 3206
Auto-Deceleration Rate 3206
Set Power Reversal Rate 3207
Set Inching/Brake Overlap 3208
Setup Display Menu 3209
Set Operator Language 3209
Set Units 3210
Set Time Format (12/24 Hour) 3210
Set Daylight Saving Time 3211
Set Time 3214
Set Date Format 3214
Set Date 3215
Setup Hydraulics 3216
Return to Set Tilt Delay/On/Off 3216
Setup General Items 3217
Light Shutdown Time-Out 3217
Impact Sensor – Enable/Disable 3218
Impact Sensor – Soft Impact Settings 3219
Impact Sensor – Hard Impact Settings 3219
Adjust Impact Sensor Settings 3220
Initial Adjustment of Soft and Hard Impact Settings 3222
Readjustment of Soft and Hard Impact Settings 3222
Impact Sensor – Impact Alarm/Shutdown Reset 3223
Impact Sensor – Alarm Time Duration and Deactivation 3224
Impact Sensor – View Impact Event Log 3225
Engine Mode Indicator 3225
Generation 1 (ECO-eLo ONLY) 3225
Generation 2 3226
Operator Checklist 3227
Operator Checklist Off-On Mode 3227
Edit Operator Checklist 3227
Set Operator Checklist Expiration 3227
View Checklist Log 3228
Clear Operator Checklist Log 3229
Clear Operator Checklist Fault 3229
Calibrations 3230
Set Tilt Stop Point 3230
Calibrate Loaded Weight 3230
524223771-2200YRM1131-(03-2020)-UK-EN 3233
Series Code / Model Designation Reference Table 3239
General 3241
Description 3241
Dash Display Menu Access 3241
Menu Navigation 3242
Main Menu 3242
Passwords 3243
Adding Passwords 3243
Hourmeters 3245
View Versions 3246
VSM Versions 3246
Dash Display Versions 3247
Engine Controller Version 3248
Transmission (Xmsn) Controller Version 3249
Truck Serial Number 3250
Truck Configuration 3251
Diagnostics 3252
Clear Fault Log 3252
View Fault Log 3253
No-Run Data Display 3254
Engine Accelerator and Throttle Data Display 3254
Engine Speeds and Governor Data Display 3255
Engine Fuel and Emissions Data Display 3256
Engine General Data Display 3258
XMSN/Brake Data Display 3259
Hydraulic Data Display 3262
General Truck Data Display 3264
Set Travel and Braking 3265
Speed Limit 3265
Acceleration Rate 3266
Auto-Deceleration Rate 3267
Set Power Reversal Rate 3267
Set Inching/Brake Overlap 3268
Setup Hydraulics 3268
Lift Maximum Speed 3269
Lower Maximum Speed 3269
Tilt Maximum Speed 3270
Auxiliary Function One, Direction A, Maximum Speed 3272
Auxiliary Function One, Direction B, Maximum Speed 3274
Auxiliary Function Two, Direction A, Maximum Speed 3274
Auxiliary Function Two, Direction B, Maximum Speed 3275
Auxiliary Function Three, Direction A, Maximum Speed 3276
Auxiliary Function Three, Direction B, Maximum Speed 3276
Lift/Lower Ramp Rate 3277
Hydraulic Auxiliary Ramp Rate 3277
Return to Set Tilt Delay/On/Off 3278
Hydraulic Input Device 3279
Auxiliary Solenoid 3279
Dual Function 3280
Setup Display 3281
Set Service Language 3281
Setup General Items 3281
Motion Alarm Activation Type 3282
Light Shutdown Time-Out 3283
Restore Default Settings 3283
Restore Engine Controller Default Calibration 3284
Impact Sensor – Enable/Disable 3284
Impact Sensor – Soft Impact Settings 3285
Impact Sensor – Hard Impact Settings 3286
Adjust Impact Sensor Settings 3287
Initial Adjustment of Soft and Hard Impact Settings 3289
Readjustment of Soft and Hard Impact Settings 3289
Impact Sensor – Impact Alarm/Shutdown Reset 3290
Impact Sensor – Alarm Time Duration and Deactivation 3291
Impact Sensor – View Impact Event Log 3292
Engine Mode Indicator 3292
Generation 1 (ECO-eLo ONLY) 3292
Generation 2 3293
Diesel Particulate Filter (DPF) Display 3294
General Description 3294
Passive Regeneration Only 3294
Regeneration Level 0 3294
Auto/Active Regeneration Inhibited 3295
Auto/Active Regeneration 3295
Regeneration Level 1 3295
Parked Regeneration Request 3296
Regeneration Level 2 3296
Warning Level 3296
Regeneration Level 3 3296
Service Level 3297
Regeneration Level 4 3297
Display, Diesel Particulate Filter (DPF), Revised 3297
Operator Interface 3297
Refer to Operator Manual 3297
CAN Communication Lost 3298
Passive Regeneration Only 3298
Regeneration Level 0 3298
Auto/Active Regeneration Inhibited 3298
Auto/Active Regeneration 3299
Regeneration Level 1 3299
Idle-up Auto/Active Regeneration 3299
Parked Regeneration Request 3299
Regeneration Level 2 3299
Warning Level 3301
Regeneration Level 3 3301
Service Level 3301
Regeneration Level 4 3301
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3301
Display, Diesel Particulate Filter (DPF), Stage V Engine 3301
Operator Interface 3302
Refer to Operator Manual 3302
CAN Communication Lost 3302
Passive Regeneration Only 3302
Regeneration Level 0 3302
Auto/Active Regeneration Inhibited 3303
Auto/Active Regeneration 3303
Regeneration Level 1 3303
Idle-up Auto/Active Regeneration 3304
Parked Regeneration Request 3304
Regeneration Level 2 3304
Warning Level 3305
Regeneration Level 3 3305
Service Level 3306
Regeneration Level 4 3306
Stage V Content 3306
Emissions System Malfunction 3306
Ash Load 3306
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3307
Operator Interface 3307
Refer to Operator Manual 3307
CAN Communication Lost 3308
Passive Regeneration Only 3308
Regeneration Level 0 3308
Auto/Active Regeneration Inhibited 3308
Auto/Active Regeneration 3309
Regeneration Level 1 3309
Idle-up Auto/Active Regeneration 3309
Parked Regeneration Request 3309
Regeneration Level 2 3309
Warning Level 3311
Regeneration Level 3 3311
Service Level 3311
Regeneration Level 4 3311
Calibrations 3312
Calibrate Transmission Valve 3314
Set Tilt Stop Point 3314
Calibrate Loaded Weight 3314
Calibrate Travel Speed Sensor 3315
Calibrate Mazda LP and Gas Accelerator Pedal 3315
524223771-2200YRM1131-(05-2021)-US-EN 3317
Series Code / Model Designation Reference Table 3323
General 3325
Description 3325
Dash Display Menu Access 3325
Menu Navigation 3326
Main Menu 3327
Passwords 3327
Adding Passwords 3327
Hourmeters 3329
View Versions 3330
VSM Versions 3330
Dash Display Versions 3331
Engine Controller Version 3332
Transmission (Xmsn) Controller Version 3333
Truck Serial Number 3334
Truck Configuration 3335
Diagnostics 3336
Clear Fault Log 3336
View Fault Log 3337
No-Run Data Display 3338
Engine Accelerator and Throttle Data Display 3339
Engine Speeds and Governor Data Display 3341
Engine Fuel and Emissions Data Display 3342
Engine General Data Display 3344
XMSN/Brake Data Display 3345
Hydraulic Data Display 3347
General Truck Data Display 3350
Set Travel and Braking 3352
Speed Limit 3352
Acceleration Rate 3353
Auto-Deceleration Rate 3353
Set Power Reversal Rate 3354
Set Inching/Brake Overlap 3354
Setup Hydraulics 3355
Lift Maximum Speed 3355
Lower Maximum Speed 3356
Tilt Maximum Speed 3356
Auxiliary Function One, Direction A, Maximum Speed 3358
Auxiliary Function One, Direction B, Maximum Speed 3361
Auxiliary Function Two, Direction A, Maximum Speed 3361
Auxiliary Function Two, Direction B, Maximum Speed 3362
Auxiliary Function Three, Direction A, Maximum Speed 3363
Auxiliary Function Three, Direction B, Maximum Speed 3363
Lift/Lower Ramp Rate 3364
Hydraulic Auxiliary Ramp Rate 3364
Return to Set Tilt Delay/On/Off 3365
Hydraulic Input Device 3366
Auxiliary Solenoid 3366
Dual Function 3367
Setup Display 3368
Set Service Language 3368
Setup General Items 3368
Motion Alarm Activation Type 3369
Light Shutdown Time-Out 3370
Restore Default Settings 3370
Restore Engine Controller Default Calibration 3371
Impact Sensor – Enable/Disable 3371
Impact Sensor – Soft Impact Settings 3372
Impact Sensor – Hard Impact Settings 3372
Adjust Impact Sensor Settings 3373
Initial Adjustment of Soft and Hard Impact Settings 3375
Readjustment of Soft and Hard Impact Settings 3375
Impact Sensor – Impact Alarm/Shutdown Reset 3376
Impact Sensor – Alarm Time Duration and Deactivation 3377
Impact Sensor – View Impact Event Log 3378
Engine Mode Indicator 3378
Generation 1 (ECO-eLo ONLY) 3378
Generation 2 3379
Diesel Particulate Filter (DPF) Display 3380
General Description 3380
Passive Regeneration Only 3380
Regeneration Level 0 3380
Auto/Active Regeneration Inhibited 3381
Auto/Active Regeneration 3381
Regeneration Level 1 3381
Parked Regeneration Request 3382
Regeneration Level 2 3382
Warning Level 3383
Regeneration Level 3 3383
Service Level 3383
Regeneration Level 4 3383
Display, Diesel Particulate Filter (DPF), Revised 3383
Operator Interface 3384
Refer to Operator Manual 3384
CAN Communication Lost 3384
Passive Regeneration Only 3384
Regeneration Level 0 3384
Auto/Active Regeneration Inhibited 3385
Auto/Active Regeneration 3385
Regeneration Level 1 3385
Idle-up Auto/Active Regeneration 3385
Parked Regeneration Request 3386
Regeneration Level 2 3386
Warning Level 3387
Regeneration Level 3 3387
Service Level 3387
Regeneration Level 4 3387
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3388
Display, Diesel Particulate Filter (DPF), Stage V Engine 3388
Operator Interface 3388
Refer to Operator Manual 3388
CAN Communication Lost 3389
Passive Regeneration Only 3389
Regeneration Level 0 3389
Auto/Active Regeneration Inhibited 3389
Auto/Active Regeneration 3390
Regeneration Level 1 3390
Idle-up Auto/Active Regeneration 3390
Parked Regeneration Request 3390
Regeneration Level 2 3390
Warning Level 3392
Regeneration Level 3 3392
Service Level 3392
Regeneration Level 4 3392
Stage V Content 3392
Emissions System Malfunction 3392
Ash Load 3393
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3394
Operator Interface 3394
Refer to Operator Manual 3394
CAN Communication Lost 3395
Passive Regeneration Only 3395
Regeneration Level 0 3395
Auto/Active Regeneration Inhibited 3395
Auto/Active Regeneration 3396
Regeneration Level 1 3396
Idle-up Auto/Active Regeneration 3396
Parked Regeneration Request 3396
Regeneration Level 2 3396
Warning Level 3398
Regeneration Level 3 3398
Service Level 3398
Regeneration Level 4 3398
Calibrations 3399
Calibrate Transmission Valve 3401
Set Tilt Stop Point 3401
Calibrate Loaded Weight 3402
Calibrate Travel Speed Sensor 3402
Calibrate Mazda LP and Gas Accelerator Pedal 3403
524223772-2200YRM1142-(01-2020)-UK-EN 3405
General 3415
Display Switch Cluster 3418
Remove 3418
Install 3421
Direction Control and Turn Signal Levers 3421
Remove 3421
Install 3423
Key Switch 3423
Remove 3423
Install 3424
Display Switch Cluster Panel Bezel and Overlay 3424
Remove 3424
Install 3424
Steering Column Repair 3424
Remove 3424
Disassemble 3427
Assemble 3427
Install 3427
Sensors and Switches 3428
General 3428
Dash and Kick Panel, Remove and Install 3428
Remove 3428
Install 3429
Accelerator Pedal Position Sensor 3430
Remove 3430
Install 3433
Brake Fluid Level Switch 3434
Remove 3434
Install 3436
Service Brake Pedal Position Sensor 3437
Remove 3437
Install 3440
Parking Brake Sensor 3441
Remove 3441
Install 3442
Service Brake Pressure Sensor 3443
Remove 3443
Install 3445
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3446
Remove 3446
Install 3446
Sensor Microswitch (Foot Directional Control Pedal) 3447
Remove 3447
Install 3450
Low Coolant Level Sensor 3451
Remove 3451
Install 3454
Fuel Level Sensor, Gas and Diesel Engines Only 3455
Remove 3455
Install 3456
Armrest Switch 3456
Remove 3456
Install 3458
Seat Sensor (Operator Presence System) 3458
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) 3458
Remove 3458
Install 3459
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3459
Remove 3459
Install 3460
Full Suspension Seats; All Lift Truck Models 3460
Remove 3460
Install 3460
Hood Shut Off Switch 3460
Remove 3460
Install 3463
Remote Key Switch 3464
Remove 3464
Install 3464
Hydraulic Filter Pressure Switch 3465
Remove 3465
Install 3467
Transmission Speed Sensor 3467
Remove 3467
Install 3470
Transmission Pressure Sensors 3471
Remove 3471
Install 3473
Transmission Temperature Sensor 3474
Remove 3474
Install 3476
Engine Speed Sensor 3478
Remove 3478
Install 3478
Intermediate Speed Sensor 3479
Remove 3479
Install 3479
Return to Set Tilt (Tilt Angle) Sensor 3479
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) 3479
Remove 3479
Install 3480
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) 3481
Remove 3481
Install 3482
Rear Horn Button Switch 3482
Remove 3482
Install 3483
Impact Sensor 3484
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) 3484
Remove 3484
Install 3487
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) 3487
Remove 3487
Install 3488
Load Weight Sensor 3489
Remove 3489
Install 3490
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3491
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3491
Crankshaft Position (CKP) Sensor 3491
Camshaft Position (CMP) Sensor 3491
Oil Pressure Sensor 3491
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3491
Engine Coolant Temperature (ECT) Sensor 3492
Air Flow Restriction Switch 3492
Remove for GM 2 4L Gas and LPG Trucks 3492
Install for GM 2 4L Gas and LPG Trucks 3492
Oxygen Sensor 3493
Remove 3493
Install 3496
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3497
Crankshaft Position (CKP) Sensor 3497
Camshaft Position (CMP) Sensor 3497
Oil Pressure Sensor 3497
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3497
Engine Coolant Temperature (ECT) Sensor 3497
Air Flow Restriction Switch 3497
Oxygen Sensor 3497
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3497
Low LPG Pressure Switch 3497
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3498
Air Filter Restriction Switch 3498
Remove 3498
Install 3498
Oil Pressure Sensor 3498
Remove 3498
Install 3498
Engine Speed Sensor 3498
Remove 3498
Install 3498
Engine Coolant Temperature (ECT) Sensor 3498
Remove 3498
Install 3498
Throttle Position Sensor (TPS) 3501
Remove 3501
Install 3502
Fuel/Water Separator Sensor 3502
Remove 3502
Install 3502
Glow Plug Relay 3503
Remove 3503
Install 3505
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3505
Air Filter Restriction Switch 3505
Remove 3505
Install 3505
Engine Oil Pressure Sensor 3510
Remove 3510
Install 3510
Engine Speed Sensor 3510
Remove 3510
Install 3511
Engine Coolant Temperature (ECT) Sensor 3511
Remove 3511
Install 3512
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3513
Remove 3513
Install 3513
Fuel/Water Separator Sensor 3514
Remove 3514
Install 3514
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3515
Intake Air Temperature Sensor 3515
Remove 3515
Install 3516
Intake Air Pressure Sensor 3516
Remove 3516
Install 3516
Air Inlet Heater 3516
Remove 3516
Install 3517
Engine Oil Pressure Sensor 3517
Remove 3517
Install 3517
Engine Coolant Temperature (ECT) Sensor 3517
Remove 3517
Install 3517
Crankshaft Position Sensor 3518
Remove 3518
Install 3518
Adjust Shim Procedure 3519
Camshaft Position Sensor 3520
Remove 3520
Install 3520
Air Flow Restriction Sensor 3521
Remove 3521
Install 3521
Fuel/Water Separator 3521
Remove 3521
Install 3522
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3522
Intake Air Temperature Sensor 3526
Remove 3526
Install 3527
Boost Sensor 3527
Remove 3527
Install 3528
Throttle Valve Assembly and Air Intake Heater 3528
Remove 3528
Install 3528
Engine Coolant Temperature (ECT) Sensor 3529
Remove 3529
Install 3529
Engine Oil Pressure Sensor 3529
Remove 3529
Install 3530
Crankshaft Position Sensor 3530
Remove 3530
Install 3530
Adjust Shim Procedure 3531
Camshaft Position Sensor 3532
Remove 3532
Install 3533
Differential Pressure Sensor 3533
Remove 3533
Install 3533
Mass Air Flow Sensor 3534
Remove 3534
Install 3535
Fuel/Water Separator 3535
Remove 3535
Install 3536
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3536
Engine Coolant Temperature (ECT) Sensor 3537
Remove 3537
Install 3537
Throttle Position Sensor 3538
Engine Oil Pressure Sensor 3538
Remove 3538
Install 3538
Engine Speed Sensor 3538
Remove 3538
Install 3538
Fuel Shut Off Solenoid 3538
Remove 3538
Install 3538
Vehicle System Manager (VSM) 3539
General 3539
VSM Replacement 3539
Remove 3539
Install 3541
Programming a New VSM and/or Display Switch Cluster 3541
General 3541
PC Service Tool Software 3542
Data Transferring 3542
New VSM 3542
New (Blank) Display Switch Cluster 3542
Used (Non-Blank) Display Switch Cluster 3542
Power Distribution Module (PDM) and Component Parts 3544
Remove 3544
PDM as a Unit 3544
Install 3548
PDM as a Unit 3548
Remove and Install 3549
PDM Component Parts 3549
Transmission Control Unit 3549
Remove 3549
Install 3553
Battery 3555
Remove 3555
Install 3555
Lights 3556
Work Lights (Front and Rear) 3556
Remove 3556
Install 3556
Strobe Light 3557
Remove 3557
Install 3557
LED Tail, Backup, and Brake Lights 3558
Remove 3558
Install 3559
Front Marker/Turn Signal Lights 3560
Replacing Whole Front Marker/Turn Signal Light Assembly 3560
Remove 3560
Install 3560
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3561
Remove 3561
Install 3561
Diesel Particulate Filter (DPF) Display 3561
Remove 3561
Clean and Inspect 3562
Install 3562
Electronic-Hydraulic Controls – Generation 1 3563
E-Hydraulic Controls – Test 3563
Mini-Levers 3563
Full Stroke Test 3563
Function Returns to Neutral Test 3563
Push Button Switch 3563
General 3564
Mini-Lever Replacement 3564
Remove 3564
Clean and Inspect 3565
Install 3565
Push Button Switch Replacement 3566
Remove 3566
Install 3568
Mini-Lever Module (MLM) 3568
Remove 3568
Install 3568
Joystick 3569
Remove and Disassemble 3569
Inspect 3569
Assemble and Install 3569
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3570
General 3570
Mini-levers, Remove and Install 3570
Armrest Assembly 3571
Remove 3571
Install 3574
Horn Button 3574
Remove 3574
Install 3574
Direction Control Switch 3575
Remove 3575
Install 3575
push (override) buttons and Toggle Switch 3575
Remove 3576
Install 3577
Joystick 3578
Remove and Disassemble 3578
Inspect 3578
Assemble and Install 3578
Joystick Armrest Slider Assembly 3579
Remove 3579
Install 3580
Electronic-Hydraulic Controls, After January, 2020 3580
E-Hydraulic Controls – TEST 3580
Mini-Levers 3580
Full Stroke Test 3580
Function Returns to Neutral Test 3580
Push (Override) Button 3581
General 3581
Mini-levers, Remove and Install 3581
Armrest Assembly 3582
Remove 3582
Install 3585
Horn Button 3585
Remove 3585
Install 3585
Direction Control Switch 3585
Remove 3585
Install 3586
Push (Override) buttons and Toggle Switch 3586
Remove 3587
Install 3589
Special Tools 3590
524223772-2200YRM1142-(08-2021)-US-EN 3593
General 3603
Display Switch Cluster 3607
Remove 3607
Install 3609
Direction Control and Turn Signal Levers 3609
Remove 3609
Install 3610
Key Switch 3611
Remove 3611
Install 3612
Display Switch Cluster Panel Bezel and Overlay 3612
Remove 3612
Install 3612
Steering Column Repair 3613
Remove 3613
Disassemble 3616
Assemble 3616
Install 3616
Sensors and Switches 3617
General 3617
Dash and Kick Panel, Remove and Install 3617
Remove 3617
Install 3618
Accelerator Pedal Position Sensor 3618
Remove 3618
Install 3622
Brake Fluid Level Switch 3623
Remove 3623
Install 3624
Service Brake Pedal Position Sensor 3626
Remove 3626
Install 3628
Parking Brake Sensor 3629
Remove 3629
Install 3631
Service Brake Pressure Sensor 3631
Remove 3631
Install 3633
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3635
Remove 3635
Install 3635
Sensor Microswitch (Foot Directional Control Pedal) 3635
Remove 3635
Install 3638
Low Coolant Level Sensor 3639
Remove 3639
Install 3642
Fuel Level Sensor, Gas and Diesel Engines Only 3643
Remove 3643
Install 3644
Armrest Switch 3644
Remove 3644
Install 3646
Seat Sensor (Operator Presence System) 3646
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) 3646
Remove 3646
Install 3647
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3647
Remove 3647
Install 3647
Full Suspension Seats; All Lift Truck Models 3648
Remove 3648
Install 3648
Hood Shut Off Switch 3649
Remove 3649
Install 3651
Remote Key Switch 3652
Remove 3652
Install 3652
Hydraulic Filter Pressure Switch 3653
Remove 3653
Install 3655
Transmission Speed Sensor 3655
Remove 3655
Install 3658
Transmission Pressure Sensors 3659
Remove 3659
Install 3661
Transmission Temperature Sensor 3662
Remove 3662
Install 3664
Engine Speed Sensor 3666
Remove 3666
Install 3667
Intermediate Speed Sensor 3667
Remove 3667
Install 3667
Return to Set Tilt (Tilt Angle) Sensor 3668
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) 3668
Remove 3668
Install 3668
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) 3668
Remove 3669
Install 3670
Rear Horn Button Switch 3671
Remove 3671
Install 3671
Impact Sensor 3672
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) 3672
Remove 3672
Install 3674
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) 3674
Remove 3674
Install 3675
Load Weight Sensor 3675
Remove 3675
Install 3677
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3678
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3678
Crankshaft Position (CKP) Sensor 3678
Camshaft Position (CMP) Sensor 3678
Oil Pressure Sensor 3678
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3678
Engine Coolant Temperature (ECT) Sensor 3679
Air Flow Restriction Switch 3679
Remove for GM 2 4L Gas and LPG Trucks 3679
Install for GM 2 4L Gas and LPG Trucks 3679
Oxygen Sensor 3680
Remove 3680
Install 3683
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3684
Crankshaft Position (CKP) Sensor 3684
Camshaft Position (CMP) Sensor 3684
Oil Pressure Sensor 3684
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3684
Engine Coolant Temperature (ECT) Sensor 3684
Air Flow Restriction Switch 3684
Oxygen Sensor 3684
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3684
Low LPG Pressure Switch 3684
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3685
Air Filter Restriction Switch 3685
Remove 3685
Install 3685
Oil Pressure Sensor 3685
Remove 3685
Install 3685
Engine Speed Sensor 3685
Remove 3685
Install 3685
Engine Coolant Temperature (ECT) Sensor 3685
Remove 3685
Install 3685
Throttle Position Sensor (TPS) 3688
Remove 3688
Install 3689
Fuel/Water Separator Sensor 3689
Remove 3689
Install 3689
Glow Plug Relay 3690
Remove 3690
Install 3692
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3692
Air Filter Restriction Switch 3692
Remove 3692
Install 3693
Engine Oil Pressure Sensor 3697
Remove 3697
Install 3697
Engine Speed Sensor 3697
Remove 3697
Install 3698
Engine Coolant Temperature (ECT) Sensor 3698
Remove 3698
Install 3699
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3700
Remove 3700
Install 3700
Fuel/Water Separator Sensor 3701
Remove 3701
Install 3701
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3702
Intake Air Temperature Sensor 3702
Remove 3702
Install 3703
Intake Air Pressure Sensor 3703
Remove 3703
Install 3703
Air Inlet Heater 3703
Remove 3703
Install 3704
Engine Oil Pressure Sensor 3704
Remove 3704
Install 3704
Engine Coolant Temperature (ECT) Sensor 3704
Remove 3704
Install 3704
Crankshaft Position Sensor 3705
Remove 3705
Install 3705
Adjust Shim Procedure 3706
Camshaft Position Sensor 3707
Remove 3707
Install 3707
Air Flow Restriction Sensor 3707
Remove 3707
Install 3708
Fuel/Water Separator 3708
Remove 3708
Install 3709
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3709
Intake Air Temperature Sensor 3713
Remove 3713
Install 3714
Boost Sensor 3714
Remove 3714
Install 3715
Throttle Valve Assembly and Air Intake Heater 3715
Remove 3715
Install 3715
Engine Coolant Temperature (ECT) Sensor 3716
Remove 3716
Install 3716
Engine Oil Pressure Sensor 3717
Remove 3717
Install 3717
Crankshaft Position Sensor 3717
Remove 3717
Install 3717
Adjust Shim Procedure 3718
Camshaft Position Sensor 3720
Remove 3720
Install 3720
Differential Pressure Sensor 3720
Remove 3720
Install 3721
Mass Air Flow Sensor 3721
Remove 3721
Install 3722
Fuel/Water Separator 3723
Remove 3723
Install 3724
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3725
Engine Coolant Temperature (ECT) Sensor 3726
Remove 3726
Install 3726
Throttle Position Sensor 3726
Engine Oil Pressure Sensor 3726
Remove 3726
Install 3726
Engine Speed Sensor 3726
Remove 3726
Install 3726
Fuel Shut Off Solenoid 3727
Remove 3727
Install 3727
Vehicle System Manager (VSM) 3728
General 3728
VSM Replacement 3728
Remove 3728
Install 3730
Programming a New VSM and/or Display Switch Cluster 3730
General 3730
PC Service Tool Software 3731
Data Transferring 3731
New VSM 3731
New (Blank) Display Switch Cluster 3731
Used (Non-Blank) Display Switch Cluster 3731
Power Distribution Module (PDM) and Component Parts 3734
Remove 3734
PDM as a Unit 3734
Install 3737
PDM as a Unit 3737
Remove and Install 3738
PDM Component Parts 3738
Transmission Control Unit (TCU) 3739
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) 3739
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) 3739
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3740
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3740
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 3740
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 3741
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 3742
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 3744
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 3744
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 3744
Battery 3745
Remove 3745
Install 3745
Lights 3746
Work Lights (Front and Rear) 3746
Remove 3746
Install 3746
Strobe Light 3747
Remove 3747
Install 3747
LED Tail, Backup, and Brake Lights 3748
Remove 3748
Install 3749
Front Marker/Turn Signal Lights 3750
Replacing Whole Front Marker/Turn Signal Light Assembly 3750
Remove 3750
Install 3750
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3751
Remove 3751
Install 3751
Diesel Particulate Filter (DPF) Display 3752
Remove 3752
Clean and Inspect 3753
Install 3753
Electronic-Hydraulic Controls – Generation 1 3754
E-Hydraulic Controls – Test 3754
Mini-Levers 3754
Full Stroke Test 3754
Function Returns to Neutral Test 3754
Push Button Switch 3754
General 3755
Mini-Lever Replacement 3755
Remove 3755
Clean and Inspect 3756
Install 3756
Push Button Switch Replacement 3757
Remove 3757
Install 3759
Mini-Lever Module (MLM) 3759
Remove 3759
Install 3759
Joystick 3760
Remove and Disassemble 3760
Inspect 3760
Assemble and Install 3760
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3761
General 3761
Mini-levers, Remove and Install 3761
Armrest Assembly 3762
Remove 3762
Install 3765
Horn Button 3765
Remove 3765
Install 3765
Direction Control Switch 3766
Remove 3766
Install 3766
push (override) buttons and Toggle Switch 3766
Remove 3767
Install 3768
Joystick 3769
Remove and Disassemble 3769
Inspect 3769
Assemble and Install 3769
Joystick Armrest Slider Assembly 3770
Remove 3770
Install 3771
Electronic-Hydraulic Controls, After January, 2020 3772
E-Hydraulic Controls – TEST 3772
Mini-Levers 3772
Full Stroke Test 3772
Function Returns to Neutral Test 3772
Push (Override) Button 3772
General 3773
Mini-levers, Remove and Install 3773
Armrest Assembly 3774
Remove 3774
Install 3777
Horn Button 3777
Remove 3777
Install 3777
Direction Control Switch 3777
Remove 3777
Install 3778
Push (Override) buttons and Toggle Switch 3778
Remove 3779
Install 3781
Special Tools 3782
524223780-8000YRM1134-(03-2020)-UK-EN 3785
Series Code / Model Designation Reference Table 3791
Description 3793
Proc_Cal_001: Service Password Entry 3795
When to Perform 3795
Why Perform 3795
How to Perform 3795
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3796
When to Perform 3796
Calibration Order 3796
Why Perform 3796
How to Perform 3797
Proc_Cal_003: Save and Exit 3798
When to Perform 3798
Why Perform 3798
How to Perform 3798
Proc_Cal_004: Lift Valve Output Threshold 3799
When to Perform 3799
Calibration Order 3799
Why Perform 3799
How to Perform 3800
Proc_Cal_005: Lower Valve Output Threshold 3802
When to Perform 3802
Calibration Order 3802
Why Perform 3802
How to Perform 3802
Proc_Cal_006: Tilt Back Valve Output Threshold 3805
When to Perform 3805
Calibration Order 3805
Why Perform 3805
How to Perform 3805
Proc_Cal_007: Tilt Forward Valve Output Threshold 3808
When to Perform 3808
Calibration Order 3808
Why Perform 3808
How to Perform 3808
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3811
When to Perform 3811
Calibration Order 3811
Why Perform 3811
How to Perform 3811
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3814
When to Perform 3814
Calibration Order 3814
Why Perform 3814
How to Perform 3814
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3817
When to Perform 3817
Calibration Order 3817
Why Perform 3817
How to Perform 3817
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3820
When to Perform 3820
Calibration Order 3820
Why Perform 3820
How to Perform 3820
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3823
When to Perform 3823
Calibration Order 3823
Why Perform 3823
How to Perform 3823
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3826
When to Perform 3826
Calibration Order 3826
Why Perform 3826
How to Perform 3826
Proc_Cal_014: Load Weight Zero Point 3830
When to Perform 3830
Calibration Order 3830
Why Perform 3830
How to Perform 3830
Proc_Cal_015: Loaded Weight Calibration 3832
When to Perform 3832
Calibration Order 3832
Why Perform 3832
How to Perform 3832
Proc_Cal_016: Transmission Valve Calibration 3835
Applicable System/Option 3835
When to Perform 3835
Calibration Order 3835
Why Perform 3835
How to Perform 3835
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3837
Applicable System/Option 3837
When to Perform 3837
Calibration Order 3837
Why Perform 3837
How to Perform 3837
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3839
Applicable System/Option 3839
When to Perform 3839
Calibration Order 3839
Why Perform 3839
How to Perform 3840
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3841
Required Tools 3841
When to Perform 3841
Calibration Order 3841
Why Perform 3842
How to Perform 3842
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3843
When to Perform 3843
Why Perform 3843
How to Perform 3843
Proc_Cal_026: Travel Speed Calibration 3845
When to Perform 3845
Calibration Order 3845
Why Perform 3845
How to Perform 3845
524223780-8000YRM1134-(05-2022)-US-EN 3849
Series Code / Model Designation Reference Table 3855
Description 3858
Proc_Cal_001: Service Password Entry 3860
When to Perform 3860
Why Perform 3860
How to Perform 3860
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3861
When to Perform 3861
Calibration Order 3861
Why Perform 3861
How to Perform 3861
Proc_Cal_003: Save and Exit 3863
When to Perform 3863
Why Perform 3863
How to Perform 3863
Proc_Cal_004: Lift Valve Output Threshold 3864
When to Perform 3864
Calibration Order 3864
Why Perform 3864
How to Perform 3864
Proc_Cal_005: Lower Valve Output Threshold 3867
When to Perform 3867
Calibration Order 3867
Why Perform 3867
How to Perform 3867
Proc_Cal_006: Tilt Back Valve Output Threshold 3870
When to Perform 3870
Calibration Order 3870
Why Perform 3870
How to Perform 3870
Proc_Cal_007: Tilt Forward Valve Output Threshold 3873
When to Perform 3873
Calibration Order 3873
Why Perform 3873
How to Perform 3873
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3876
When to Perform 3876
Calibration Order 3876
Why Perform 3876
How to Perform 3876
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3879
When to Perform 3879
Calibration Order 3879
Why Perform 3879
How to Perform 3879
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3882
When to Perform 3882
Calibration Order 3882
Why Perform 3882
How to Perform 3882
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3885
When to Perform 3885
Calibration Order 3885
Why Perform 3885
How to Perform 3885
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3888
When to Perform 3888
Calibration Order 3888
Why Perform 3888
How to Perform 3888
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3891
When to Perform 3891
Calibration Order 3891
Why Perform 3891
How to Perform 3891
Proc_Cal_014: Load Weight Zero Point 3894
When to Perform 3894
Calibration Order 3894
Why Perform 3894
How to Perform 3894
Proc_Cal_015: Loaded Weight Calibration 3896
When to Perform 3896
Calibration Order 3896
Why Perform 3896
How to Perform 3896
Proc_Cal_016: Transmission Valve Calibration 3899
Applicable System/Option 3899
When to Perform 3899
Calibration Order 3899
Why Perform 3899
How to Perform 3899
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3901
Applicable System/Option 3901
When to Perform 3901
Calibration Order 3901
Why Perform 3901
How to Perform 3901
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3904
Applicable System/Option 3904
When to Perform 3904
Calibration Order 3904
Why Perform 3904
How to Perform 3904
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3907
Required Tools 3907
When to Perform 3907
Calibration Order 3907
Why Perform 3907
How to Perform 3907
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3909
When to Perform 3909
Why Perform 3909
How to Perform 3909
Proc_Cal_026: Travel Speed Calibration 3911
When to Perform 3911
Calibration Order 3911
Why Perform 3911
How to Perform 3911
524262274-0100YRM1243-(11-2016)-US-EN 3915
General 3919
Description 3920
Hood, Seat, and Side Covers Replacement 3922
Remove 3922
Install 3922
Steering Column 3929
Description 3930
Steering Column Repair 3930
Remove 3930
Disassemble 3932
Clean 3935
Inspect 3935
Assemble 3935
Install 3935
LPG Tank and Bracket Replacement 3936
Counterweight Replacement 3936
Remove 3936
Install 3939
Tow Pin 3943
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) 3943
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) 3943
Overhead Guard Replacement 3944
Remove 3944
Install 3945
LED Tail, Backup, and Brake Lights, Replace 3945
Operator Restraint System Replacement 3946
Description 3946
Engine Replacement 3947
Remove Engine Only 3947
Install Engine only 3974
Remove Engine and Transmission 3977
Install Engine and Transmission 3981
Electronic Throttle Replacement 3985
Cummins 4 5L Diesel Engine With Electronic Throttle 3985
Remove 3985
Install 3988
Pull Actuator Linkage Adjustment 3990
Low Idle Adjustment 3990
Throttle Pedal and Cable Adjustment 3991
Cummins 4 5L Diesel Engine with Basic Power Shift Transmission 3991
Kubota 3 6L Diesel Engine 3991
Exhaust System Repair 3994
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) 3994
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) 3994
Remove 3994
Inspect 3994
Install 3996
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) 3996
Remove 3996
Inspect 3998
Install 3998
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 3998
Remove 3998
Inspect 4000
Install 4000
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) 4000
Remove 4000
Inspect 4003
Diesel Particulate Filter 4005
Disassemble 4005
CLEAN AND INSPECT 4006
Assembly 4006
Install 4007
Cooling System 4008
Description 4008
Hydraulic Filter Assembly Repair 4009
Remove 4009
Disassemble 4009
Clean 4010
Inspect 4010
Assemble 4010
Install 4010
Fuel and Hydraulic Tanks Repair 4010
Inspect 4010
Clean 4011
Steam Method of Cleaning 4011
Chemical Solution Method of Cleaning 4012
Additional Preparations for Repair 4012
Small Leaks, Repair 4012
Large Leaks, Repair 4012
Preparations for Use After Repair 4012
Safety Labels 4012
524262278-1400YRM1246-(02-2018)-US-EN 4023
General 4027
Identification Plate 4028
Drive Axle Removal 4028
Hub Seal Replacement 4040
Planetary Reduction Repair 4049
Clean and Inspect 4058
Brake Repair 4071
Clean and Inspect 4087
Wet Brake Noise Reduction 4103
General 4103
Adding Additive To Transmission 4104
Bevel Pinion 4105
Clean and Inspect 4110
Differential Unit 4122
Disassemble 4133
Clean and Inspect 4139
Assemble 4140
Drive Axle Installation 4163
Special Tools 4173
Torque Specifications 4173
524262279-1800YRM1247-(06-2021)-US-EN 4177
General 4181
Dry Brake System 4181
Wet Brake System 4181
Service Brakes Repair (Dry Brake) 4185
Remove and Disassemble 4185
Clean 4187
Inspect 4188
Assemble and Install 4189
Adjust 4192
Parking Brake Repair 4193
Dry Brake System 4193
Remove and Disassembly 4193
Assemble and Install 4195
Wet Brake System 4195
Remove and Install 4195
Assemble and Install 4202
Adjust 4202
Dry Brake System 4202
Wet Brake System 4203
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 4203
Master Cylinder Repair 4205
Remove 4205
Disassemble 4209
Clean and Inspect 4210
Assemble 4211
Install and Adjust 4211
Accumulator 4214
Pre-Charge Check 4214
Remove 4215
Install 4217
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 4218
Remove 4218
Modulating Brake Valve 4220
Disassemble 4220
Clean and Inspect 4221
Assemble 4221
Accumulator Charge Valve 4222
Disassemble 4222
Clean and Inspect 4224
Assemble 4224
Install 4225
Pressure Checks 4226
Accumulator Charge Valve Check 4226
Accumulator Check 4226
Service Brakes Adjustment (Dry Brake) 4227
Service Brakes Adjustment 4227
Brake System Air Removal 4229
Using Pressure Bleed System 4229
Using Brake Pedal Pressure 4229
Lift Truck Models with Master Cylinder 4229
Lift Truck Models with Modulating Brake Valve 4230
Brake Pedal Adjustment 4231
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) 4231
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4232
Free Pedal Adjustment 4234
Torque Specifications 4235
524262279-1800YRM1247-(09-2018)-UK-EN 4237
General 4241
Dry Brake System 4241
Wet Brake System 4242
Service Brakes Repair (Dry Brake) 4246
Remove and Disassemble 4246
Clean 4248
Inspect 4249
Assemble and Install 4249
Adjust 4253
Parking Brake Repair 4253
Dry Brake System 4254
Remove and Disassembly 4254
Assemble and Install 4256
Wet Brake System 4256
Remove and Install 4257
Assemble and Install 4263
Adjust 4263
Dry Brake System 4263
Wet Brake System 4264
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 4264
Master Cylinder Repair 4265
Remove 4265
Disassemble 4270
Clean and Inspect 4271
Assemble 4272
Install and Adjust 4272
Accumulator 4274
Pre-Charge Check 4275
Remove 4276
Install 4278
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 4278
Remove 4279
Modulating Brake Valve 4280
Disassemble 4280
Clean and Inspect 4282
Assemble 4282
Accumulator Charge Valve 4283
Disassemble 4283
Clean and Inspect 4285
Assemble 4285
Install 4286
Pressure Checks 4287
Accumulator Charge Valve Check 4287
Accumulator Check 4287
Service Brakes Adjustment (Dry Brake) 4288
Service Brakes Adjustment 4288
Brake System Air Removal 4289
Using Pressure Bleed System 4289
Using Brake Pedal Pressure 4290
Lift Truck Models with Master Cylinder 4290
Lift Truck Models with Modulating Brake Valve 4290
Brake Pedal Adjustment 4291
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) 4291
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4292
Free Pedal Adjustment 4294
Torque Specifications 4295
524265337-0600YRM1251-(09-2015)-US-EN 4299
General 4305
Engine Removal and Installation 4305
Cylinder Head Repair 4305
Remove and Disassemble 4305
Clean and Inspect 4307
Valve Oil Seals 4310
Remove and Disassemble 4310
Cylinder Leak Down Test 4310
Clean and Inspect 4311
Assemble and Install 4311
Valve Guides and Seats, Repairs 4313
Valves, Repair 4313
Valve Seats, Repair 4314
Valve Springs 4315
Assemble and Install 4316
Engine Block Cleaning and Inspection 4319
Clean and Inspect 4320
Piston Bore Preparation 4322
Engine Mounts Installation 4322
Remove 4322
Clean and Inspect 4323
Install 4323
Lubrication System Repair 4324
Oil Pump, Remove and Disassemble 4324
Clean and Inspect 4325
Oil Pump, Assemble and Install 4326
Oil Pan, Install 4328
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4330
Timing Cover 4330
Remove 4330
Install 4332
Timing Sprockets 4332
Remove 4332
Install 4332
Camshaft 4332
Remove 4332
Inspect 4333
Install 4333
Balance Shaft 4334
Remove 4334
Install 4335
Valve Lifters 4336
Remove 4336
Clean and Inspect 4336
Install 4337
Crankshaft Repair 4337
Remove 4338
Inspect and Repair 4338
How to Check Clearance Between Main Bearings and Their Journals 4339
Install 4340
Piston and Connecting Rod Assemblies Repair 4342
Connecting Rod Bearings, Replace 4342
Piston and Connecting Rod Assemblies, Remove 4343
Disassemble 4343
Piston, Clean and Inspect 4344
Cylinder Bores, Inspect and Repair 4344
Piston Rings 4345
Assemble 4346
Piston and Connecting Rod Assemblies, Install 4346
Flywheel and Flywheel Housing Repair 4346
Flywheel, Remove 4347
Clean 4347
Inspect 4347
Flywheel, Install 4348
Coolant Pump Repair 4348
Remove 4348
Clean and Inspect 4349
Install 4349
Thermostat Replacement 4349
Remove 4350
Thermostat Operation Check 4350
Install 4350
Starter Replacement 4351
4351
Remove 4351
Install 4354
Fan Assembly Replacement 4355
Remove 4355
Inspect 4357
Install 4357
Drive Belt Installation 4358
Remove 4358
Clean 4358
Inspect 4358
Installation 4359
Compression Check 4360
Engine Specifications 4360
Engine Data 4360
Cylinder Head 4360
Hydraulic Valve Lifter 4361
Camshaft 4361
Pistons 4361
Crankshaft 4362
Connecting Rods 4362
Balance Shaft 4363
Cooling System 4363
Lubrication System 4363
Torque Specifications 4364
524265342-4000YRM1250-(06-2021)-US-EN 4369
Safety Procedures When Working Near Mast 4375
Fork Replacement 4378
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4378
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4379
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) 4381
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4382
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4383
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) 4384
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4384
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) 4385
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4386
Fixed Carriage Replacement 4388
Remove, Carriage With Hook Forks 4388
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4396
Install, Carriage With Hook Forks 4397
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4397
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4398
Connecting Attachment Hydraulic Quick Disconnect Hoses 4398
Integral Sideshift Carriage Repair 4399
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) 4399
Disassemble 4399
Clean and Inspect 4402
Assemble 4402
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) 4403
Hang On Sideshift Carriage Repair 4404
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) 4404
Disassemble 4416
Clean and Inspect 4425
Assemble 4426
Install 4427
Hang-On Sideshift Carriage Repair 4429
Remove 4429
Disassemble Carriage 4431
Clean and Inspect 4434
Assemble 4434
Install 4437
Fork Positioner 4440
Two-Stage Mast With Limited Free-Lift Repair 4441
Remove 4441
Disassemble 4444
Clean and Inspect 4447
Assemble 4465
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) 4467
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) 4469
Header Hose Alignment 4480
Two-Stage Mast With Full Free-Lift Repair 4491
Remove 4491
Disassemble 4493
Clean and Inspect 4504
Assemble 4505
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) 4507
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) 4510
Header Hose Installation and Adjustment 4514
Installation 4514
Adjustment 4515
Three-Stage Mast With Full Free-Lift Repair 4516
Remove 4516
Disassemble 4518
Clean and Inspect 4548
Assemble 4550
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) 4553
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) 4558
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) 4565
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) 4572
Mast Operation Check 4576
Tilt Cylinder Adjustment 4577
Lift Chains Adjustment 4577
Mast Adjustments 4579
Load Roller Adjustment 4579
Mast Side Kicking Adjustment 4581
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4582
Carriage Adjustments 4584
Series Code / Model Designation Reference Table 4585
524265342-4000YRM1250-(09-2018)-UK-EN 4589
Safety Procedures When Working Near Mast 4595
Fork Replacement 4597
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4597
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4599
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) 4600
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4601
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4602
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) 4603
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4603
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) 4605
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4605
Fixed Carriage Replacement 4607
Remove, Carriage With Hook Forks 4607
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4616
Install, Carriage With Hook Forks 4617
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4617
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4618
Connecting Attachment Hydraulic Quick Disconnect Hoses 4618
Integral Sideshift Carriage Repair 4619
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) 4619
Disassemble 4619
Clean and Inspect 4622
Assemble 4622
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) 4623
Hang On Sideshift Carriage Repair 4623
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) 4623
Disassemble 4635
Clean and Inspect 4644
Assemble 4645
Install 4646
Bolzoni Hang-On Sideshift Carriage Repair 4648
Remove 4648
Disassemble Carriage 4650
Clean and Inspect 4653
Assemble 4653
Install 4656
Fork Positioner 4658
Two-Stage Mast With Limited Free-Lift Repair 4659
Remove 4659
Disassemble 4663
Clean and Inspect 4666
Assemble 4683
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) 4685
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) 4686
Header Hose Alignment 4698
Two-Stage Mast With Full Free-Lift Repair 4708
Remove 4708
Disassemble 4710
Clean and Inspect 4722
Assemble 4723
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) 4725
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) 4728
Header Hose Installation and Adjustment 4732
Installation 4732
Adjustment 4732
Three-Stage Mast With Full Free-Lift Repair 4733
Remove 4733
Disassemble 4735
Clean and Inspect 4765
Assemble 4766
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) 4770
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) 4775
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) 4782
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) 4788
Mast Operation Check 4792
Tilt Cylinder Adjustment 4792
Lift Chains Adjustment 4793
Mast Adjustments 4794
Load Roller Adjustment 4794
Mast Side Kicking Adjustment 4796
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4797
Carriage Adjustments 4800
550043871-0900YRM1556-(04-2018)-US-EN 4803
General 4807
LPG Tank and Bracket 4807
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) 4807
Remove 4807
Install 4815
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) 4816
Remove 4816
Install 4818
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4818
Remove 4818
Install 4820
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4820
Remove 4820
Install 4820
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) 4821
Remove 4821
Install 4823
Fuel Filter Unit 4823
Fuel Filter Element 4824
Remove 4824
Clean and Inspect 4824
Install 4825
Fuel Filter Housing with LP Vapor Sensor 4825
Remove 4825
Disassemble 4827
Clean and Inspect 4828
Assemble 4828
Install 4829
Throttle Body 4830
Remove 4830
Clean 4834
Install 4834
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 4835
Remove 4835
Install 4836
Control System 4836
Engine Control Unit (ECU) 4837
Remove 4837
Install 4838
Low Pressure Switch 4838
Remove 4838
Install 4838
Low Fuel Sensor 4839
Remove 4839
Install 4839
LP Converter 4840
Remove and Disassemble 4840
Assemble and Install 4841
LPG Lock-Off 4841
Remove 4842
Install 4843
Exhaust System 4844
Counterweight Exhaust 4844
Remove and Disassemble 4844
Inspect 4846
Assemble and Install 4846
Overhead Exhaust 4847
Remove and Disassemble 4847
Inspect 4849
Assemble and Install 4849
Exhaust Manifold 4849
Remove 4849
Install 4851
Oxygen (HEGO) Sensor 4851
Remove 4851
Install 4851
LPG Fuel Testing 4852
General 4852
Available Fuel Tests 4852
Composition Test (ASTM D-2163) 4852
Ammonia Test (ASTM D-4490) 4852
Basic Nitrogen Test (ASTM UOP269-90) 4852
Residues Test (ASTM D-2158) 4852
Vapor Pressure Test (ASTM D-2598) 4852
Sulfur Compounds Test (ASTM D-5623) 4852
Methanol Test (ASTM D-4864) 4853
Copper Corrosion (ASTM D-1838) 4853
Where To Send LPG Fuel Samples For Testing 4853
550048401-0900YRM1570-(03-2015)-US-EN 4857
550048681-1300YRM1569-(11-2018)-US-EN 4887
General 4891
Serial Number 4891
Charge Pump Repair 4891
Lift Trucks Manufactured Before July, 2013 4891
Remove 4891
Inspect 4892
Install 4892
Lift Trucks Manufactured After July, 2013 4892
Remove 4892
Inspect 4893
Install 4893
Torque Converter Replace 4893
Remove 4893
Install 4899
Housings and Chain Drive Repair 4904
Remove 4905
Clean 4913
Inspect 4913
Install 4913
Clutch Packs Repair- 1 Speed Transmission 4919
Remove and Disassemble 4919
Transmission, Remove and Disassemble 4919
Clean 4931
Inspect 4931
Assemble and Install 4932
Transmission, Assemble and Install 4940
Clutch Packs Repair- 2 Speed Transmission 4943
Remove and Disassemble 4944
Transmission, Remove and Disassemble 4944
Clean 4958
Inspect 4958
Assemble and Install 4959
Transmission, Assemble and Install 4968
Control Valve Repair 4970
Remove and Disassemble 4971
Clean 4974
Inspect 4974
Assemble and Install 4974
Foot Directional Control Pedal Repair 4975
Remove and Disassemble 4975
Assemble and Install 4979
Direction Control Lever 4980
Remove 4980
Install 4980
550055280-1400YRM1582-(01-2019)-US-EN 4985
General 4989
Identification Plate 4989
Drive Axle Removal 4990
Reduction Gear Assembly 4995
Remove 4995
Disassemble 4998
Clean and Inspect 5002
Assemble 5002
Install 5011
Wet Disc Brake Repair 5014
General 5014
Remove 5015
Clean and Inspect 5018
Install 5019
Initial Steps For Install 5019
Final Steps For Install 5026
Wet Brake Noise Reduction 5029
General 5029
Adding Additive To Transmission 5029
Piston Housing 5031
Remove 5031
Disassemble 5032
Clean and Inspect 5033
Assemble 5033
Install 5034
Parking Brake Control Lever 5035
Remove 5035
Clean and Inspect 5036
Install 5036
Differential Repair 5038
Initial Removal Steps for Differential Housing and drive axle trumpet arm (right side) 5038
Input Pinion Carrier 5038
Remove 5039
Disassemble 5039
Clean and Inspect 5040
Assemble 5040
Preload Pinion Bearings 5042
Differential Housing and Drive Axle Trumpet Arm (Right Side) 5042
Remove 5044
Disassemble 5044
Clean and Inspect 5045
Assemble 5045
Install 5047
Ring Gear Backlash 5047
Final Installation Steps for Differential Housing and drive axle trumpet arm (right side) 5048
Pinion and Motor Carrier 5049
Install 5049
Drive Axle Installation 5052
Special Tools 5057
Special Tools 5057
Torque specifications 5059
550055283-8000YRM1585-(06-2021)-US-EN 5063
General Information About Diagrams and Schematics 5067
Symbol Definitions 5067
Diagrams Manual Applications 5068
Diagrams and Schematics 5070
550055283-8000YRM1585-(07-2020)-UK-EN 5159
General Information About Diagrams and Schematics 5163
Symbol Definitions 5163
Diagrams Manual Applications 5164
Diagrams and Schematics 5166
550064329-1800YRM1597-(03-2017)-US-EN 5255
Wet Brake System 5259
Service Brake Repair 5260
Parking Brake Repair 5260
Remove and Disassemble 5260
Assemble and Install 5261
Adjust 5262
Lift Trucks With a Foot Directional Control Pedal or Forward Reverse Lever 5262
Master Cylinder and Booster 5262
Remove 5262
Disassemble 5264
Clean and Inspect 5265
Assemble 5265
Install and Adjust 5265
Brake System Air Removal 5267
Using Pressure Bleed System 5267
Using Brake Pedal Pressure 5268
Lift Truck Models with Master Cylinder 5268
Brake Pedal Adjustment 5269
Free Pedal Adjustment 5270
Torque Specifications 5270
550064334-8000YRM1598-(10-2016)-US-EN 5273
General 5279
Serial Number Data 5279
How to Move Disabled Lift Truck 5280
How to Tow Lift Truck 5280
How to Put Lift Truck on Blocks 5280
How to Raise Drive Tires 5280
How to Raise Steering Tires 5282
How to Clean a Lift Truck 5282
Maintenance Schedule 5283
Maintenance Procedures Every 8 Hours or Daily 5297
How to Make Checks With Engine Stopped 5298
Tires and Wheels 5298
Safety Labels 5298
Mast, Carriage, Lift Chains, Header Hoses, Attachment 5299
Operator Restraint System 5300
Emergency Locking Retractor (ELR) 5300
Adjust Seat – Full Suspension 5300
Adjust Seat – Internal Suspension 5301
Hood and Seat Latches 5302
Engine Compartment 5302
Paper Application 5302
Fuel, Oil, and Coolant Leaks, Check 5303
Hydraulic Hoses 5304
Coolant Hoses 5304
Steering Column Gas Cylinder 5304
Transmission 5304
Hydraulic System Oil 5304
Engine Oil 5304
Air Filter 5306
Forks 5306
Remove 5306
Inspect 5307
Install 5307
Adjust 5308
Integral Sideshift Carriage 5308
How to Make Checks With Engine Running 5309
Indicator Lights, Horn, Fuses, and Relays 5309
Service Brakes 5309
Brake Oil Level 5309
Operation, Check 5309
Parking Brake 5312
Engine Oil Pressure 5312
Cooling System 5312
Steering System 5313
Control Levers and Pedals 5313
Lift System, Operate 5313
First Service After First 100 Hours of Operation 5314
Engine Oil and Oil Filter 5314
Maintenance Procedures Every 250 Hours or 6 Months 5315
Engine Oil and Oil Filter 5315
Drive Belt 5315
GM 4 3L Engine 5315
Fan and Alternator Drive Belt 5315
Drain Tar From LPG Converter 5316
Maintenance Procedures Every 500 Hours or 6 Months 5317
Hydraulic System Oil 5317
Hydraulic Tank Breather 5317
Inspect 5317
Battery 5318
Clean Debris From Radiator Core 5318
Transmission Oil Level 5319
Wet Brake Center Body Oil Level Check 5320
Forks 5320
Mast Lubrication 5322
Header Hose Checks 5324
Lift Chain Lubrication 5324
Tilt Cylinder Lubrication 5325
Master Brake Cylinder Rod End Pin Lubrication 5326
Manual Hydraulic Levers Lubrication 5326
Brake Oil 5327
Tie Rod Lubrication 5328
Parking Brake Adjustment 5328
Maintenance Procedures Every 1000 Hours or 6 Months 5328
Valve Clearance, Check and Adjust 5329
Ignition System 5329
GM 4 3L Engine 5329
LPG Fuel Filter Element Replace, GM 4 3L Engine 5329
Remove 5329
Install 5329
Lift Chains Wear Check 5330
Lift Chain Lubrication 5330
Integral Sideshift Carriage, Check Sliding Surfaces 5331
Steering Axle (Spindle Bearings) 5331
Control Levers and Pedals 5331
Parking Brake Lever Lubrication, Dana Wet Brake Axle 5332
Normal Operating Environment 5332
Heavy Duty or Contaminated Environment 5332
Remove 5332
Clean and Inspect 5334
Install 5334
Inspect Engine Electrical System, Connectors 5334
Maintenance Procedures Every 2000 Hours or Annually 5335
Hydraulic System 5335
Hydraulic Filter, Replace 5335
Hydraulic Tank Breather, Replace 5336
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 5337
Cooling System 5337
Air Filter 5338
Gasoline Fuel Filter 5339
Remove and Replace for Lift Trucks Equipped with PSI 5339
LPG Fuel Injector, GM Engines 5340
Gasoline Fuel Injector, GM Engines 5340
Forks 5340
Transmission and Wet Brake Planetary Carrier Housing Oil Change (Dana Drive Axle) 5341
Wet Brake Center Section Oil Change (Dana Drive Axle) 5343
Remove 5343
Install 5343
Wet Brake Oil Change (NMHG Drive Axle) 5343
Brake Oil (Master Cylinder), Change 5346
Test LPG/GAS Regulator Pressure 5346
Check Throttle Shaft for Sticking 5346
Inspect Exhaust Manifold and Piping for Leaks 5346
Wheel Bearings 5347
Steer Wheels, Lubrication 5347
Maintenance Procedures Every 4000 Hours or 2 Years 5347
Hydraulic Oil, Replace 5347
Weld Inspection 5350
Safety Procedures When Working Near Mast 5351
Hood Latch Check 5354
Lift Chain Adjustments 5354
Jump-Starting the Lift Truck 5356
Jump-Starting Using a Battery Charger 5356
Jump-Starting a Lift Truck Using Another Lift Truck 5356
Welding Repairs 5356
Overhead Guard Changes 5357
Wheel and Tire Replacement 5358
General 5358
Solid Rubber Tire, Change (GC/GLCSeries) 5358
Remove and Install Tire on Wheel 5358
Adhesives and Sealants 5359
550064337-8000YRM1598-(10-2016)-UK-EN 5363
General 5369
Serial Number Data 5369
How to Move Disabled Lift Truck 5370
How to Tow Lift Truck 5370
How to Put Lift Truck on Blocks 5370
How to Raise Drive Tires 5370
How to Raise Steering Tires 5372
How to Clean a Lift Truck 5372
Maintenance Schedule 5373
Maintenance Procedures Every 8 Hours or Daily 5385
How to Make Checks With Engine Stopped 5385
Tires and Wheels 5385
Safety Labels 5385
Mast, Carriage, Lift Chains, Header Hoses, Attachment 5386
Operator Restraint System 5387
Emergency Locking Retractor (ELR) 5387
Adjust Seat – Full Suspension 5387
Adjust Seat – Internal Suspension 5388
Hood and Seat Latches 5389
Engine Compartment 5389
Paper Application 5389
Fuel, Oil, and Coolant Leaks, Check 5390
Hydraulic Hoses 5390
Coolant Hoses 5390
Steering Column Gas Cylinder 5390
Transmission 5390
Hydraulic System Oil 5391
Engine Oil 5391
Air Filter 5391
Forks 5392
Remove 5392
Inspect 5393
Install 5393
Adjust 5394
Integral Sideshift Carriage 5394
How to Make Checks With Engine Running 5395
Indicator Lights, Horn, Fuses, and Relays 5395
Service Brakes 5395
Brake Oil Level 5395
Operation, Check 5395
Parking Brake 5398
Engine Oil Pressure 5398
Cooling System 5398
Steering System 5399
Control Levers and Pedals 5399
Lift System, Operate 5399
First Service After First 100 Hours of Operation 5400
Engine Oil and Oil Filter 5400
Maintenance Procedures Every 500 Hours or 1 Year 5401
Hydraulic System Oil 5401
Hydraulic Tank Breather 5401
Inspect 5401
Battery 5402
Engine Oil and Oil Filter 5402
Drain Tar From LPG Regulator 5403
Drain Tar From LPG Converter 5403
Drive Belt 5404
GM 4 3L Engine 5404
Fan and Alternator Drive Belt 5404
Clean Debris From Radiator Core 5404
Transmission Oil Level 5405
Wet Brake Center Body Oil Level Check 5406
Forks 5406
Mast Lubrication 5408
Header Hose Checks 5410
Lift Chain Lubrication 5410
Tilt Cylinder Lubrication 5411
Master Brake Cylinder Rod End Pin Lubrication 5412
Manual Hydraulic Levers Lubrication 5412
Brake Oil 5413
Tie Rod Lubrication 5414
Parking Brake Adjustment 5414
Maintenance Procedures Every 1000 Hours or 1 Year 5414
Valve Clearance, Check and Adjust 5415
Ignition System 5415
GM 4 3L Engine 5415
LPG Fuel Filter Element Replace, GM 4 3L Engine 5415
Remove 5415
Install 5416
Lift Chains Wear Check 5416
Lift Chain Lubrication 5416
Integral Sideshift Carriage, Check Sliding Surfaces 5417
Steering Axle (Spindle Bearings) 5417
Control Levers and Pedals 5417
Parking Brake Lever Lubrication, Dana Wet Brake Axle 5418
Normal Operating Environment 5418
Heavy Duty or Contaminated Environment 5418
Remove 5418
Clean and Inspect 5420
Install 5420
Inspect Engine Electrical System, Connectors 5421
Maintenance Procedures Every 2000 Hours or Annually 5421
Hydraulic System 5421
Hydraulic Filter, Replace 5421
Hydraulic Tank Breather, Replace 5422
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 5424
Cooling System 5424
Air Filter 5424
LPG Fuel Injector, GM Engines 5426
Forks 5426
Transmission and Wet Brake Planetary Carrier Housing Oil Change (Dana Drive Axle) 5426
Wet Brake Center Section Oil Change (Dana Drive Axle) 5429
Remove 5429
Install 5429
Wet Brake Oil Change (NMHG Drive Axle) 5430
Brake Oil (Master Cylinder), Change 5431
Test LPG/GAS Regulator Pressure 5431
Check Throttle Shaft for Sticking 5432
Inspect Exhaust Manifold and Piping for Leaks 5432
Wheel Bearings 5432
Steer Wheels, Lubrication 5432
Maintenance Procedures Every 4000 Hours or 2 Years 5432
Hydraulic Oil, Replace 5432
Weld Inspection 5435
Safety Procedures When Working Near Mast 5436
Hood Latch Check 5439
Lift Chain Adjustments 5439
Jump-Starting the Lift Truck 5441
Jump-Starting Using a Battery Charger 5441
Jump-Starting a Lift Truck Using Another Lift Truck 5441
Welding Repairs 5441
Overhead Guard Changes 5442
Wheel and Tire Replacement 5442
General 5442
Solid Rubber Tire, Change (GC/GLCSeries) 5442
Remove and Install Tire on Wheel 5443
Snap-On-Tire, Change 5444
Easy Mounting Style Solid Rubber Tires on Pneumatic Wheels, Change 5447
Adhesives and Sealants 5452
550064342-8000YRM1599-(10-2016)-US-EN 5455
Lift Truck Lifting Capacity 5459
Counterweight Weights 5459
Tire Sizes 5459
Capacities 5459
Electrical System 5462
Transmission Oil Pressures 5462
Hydraulic System Relief Pressures 5465
Steering System 5465
Stall Speeds (in RPM ±100 rpm) 5465
GM 4 3L Gas/LPG 5465
Mast Speeds 5466
Tilt Angles 5466
Front End Equipment 5466
Mast Creep 5467
Engine Specifications 5467
GM 4 3L Gas/LPG 5467
Torque Specifications 5468
Frame 5468
Mast 5468
Steering Axle 5468
Drive Axle – (Dana Spicer) 5468
Drive Axle – (NMHG) 5468
Transmission 5469
Engine – GM 4 3L 5469
550073240-1900YRM1620-(01-2023)-US-EN 5473
Proper Flushing after Major Hydraulic Repairs 5479
Introduction 5479
The Phases of Wear 5479
Causes of Hydraulic System Failure 5479
Progression of Contaminant Caused Hydraulic System Failure 5480
Hydraulic System Flushing Techniques 5480
Double Oil and Filter Change 5480
Mechanical Cleaning 5481
Cleaning of Components 5481
How to Clean Tubes and Hoses 5481
Filter Caddy 5481
Start-Up Procedure for Cleaned System 5482
Contaminated Oil Coolers 5482
Additional Filter Caddy Functions 5483
How to Handle Different Fluids 5483
Water Removal Filters 5483
Fluid Conditioning and System Flushing Procedures 5484
Operation of the Filter Caddy 5484
Filter Caddy operation 5484
Fluid Conditioning Procedure 5484
Filter Caddy Start-Up 5485
System Flushing Procedure 5485
Component Cleaning Procedure 5486
Reservoir Cleaning Procedure 5486
Cylinder Cleaning Procedure 5486
Hose and Tube Cleaning Procedure 5486
Valve Cleaning Procedure 5487
Front-End Attachment Cleaning Procedure 5488
System Flushing Procedure 5488
Filter Caddy Start-Up 5489
System Start-Up and Flushing 5489
Reservoir Fluid Cleaning Times 5490
Dealing With Different Fluid Types 5491
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5491
Filter Caddy Maintenance 5491
Servicing the Strainer 5491
DC Motor 5491
Hydraulic Oil Sampling Method and Procedure 5492
Hydraulic Oil Sampling Method 5492
Objective 5492
General Guidelines 5492
Synopsis 5493
Hydraulic Oil Analysis Report Guidelines 5494
Sampling Conditions 5494
Equipment 5494
Sampling Procedure 5495
Hydraulic Oil Sampling 5495
Sample Labeling 5495
Results Documentation 5495
550073240-1900YRM1620-(03-2020)-UK-EN 5497
Proper Flushing after Major Hydraulic Repairs 5501
Introduction 5501
The Phases of Wear 5501
Causes of Hydraulic System Failure 5501
Progression of Contaminant Caused Hydraulic System Failure 5502
Hydraulic System Flushing Techniques 5502
Double Oil and Filter Change 5502
Mechanical Cleaning 5503
Cleaning of Components 5503
How to Clean Tubes and Hoses 5503
Filter Caddy 5503
Start-Up Procedure for Cleaned System 5504
Contaminated Oil Coolers 5504
Additional Filter Caddy Functions 5504
How to Handle Different Fluids 5504
Water Removal Filters 5505
Fluid Conditioning and System Flushing Procedures 5505
Operation of the Filter Caddy 5505
Filter Caddy operation 5505
Fluid Conditioning Procedure 5506
Filter Caddy Start-Up 5506
System Flushing Procedure 5507
Component Cleaning Procedure 5507
Reservoir Cleaning Procedure 5507
Cylinder Cleaning Procedure 5507
Hose and Tube Cleaning Procedure 5508
Valve Cleaning Procedure 5508
Front-End Attachment Cleaning Procedure 5509
System Flushing Procedure 5509
Filter Caddy Start-Up 5510
System Start-Up and Flushing 5510
Reservoir Fluid Cleaning Times 5511
Dealing With Different Fluid Types 5511
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5511
Filter Caddy Maintenance 5512
Servicing the Strainer 5512
DC Motor 5512
Hydraulic Oil Sampling Method and Procedure 5512
Hydraulic Oil Sampling Method 5512
Objective 5512
General Guidelines 5512
Synopsis 5513
Hydraulic Oil Analysis Report Guidelines 5514
Sampling Conditions 5515
Equipment 5515
Sampling Procedure 5515
Hydraulic Oil Sampling 5515
Sample Labeling 5516
Results Documentation 5516
550096331-8000YRM1689-(03-2020)-UK-EN 5519
General Information About Diagrams and Schematics 5523
Symbol Definitions 5523
Diagrams Manual Applications 5524
Diagrams and Schematics 5526
550096331-8000YRM1689-(06-2021)-US-EN 5629
General Information About Diagrams and Schematics 5633
Symbol Definitions 5633
Diagrams Manual Applications 5634
Diagrams and Schematics 5636

S.V 06/24