Yale Forklift F879 (GLC_GDC60-70VX) Service Manual – PDF DOWNLOAD

Description

Yale Forklift F879 (GLC_GDC60-70VX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift F879 (GLC_GDC60-70VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 7414
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift F879 (GLC_GDC60-70VX) 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
524223769-2200YRM1128-(01-2023)-US-EN 2773
Series Code / Model Designation Reference Table 2781
General 2783
Deutsch Crimping Tool 2784
How to Strip a Wire for Use With Deutsch Crimping Tool 2784
How to Crimp With the Deutsch Crimping Tool 2785
Calibration Test for the Deutsch Crimping Tool 2787
Deutsch Connectors 2789
DT, DTM, and DTP Series Connectors 2789
HD Series Connectors 2832
Metri-Pack Connectors 2854
Remove and Install 2854
Micro-Pack Connectors 2857
Weather-Pack Connectors 2858
AMPSEAL Crimping Tools 2860
AMP Hand Crimping Tool With Certi-Crimp 2860
Description 2860
Stripping Wire for Use with AMP Hand Crimping Tool 2861
Insulation Crimp Adjustment 2862
Maintenance and Inspection for AMP Hand Crimping Tool 2862
AMP Hand Crimping Tool 2862
Crimp Height Inspection 2862
How to use AMP Hand Crimping Tool 2863
AMP Pro-Crimper II Tool 2863
Description 2863
Remove and Install Die Set and Locator Assembly 2864
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2864
Contact Support Adjustment 2865
Crimp Height Adjustment 2866
Maintenance and Inspection Procedures 2866
PRO-CRIMPER II Tool 2866
Crimp Height Inspection 2866
How to Use AMP PRO-CRIMPER II Tool 2867
AMPSEAL Connector Assemblies 2868
Description for Plug Connector Assembly 2868
Seal Plug 2869
Contact Crimping 2869
Description for Plug Connector and Header Assembly 2874
Voltage Reading 2877
Seal Plug 2877
Contact Crimping 2877
AMP Superseal 1 5 Crimping Tools 2884
Mini Mic Receptacle and Tab Contacts 2884
Description 2884
Crimping Conditions and Measurements 2884
Insertion of Rubber Seal on Cable 2886
AMP Hand Application Tool 2891
Description 2891
Maintenance and Inspection 2891
Crimp Height Inspection 2891
Crimp Height Adjustment 2892
How to Use AMP Hand Application Tool 2892
AMP Pro-Crimper II Tool 2893
Description 2893
Remove and Install Die Set and Locator Assembly 2893
Adjustments 2894
Contact Support 2894
Crimp Height 2895
Inspections and Maintenance 2896
Crimp Height Inspection 2896
Visual Inspection 2896
Maintenance 2897
How to Use Pro-Crimper II Tool 2897
AMP Superseal 1 5 Connector Assemblies 2898
Description 2898
Repair and Maintenance 2905
Panel Mount Option 2905
AMP Fastin-Faston Hand Tools 2906
Description – AMP Double Action Hand Tool 2906
Maintenance and Inspection Procedures 2906
Daily Maintenance 2906
Periodic Tool Inspection 2907
Lubrication 2907
Visual Inspection 2907
Crimp Height Inspection 2907
Certi-Crimp Ratchet Inspection 2908
How to Use AMP Double Action Hand Tool 2909
Description – AMP Extraction Tool 2910
Maintenance and Inspection 2911
How to Use AMP Extraction Tool 2911
AMP Fastin-Faston Receptacles and Housings 2913
Description 2913
Wire Repair 2921
Wire Splicing Requirements 2921
Deutsch Jiffy Splice 2922
Twisted/Shielded Cable and Leads Repair 2928
Special Tools 2930
524223769-2200YRM1128-(07-2020)-UK-EN 2939
Series Code / Model Designation Reference Table 2945
General 2948
Deutsch Crimping Tool 2948
How to Strip a Wire for Use With Deutsch Crimping Tool 2948
How to Crimp With the Deutsch Crimping Tool 2949
Calibration Test for the Deutsch Crimping Tool 2951
Deutsch Connectors 2953
DT, DTM, and DTP Series Connectors 2953
HD Series Connectors 2995
Metri-Pack Connectors 3018
Remove and Install 3018
Micro-Pack Connectors 3020
Weather-Pack Connectors 3021
AMPSEAL Crimping Tools 3023
AMP Hand Crimping Tool With Certi-Crimp 3023
Description 3023
Stripping Wire for Use with AMP Hand Crimping Tool 3023
Insulation Crimp Adjustment 3024
Maintenance and Inspection for AMP Hand Crimping Tool 3024
AMP Hand Crimping Tool 3024
Crimp Height Inspection 3024
How to use AMP Hand Crimping Tool 3025
AMP Pro-Crimper II Tool 3025
Description 3025
Remove and Install Die Set and Locator Assembly 3026
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3027
Contact Support Adjustment 3027
Crimp Height Adjustment 3028
Maintenance and Inspection Procedures 3028
PRO-CRIMPER II Tool 3028
Crimp Height Inspection 3028
How to Use AMP PRO-CRIMPER II Tool 3029
AMPSEAL Connector Assemblies 3030
Description for Plug Connector Assembly 3030
Seal Plug 3031
Contact Crimping 3031
Description for Plug Connector and Header Assembly 3036
Voltage Reading 3038
Seal Plug 3038
Contact Crimping 3038
AMP Superseal 1 5 Crimping Tools 3045
Mini Mic Receptacle and Tab Contacts 3045
Description 3045
Crimping Conditions and Measurements 3045
Insertion of Rubber Seal on Cable 3047
AMP Hand Application Tool 3052
Description 3052
Maintenance and Inspection 3052
Crimp Height Inspection 3052
Crimp Height Adjustment 3053
How to Use AMP Hand Application Tool 3053
AMP Pro-Crimper II Tool 3054
Description 3054
Remove and Install Die Set and Locator Assembly 3055
Adjustments 3055
Contact Support 3055
Crimp Height 3056
Inspections and Maintenance 3057
Crimp Height Inspection 3057
Visual Inspection 3057
Maintenance 3058
How to Use Pro-Crimper II Tool 3058
AMP Superseal 1 5 Connector Assemblies 3059
Description 3059
Repair and Maintenance 3066
Panel Mount Option 3066
AMP Fastin-Faston Hand Tools 3067
Description – AMP Double Action Hand Tool 3067
Maintenance and Inspection Procedures 3067
Daily Maintenance 3067
Periodic Tool Inspection 3068
Lubrication 3068
Visual Inspection 3068
Crimp Height Inspection 3068
Certi-Crimp Ratchet Inspection 3069
How to Use AMP Double Action Hand Tool 3070
Description – AMP Extraction Tool 3071
Maintenance and Inspection 3071
How to Use AMP Extraction Tool 3072
AMP Fastin-Faston Receptacles and Housings 3073
Description 3073
Wire Repair 3080
Wire Splicing Requirements 3080
Deutsch Jiffy Splice 3081
Twisted/Shielded Cable and Leads Repair 3086
Special Tools 3089
524223770-2200YRM1130-(03-2020)-UK-EN 3097
General 3101
Description 3101
Dash Display Menu Access 3101
Menu Navigation 3102
Standard Display 3102
Main Menu 3102
Passwords Menu 3103
Password Administration 3103
Add Password 3103
Delete Password 3104
Edit Password 3104
Other Password Functions 3105
Operator Passwords – Enable/Disable 3105
Password Time-Out Delay 3105
Passwords – Number Wrong to Disable 3106
Lockout Reset Password 3106
View Password Log 3107
View Versions 3108
VSM Versions 3108
Dash Display Versions 3109
Engine Controller Version 3110
Transmission (Xmsn) Controller Version 3111
Truck Serial Number 3112
Diagnostics 3113
View Fault Log 3113
Set Travel and Braking 3114
Speed Limit 3114
Acceleration Rate 3115
Auto-Deceleration Rate 3115
Set Power Reversal Rate 3116
Set Inching/Brake Overlap 3117
Setup Display Menu 3118
Set Operator Language 3118
Set Units 3119
Set Time Format (12/24 Hour) 3119
Set Daylight Saving Time 3119
Set Time 3122
Set Date Format 3123
Set Date 3123
Setup Hydraulics 3124
Return to Set Tilt Delay/On/Off 3124
Setup General Items 3125
Light Shutdown Time-Out 3125
Impact Sensor – Enable/Disable 3126
Impact Sensor – Soft Impact Settings 3127
Impact Sensor – Hard Impact Settings 3128
Adjust Impact Sensor Settings 3128
Initial Adjustment of Soft and Hard Impact Settings 3130
Readjustment of Soft and Hard Impact Settings 3130
Impact Sensor – Impact Alarm/Shutdown Reset 3131
Impact Sensor – Alarm Time Duration and Deactivation 3132
Impact Sensor – View Impact Event Log 3133
Engine Mode Indicator 3134
Generation 1 (ECO-eLo ONLY) 3134
Generation 2 3135
Operator Checklist 3136
Operator Checklist Off-On Mode 3136
Edit Operator Checklist 3136
Set Operator Checklist Expiration 3137
View Checklist Log 3137
Clear Operator Checklist Log 3138
Clear Operator Checklist Fault 3138
Calibrations 3139
Set Tilt Stop Point 3139
Calibrate Loaded Weight 3139
524223770-2200YRM1130-(05-2021)-US-EN 3141
General 3145
Description 3145
Dash Display Menu Access 3145
Menu Navigation 3146
Standard Display 3146
Main Menu 3146
Passwords Menu 3147
Password Administration 3147
Add Password 3147
Delete Password 3147
Edit Password 3148
Other Password Functions 3149
Operator Passwords – Enable/Disable 3149
Password Time-Out Delay 3149
Passwords – Number Wrong to Disable 3149
Lockout Reset Password 3150
View Password Log 3150
View Versions 3151
VSM Versions 3151
Dash Display Versions 3152
Engine Controller Version 3153
Transmission (Xmsn) Controller Version 3154
Truck Serial Number 3155
Diagnostics 3156
View Fault Log 3156
Set Travel and Braking 3157
Speed Limit 3157
Acceleration Rate 3158
Auto-Deceleration Rate 3158
Set Power Reversal Rate 3159
Set Inching/Brake Overlap 3160
Setup Display Menu 3161
Set Operator Language 3161
Set Units 3162
Set Time Format (12/24 Hour) 3162
Set Daylight Saving Time 3163
Set Time 3166
Set Date Format 3166
Set Date 3167
Setup Hydraulics 3168
Return to Set Tilt Delay/On/Off 3168
Setup General Items 3169
Light Shutdown Time-Out 3169
Impact Sensor – Enable/Disable 3170
Impact Sensor – Soft Impact Settings 3171
Impact Sensor – Hard Impact Settings 3171
Adjust Impact Sensor Settings 3172
Initial Adjustment of Soft and Hard Impact Settings 3174
Readjustment of Soft and Hard Impact Settings 3174
Impact Sensor – Impact Alarm/Shutdown Reset 3175
Impact Sensor – Alarm Time Duration and Deactivation 3176
Impact Sensor – View Impact Event Log 3177
Engine Mode Indicator 3177
Generation 1 (ECO-eLo ONLY) 3177
Generation 2 3178
Operator Checklist 3179
Operator Checklist Off-On Mode 3179
Edit Operator Checklist 3179
Set Operator Checklist Expiration 3179
View Checklist Log 3180
Clear Operator Checklist Log 3181
Clear Operator Checklist Fault 3181
Calibrations 3182
Set Tilt Stop Point 3182
Calibrate Loaded Weight 3182
524223771-2200YRM1131-(03-2020)-UK-EN 3185
Series Code / Model Designation Reference Table 3191
General 3193
Description 3193
Dash Display Menu Access 3193
Menu Navigation 3194
Main Menu 3194
Passwords 3195
Adding Passwords 3195
Hourmeters 3197
View Versions 3198
VSM Versions 3198
Dash Display Versions 3199
Engine Controller Version 3200
Transmission (Xmsn) Controller Version 3201
Truck Serial Number 3202
Truck Configuration 3203
Diagnostics 3204
Clear Fault Log 3204
View Fault Log 3205
No-Run Data Display 3206
Engine Accelerator and Throttle Data Display 3206
Engine Speeds and Governor Data Display 3207
Engine Fuel and Emissions Data Display 3208
Engine General Data Display 3210
XMSN/Brake Data Display 3211
Hydraulic Data Display 3214
General Truck Data Display 3216
Set Travel and Braking 3217
Speed Limit 3217
Acceleration Rate 3218
Auto-Deceleration Rate 3219
Set Power Reversal Rate 3219
Set Inching/Brake Overlap 3220
Setup Hydraulics 3220
Lift Maximum Speed 3221
Lower Maximum Speed 3221
Tilt Maximum Speed 3222
Auxiliary Function One, Direction A, Maximum Speed 3224
Auxiliary Function One, Direction B, Maximum Speed 3226
Auxiliary Function Two, Direction A, Maximum Speed 3226
Auxiliary Function Two, Direction B, Maximum Speed 3227
Auxiliary Function Three, Direction A, Maximum Speed 3228
Auxiliary Function Three, Direction B, Maximum Speed 3228
Lift/Lower Ramp Rate 3229
Hydraulic Auxiliary Ramp Rate 3229
Return to Set Tilt Delay/On/Off 3230
Hydraulic Input Device 3231
Auxiliary Solenoid 3231
Dual Function 3232
Setup Display 3233
Set Service Language 3233
Setup General Items 3233
Motion Alarm Activation Type 3234
Light Shutdown Time-Out 3235
Restore Default Settings 3235
Restore Engine Controller Default Calibration 3236
Impact Sensor – Enable/Disable 3236
Impact Sensor – Soft Impact Settings 3237
Impact Sensor – Hard Impact Settings 3238
Adjust Impact Sensor Settings 3239
Initial Adjustment of Soft and Hard Impact Settings 3241
Readjustment of Soft and Hard Impact Settings 3241
Impact Sensor – Impact Alarm/Shutdown Reset 3242
Impact Sensor – Alarm Time Duration and Deactivation 3243
Impact Sensor – View Impact Event Log 3244
Engine Mode Indicator 3244
Generation 1 (ECO-eLo ONLY) 3244
Generation 2 3245
Diesel Particulate Filter (DPF) Display 3246
General Description 3246
Passive Regeneration Only 3246
Regeneration Level 0 3246
Auto/Active Regeneration Inhibited 3247
Auto/Active Regeneration 3247
Regeneration Level 1 3247
Parked Regeneration Request 3248
Regeneration Level 2 3248
Warning Level 3248
Regeneration Level 3 3248
Service Level 3249
Regeneration Level 4 3249
Display, Diesel Particulate Filter (DPF), Revised 3249
Operator Interface 3249
Refer to Operator Manual 3249
CAN Communication Lost 3250
Passive Regeneration Only 3250
Regeneration Level 0 3250
Auto/Active Regeneration Inhibited 3250
Auto/Active Regeneration 3251
Regeneration Level 1 3251
Idle-up Auto/Active Regeneration 3251
Parked Regeneration Request 3251
Regeneration Level 2 3251
Warning Level 3253
Regeneration Level 3 3253
Service Level 3253
Regeneration Level 4 3253
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3253
Display, Diesel Particulate Filter (DPF), Stage V Engine 3253
Operator Interface 3254
Refer to Operator Manual 3254
CAN Communication Lost 3254
Passive Regeneration Only 3254
Regeneration Level 0 3254
Auto/Active Regeneration Inhibited 3255
Auto/Active Regeneration 3255
Regeneration Level 1 3255
Idle-up Auto/Active Regeneration 3256
Parked Regeneration Request 3256
Regeneration Level 2 3256
Warning Level 3257
Regeneration Level 3 3257
Service Level 3258
Regeneration Level 4 3258
Stage V Content 3258
Emissions System Malfunction 3258
Ash Load 3258
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3259
Operator Interface 3259
Refer to Operator Manual 3259
CAN Communication Lost 3260
Passive Regeneration Only 3260
Regeneration Level 0 3260
Auto/Active Regeneration Inhibited 3260
Auto/Active Regeneration 3261
Regeneration Level 1 3261
Idle-up Auto/Active Regeneration 3261
Parked Regeneration Request 3261
Regeneration Level 2 3261
Warning Level 3263
Regeneration Level 3 3263
Service Level 3263
Regeneration Level 4 3263
Calibrations 3264
Calibrate Transmission Valve 3266
Set Tilt Stop Point 3266
Calibrate Loaded Weight 3266
Calibrate Travel Speed Sensor 3267
Calibrate Mazda LP and Gas Accelerator Pedal 3267
524223771-2200YRM1131-(05-2021)-US-EN 3269
Series Code / Model Designation Reference Table 3275
General 3277
Description 3277
Dash Display Menu Access 3277
Menu Navigation 3278
Main Menu 3279
Passwords 3279
Adding Passwords 3279
Hourmeters 3281
View Versions 3282
VSM Versions 3282
Dash Display Versions 3283
Engine Controller Version 3284
Transmission (Xmsn) Controller Version 3285
Truck Serial Number 3286
Truck Configuration 3287
Diagnostics 3288
Clear Fault Log 3288
View Fault Log 3289
No-Run Data Display 3290
Engine Accelerator and Throttle Data Display 3291
Engine Speeds and Governor Data Display 3293
Engine Fuel and Emissions Data Display 3294
Engine General Data Display 3296
XMSN/Brake Data Display 3297
Hydraulic Data Display 3299
General Truck Data Display 3302
Set Travel and Braking 3304
Speed Limit 3304
Acceleration Rate 3305
Auto-Deceleration Rate 3305
Set Power Reversal Rate 3306
Set Inching/Brake Overlap 3306
Setup Hydraulics 3307
Lift Maximum Speed 3307
Lower Maximum Speed 3308
Tilt Maximum Speed 3308
Auxiliary Function One, Direction A, Maximum Speed 3310
Auxiliary Function One, Direction B, Maximum Speed 3313
Auxiliary Function Two, Direction A, Maximum Speed 3313
Auxiliary Function Two, Direction B, Maximum Speed 3314
Auxiliary Function Three, Direction A, Maximum Speed 3315
Auxiliary Function Three, Direction B, Maximum Speed 3315
Lift/Lower Ramp Rate 3316
Hydraulic Auxiliary Ramp Rate 3316
Return to Set Tilt Delay/On/Off 3317
Hydraulic Input Device 3318
Auxiliary Solenoid 3318
Dual Function 3319
Setup Display 3320
Set Service Language 3320
Setup General Items 3320
Motion Alarm Activation Type 3321
Light Shutdown Time-Out 3322
Restore Default Settings 3322
Restore Engine Controller Default Calibration 3323
Impact Sensor – Enable/Disable 3323
Impact Sensor – Soft Impact Settings 3324
Impact Sensor – Hard Impact Settings 3324
Adjust Impact Sensor Settings 3325
Initial Adjustment of Soft and Hard Impact Settings 3327
Readjustment of Soft and Hard Impact Settings 3327
Impact Sensor – Impact Alarm/Shutdown Reset 3328
Impact Sensor – Alarm Time Duration and Deactivation 3329
Impact Sensor – View Impact Event Log 3330
Engine Mode Indicator 3330
Generation 1 (ECO-eLo ONLY) 3330
Generation 2 3331
Diesel Particulate Filter (DPF) Display 3332
General Description 3332
Passive Regeneration Only 3332
Regeneration Level 0 3332
Auto/Active Regeneration Inhibited 3333
Auto/Active Regeneration 3333
Regeneration Level 1 3333
Parked Regeneration Request 3334
Regeneration Level 2 3334
Warning Level 3335
Regeneration Level 3 3335
Service Level 3335
Regeneration Level 4 3335
Display, Diesel Particulate Filter (DPF), Revised 3335
Operator Interface 3336
Refer to Operator Manual 3336
CAN Communication Lost 3336
Passive Regeneration Only 3336
Regeneration Level 0 3336
Auto/Active Regeneration Inhibited 3337
Auto/Active Regeneration 3337
Regeneration Level 1 3337
Idle-up Auto/Active Regeneration 3337
Parked Regeneration Request 3338
Regeneration Level 2 3338
Warning Level 3339
Regeneration Level 3 3339
Service Level 3339
Regeneration Level 4 3339
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3340
Display, Diesel Particulate Filter (DPF), Stage V Engine 3340
Operator Interface 3340
Refer to Operator Manual 3340
CAN Communication Lost 3341
Passive Regeneration Only 3341
Regeneration Level 0 3341
Auto/Active Regeneration Inhibited 3341
Auto/Active Regeneration 3342
Regeneration Level 1 3342
Idle-up Auto/Active Regeneration 3342
Parked Regeneration Request 3342
Regeneration Level 2 3342
Warning Level 3344
Regeneration Level 3 3344
Service Level 3344
Regeneration Level 4 3344
Stage V Content 3344
Emissions System Malfunction 3344
Ash Load 3345
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3346
Operator Interface 3346
Refer to Operator Manual 3346
CAN Communication Lost 3347
Passive Regeneration Only 3347
Regeneration Level 0 3347
Auto/Active Regeneration Inhibited 3347
Auto/Active Regeneration 3348
Regeneration Level 1 3348
Idle-up Auto/Active Regeneration 3348
Parked Regeneration Request 3348
Regeneration Level 2 3348
Warning Level 3350
Regeneration Level 3 3350
Service Level 3350
Regeneration Level 4 3350
Calibrations 3351
Calibrate Transmission Valve 3353
Set Tilt Stop Point 3353
Calibrate Loaded Weight 3354
Calibrate Travel Speed Sensor 3354
Calibrate Mazda LP and Gas Accelerator Pedal 3355
524223772-2200YRM1142-(01-2020)-UK-EN 3357
General 3367
Display Switch Cluster 3370
Remove 3370
Install 3373
Direction Control and Turn Signal Levers 3373
Remove 3373
Install 3375
Key Switch 3375
Remove 3375
Install 3376
Display Switch Cluster Panel Bezel and Overlay 3376
Remove 3376
Install 3376
Steering Column Repair 3376
Remove 3376
Disassemble 3379
Assemble 3379
Install 3379
Sensors and Switches 3380
General 3380
Dash and Kick Panel, Remove and Install 3380
Remove 3380
Install 3381
Accelerator Pedal Position Sensor 3382
Remove 3382
Install 3385
Brake Fluid Level Switch 3386
Remove 3386
Install 3388
Service Brake Pedal Position Sensor 3389
Remove 3389
Install 3392
Parking Brake Sensor 3393
Remove 3393
Install 3394
Service Brake Pressure Sensor 3395
Remove 3395
Install 3397
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3398
Remove 3398
Install 3398
Sensor Microswitch (Foot Directional Control Pedal) 3399
Remove 3399
Install 3402
Low Coolant Level Sensor 3403
Remove 3403
Install 3406
Fuel Level Sensor, Gas and Diesel Engines Only 3407
Remove 3407
Install 3408
Armrest Switch 3408
Remove 3408
Install 3410
Seat Sensor (Operator Presence System) 3410
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) 3410
Remove 3410
Install 3411
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3411
Remove 3411
Install 3412
Full Suspension Seats; All Lift Truck Models 3412
Remove 3412
Install 3412
Hood Shut Off Switch 3412
Remove 3412
Install 3415
Remote Key Switch 3416
Remove 3416
Install 3416
Hydraulic Filter Pressure Switch 3417
Remove 3417
Install 3419
Transmission Speed Sensor 3419
Remove 3419
Install 3422
Transmission Pressure Sensors 3423
Remove 3423
Install 3425
Transmission Temperature Sensor 3426
Remove 3426
Install 3428
Engine Speed Sensor 3430
Remove 3430
Install 3430
Intermediate Speed Sensor 3431
Remove 3431
Install 3431
Return to Set Tilt (Tilt Angle) Sensor 3431
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) 3431
Remove 3431
Install 3432
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) 3433
Remove 3433
Install 3434
Rear Horn Button Switch 3434
Remove 3434
Install 3435
Impact Sensor 3436
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) 3436
Remove 3436
Install 3439
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) 3439
Remove 3439
Install 3440
Load Weight Sensor 3441
Remove 3441
Install 3442
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3443
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3443
Crankshaft Position (CKP) Sensor 3443
Camshaft Position (CMP) Sensor 3443
Oil Pressure Sensor 3443
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3443
Engine Coolant Temperature (ECT) Sensor 3444
Air Flow Restriction Switch 3444
Remove for GM 2 4L Gas and LPG Trucks 3444
Install for GM 2 4L Gas and LPG Trucks 3444
Oxygen Sensor 3445
Remove 3445
Install 3448
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3449
Crankshaft Position (CKP) Sensor 3449
Camshaft Position (CMP) Sensor 3449
Oil Pressure Sensor 3449
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3449
Engine Coolant Temperature (ECT) Sensor 3449
Air Flow Restriction Switch 3449
Oxygen Sensor 3449
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3449
Low LPG Pressure Switch 3449
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3450
Air Filter Restriction Switch 3450
Remove 3450
Install 3450
Oil Pressure Sensor 3450
Remove 3450
Install 3450
Engine Speed Sensor 3450
Remove 3450
Install 3450
Engine Coolant Temperature (ECT) Sensor 3450
Remove 3450
Install 3450
Throttle Position Sensor (TPS) 3453
Remove 3453
Install 3454
Fuel/Water Separator Sensor 3454
Remove 3454
Install 3454
Glow Plug Relay 3455
Remove 3455
Install 3457
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3457
Air Filter Restriction Switch 3457
Remove 3457
Install 3457
Engine Oil Pressure Sensor 3462
Remove 3462
Install 3462
Engine Speed Sensor 3462
Remove 3462
Install 3463
Engine Coolant Temperature (ECT) Sensor 3463
Remove 3463
Install 3464
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3465
Remove 3465
Install 3465
Fuel/Water Separator Sensor 3466
Remove 3466
Install 3466
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3467
Intake Air Temperature Sensor 3467
Remove 3467
Install 3468
Intake Air Pressure Sensor 3468
Remove 3468
Install 3468
Air Inlet Heater 3468
Remove 3468
Install 3469
Engine Oil Pressure Sensor 3469
Remove 3469
Install 3469
Engine Coolant Temperature (ECT) Sensor 3469
Remove 3469
Install 3469
Crankshaft Position Sensor 3470
Remove 3470
Install 3470
Adjust Shim Procedure 3471
Camshaft Position Sensor 3472
Remove 3472
Install 3472
Air Flow Restriction Sensor 3473
Remove 3473
Install 3473
Fuel/Water Separator 3473
Remove 3473
Install 3474
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3474
Intake Air Temperature Sensor 3478
Remove 3478
Install 3479
Boost Sensor 3479
Remove 3479
Install 3480
Throttle Valve Assembly and Air Intake Heater 3480
Remove 3480
Install 3480
Engine Coolant Temperature (ECT) Sensor 3481
Remove 3481
Install 3481
Engine Oil Pressure Sensor 3481
Remove 3481
Install 3482
Crankshaft Position Sensor 3482
Remove 3482
Install 3482
Adjust Shim Procedure 3483
Camshaft Position Sensor 3484
Remove 3484
Install 3485
Differential Pressure Sensor 3485
Remove 3485
Install 3485
Mass Air Flow Sensor 3486
Remove 3486
Install 3487
Fuel/Water Separator 3487
Remove 3487
Install 3488
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3488
Engine Coolant Temperature (ECT) Sensor 3489
Remove 3489
Install 3489
Throttle Position Sensor 3490
Engine Oil Pressure Sensor 3490
Remove 3490
Install 3490
Engine Speed Sensor 3490
Remove 3490
Install 3490
Fuel Shut Off Solenoid 3490
Remove 3490
Install 3490
Vehicle System Manager (VSM) 3491
General 3491
VSM Replacement 3491
Remove 3491
Install 3493
Programming a New VSM and/or Display Switch Cluster 3493
General 3493
PC Service Tool Software 3494
Data Transferring 3494
New VSM 3494
New (Blank) Display Switch Cluster 3494
Used (Non-Blank) Display Switch Cluster 3494
Power Distribution Module (PDM) and Component Parts 3496
Remove 3496
PDM as a Unit 3496
Install 3500
PDM as a Unit 3500
Remove and Install 3501
PDM Component Parts 3501
Transmission Control Unit 3501
Remove 3501
Install 3505
Battery 3507
Remove 3507
Install 3507
Lights 3508
Work Lights (Front and Rear) 3508
Remove 3508
Install 3508
Strobe Light 3509
Remove 3509
Install 3509
LED Tail, Backup, and Brake Lights 3510
Remove 3510
Install 3511
Front Marker/Turn Signal Lights 3512
Replacing Whole Front Marker/Turn Signal Light Assembly 3512
Remove 3512
Install 3512
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3513
Remove 3513
Install 3513
Diesel Particulate Filter (DPF) Display 3513
Remove 3513
Clean and Inspect 3514
Install 3514
Electronic-Hydraulic Controls – Generation 1 3515
E-Hydraulic Controls – Test 3515
Mini-Levers 3515
Full Stroke Test 3515
Function Returns to Neutral Test 3515
Push Button Switch 3515
General 3516
Mini-Lever Replacement 3516
Remove 3516
Clean and Inspect 3517
Install 3517
Push Button Switch Replacement 3518
Remove 3518
Install 3520
Mini-Lever Module (MLM) 3520
Remove 3520
Install 3520
Joystick 3521
Remove and Disassemble 3521
Inspect 3521
Assemble and Install 3521
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3522
General 3522
Mini-levers, Remove and Install 3522
Armrest Assembly 3523
Remove 3523
Install 3526
Horn Button 3526
Remove 3526
Install 3526
Direction Control Switch 3527
Remove 3527
Install 3527
push (override) buttons and Toggle Switch 3527
Remove 3528
Install 3529
Joystick 3530
Remove and Disassemble 3530
Inspect 3530
Assemble and Install 3530
Joystick Armrest Slider Assembly 3531
Remove 3531
Install 3532
Electronic-Hydraulic Controls, After January, 2020 3532
E-Hydraulic Controls – TEST 3532
Mini-Levers 3532
Full Stroke Test 3532
Function Returns to Neutral Test 3532
Push (Override) Button 3533
General 3533
Mini-levers, Remove and Install 3533
Armrest Assembly 3534
Remove 3534
Install 3537
Horn Button 3537
Remove 3537
Install 3537
Direction Control Switch 3537
Remove 3537
Install 3538
Push (Override) buttons and Toggle Switch 3538
Remove 3539
Install 3541
Special Tools 3542
524223772-2200YRM1142-(08-2021)-US-EN 3545
General 3555
Display Switch Cluster 3559
Remove 3559
Install 3561
Direction Control and Turn Signal Levers 3561
Remove 3561
Install 3562
Key Switch 3563
Remove 3563
Install 3564
Display Switch Cluster Panel Bezel and Overlay 3564
Remove 3564
Install 3564
Steering Column Repair 3565
Remove 3565
Disassemble 3568
Assemble 3568
Install 3568
Sensors and Switches 3569
General 3569
Dash and Kick Panel, Remove and Install 3569
Remove 3569
Install 3570
Accelerator Pedal Position Sensor 3570
Remove 3570
Install 3574
Brake Fluid Level Switch 3575
Remove 3575
Install 3576
Service Brake Pedal Position Sensor 3578
Remove 3578
Install 3580
Parking Brake Sensor 3581
Remove 3581
Install 3583
Service Brake Pressure Sensor 3583
Remove 3583
Install 3585
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3587
Remove 3587
Install 3587
Sensor Microswitch (Foot Directional Control Pedal) 3587
Remove 3587
Install 3590
Low Coolant Level Sensor 3591
Remove 3591
Install 3594
Fuel Level Sensor, Gas and Diesel Engines Only 3595
Remove 3595
Install 3596
Armrest Switch 3596
Remove 3596
Install 3598
Seat Sensor (Operator Presence System) 3598
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) 3598
Remove 3598
Install 3599
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3599
Remove 3599
Install 3599
Full Suspension Seats; All Lift Truck Models 3600
Remove 3600
Install 3600
Hood Shut Off Switch 3601
Remove 3601
Install 3603
Remote Key Switch 3604
Remove 3604
Install 3604
Hydraulic Filter Pressure Switch 3605
Remove 3605
Install 3607
Transmission Speed Sensor 3607
Remove 3607
Install 3610
Transmission Pressure Sensors 3611
Remove 3611
Install 3613
Transmission Temperature Sensor 3614
Remove 3614
Install 3616
Engine Speed Sensor 3618
Remove 3618
Install 3619
Intermediate Speed Sensor 3619
Remove 3619
Install 3619
Return to Set Tilt (Tilt Angle) Sensor 3620
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) 3620
Remove 3620
Install 3620
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) 3620
Remove 3621
Install 3622
Rear Horn Button Switch 3623
Remove 3623
Install 3623
Impact Sensor 3624
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) 3624
Remove 3624
Install 3626
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) 3626
Remove 3626
Install 3627
Load Weight Sensor 3627
Remove 3627
Install 3629
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3630
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3630
Crankshaft Position (CKP) Sensor 3630
Camshaft Position (CMP) Sensor 3630
Oil Pressure Sensor 3630
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3630
Engine Coolant Temperature (ECT) Sensor 3631
Air Flow Restriction Switch 3631
Remove for GM 2 4L Gas and LPG Trucks 3631
Install for GM 2 4L Gas and LPG Trucks 3631
Oxygen Sensor 3632
Remove 3632
Install 3635
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3636
Crankshaft Position (CKP) Sensor 3636
Camshaft Position (CMP) Sensor 3636
Oil Pressure Sensor 3636
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3636
Engine Coolant Temperature (ECT) Sensor 3636
Air Flow Restriction Switch 3636
Oxygen Sensor 3636
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3636
Low LPG Pressure Switch 3636
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3637
Air Filter Restriction Switch 3637
Remove 3637
Install 3637
Oil Pressure Sensor 3637
Remove 3637
Install 3637
Engine Speed Sensor 3637
Remove 3637
Install 3637
Engine Coolant Temperature (ECT) Sensor 3637
Remove 3637
Install 3637
Throttle Position Sensor (TPS) 3640
Remove 3640
Install 3641
Fuel/Water Separator Sensor 3641
Remove 3641
Install 3641
Glow Plug Relay 3642
Remove 3642
Install 3644
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3644
Air Filter Restriction Switch 3644
Remove 3644
Install 3645
Engine Oil Pressure Sensor 3649
Remove 3649
Install 3649
Engine Speed Sensor 3649
Remove 3649
Install 3650
Engine Coolant Temperature (ECT) Sensor 3650
Remove 3650
Install 3651
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3652
Remove 3652
Install 3652
Fuel/Water Separator Sensor 3653
Remove 3653
Install 3653
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3654
Intake Air Temperature Sensor 3654
Remove 3654
Install 3655
Intake Air Pressure Sensor 3655
Remove 3655
Install 3655
Air Inlet Heater 3655
Remove 3655
Install 3656
Engine Oil Pressure Sensor 3656
Remove 3656
Install 3656
Engine Coolant Temperature (ECT) Sensor 3656
Remove 3656
Install 3656
Crankshaft Position Sensor 3657
Remove 3657
Install 3657
Adjust Shim Procedure 3658
Camshaft Position Sensor 3659
Remove 3659
Install 3659
Air Flow Restriction Sensor 3659
Remove 3659
Install 3660
Fuel/Water Separator 3660
Remove 3660
Install 3661
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3661
Intake Air Temperature Sensor 3665
Remove 3665
Install 3666
Boost Sensor 3666
Remove 3666
Install 3667
Throttle Valve Assembly and Air Intake Heater 3667
Remove 3667
Install 3667
Engine Coolant Temperature (ECT) Sensor 3668
Remove 3668
Install 3668
Engine Oil Pressure Sensor 3669
Remove 3669
Install 3669
Crankshaft Position Sensor 3669
Remove 3669
Install 3669
Adjust Shim Procedure 3670
Camshaft Position Sensor 3672
Remove 3672
Install 3672
Differential Pressure Sensor 3672
Remove 3672
Install 3673
Mass Air Flow Sensor 3673
Remove 3673
Install 3674
Fuel/Water Separator 3675
Remove 3675
Install 3676
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3677
Engine Coolant Temperature (ECT) Sensor 3678
Remove 3678
Install 3678
Throttle Position Sensor 3678
Engine Oil Pressure Sensor 3678
Remove 3678
Install 3678
Engine Speed Sensor 3678
Remove 3678
Install 3678
Fuel Shut Off Solenoid 3679
Remove 3679
Install 3679
Vehicle System Manager (VSM) 3680
General 3680
VSM Replacement 3680
Remove 3680
Install 3682
Programming a New VSM and/or Display Switch Cluster 3682
General 3682
PC Service Tool Software 3683
Data Transferring 3683
New VSM 3683
New (Blank) Display Switch Cluster 3683
Used (Non-Blank) Display Switch Cluster 3683
Power Distribution Module (PDM) and Component Parts 3686
Remove 3686
PDM as a Unit 3686
Install 3689
PDM as a Unit 3689
Remove and Install 3690
PDM Component Parts 3690
Transmission Control Unit (TCU) 3691
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) 3691
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) 3691
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3692
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 3692
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 3692
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 3693
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 3694
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 3696
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 3696
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 3696
Battery 3697
Remove 3697
Install 3697
Lights 3698
Work Lights (Front and Rear) 3698
Remove 3698
Install 3698
Strobe Light 3699
Remove 3699
Install 3699
LED Tail, Backup, and Brake Lights 3700
Remove 3700
Install 3701
Front Marker/Turn Signal Lights 3702
Replacing Whole Front Marker/Turn Signal Light Assembly 3702
Remove 3702
Install 3702
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3703
Remove 3703
Install 3703
Diesel Particulate Filter (DPF) Display 3704
Remove 3704
Clean and Inspect 3705
Install 3705
Electronic-Hydraulic Controls – Generation 1 3706
E-Hydraulic Controls – Test 3706
Mini-Levers 3706
Full Stroke Test 3706
Function Returns to Neutral Test 3706
Push Button Switch 3706
General 3707
Mini-Lever Replacement 3707
Remove 3707
Clean and Inspect 3708
Install 3708
Push Button Switch Replacement 3709
Remove 3709
Install 3711
Mini-Lever Module (MLM) 3711
Remove 3711
Install 3711
Joystick 3712
Remove and Disassemble 3712
Inspect 3712
Assemble and Install 3712
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3713
General 3713
Mini-levers, Remove and Install 3713
Armrest Assembly 3714
Remove 3714
Install 3717
Horn Button 3717
Remove 3717
Install 3717
Direction Control Switch 3718
Remove 3718
Install 3718
push (override) buttons and Toggle Switch 3718
Remove 3719
Install 3720
Joystick 3721
Remove and Disassemble 3721
Inspect 3721
Assemble and Install 3721
Joystick Armrest Slider Assembly 3722
Remove 3722
Install 3723
Electronic-Hydraulic Controls, After January, 2020 3724
E-Hydraulic Controls – TEST 3724
Mini-Levers 3724
Full Stroke Test 3724
Function Returns to Neutral Test 3724
Push (Override) Button 3724
General 3725
Mini-levers, Remove and Install 3725
Armrest Assembly 3726
Remove 3726
Install 3729
Horn Button 3729
Remove 3729
Install 3729
Direction Control Switch 3729
Remove 3729
Install 3730
Push (Override) buttons and Toggle Switch 3730
Remove 3731
Install 3733
Special Tools 3734
524223780-8000YRM1134-(03-2020)-UK-EN 3737
Series Code / Model Designation Reference Table 3743
Description 3745
Proc_Cal_001: Service Password Entry 3747
When to Perform 3747
Why Perform 3747
How to Perform 3747
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3748
When to Perform 3748
Calibration Order 3748
Why Perform 3748
How to Perform 3749
Proc_Cal_003: Save and Exit 3750
When to Perform 3750
Why Perform 3750
How to Perform 3750
Proc_Cal_004: Lift Valve Output Threshold 3751
When to Perform 3751
Calibration Order 3751
Why Perform 3751
How to Perform 3752
Proc_Cal_005: Lower Valve Output Threshold 3754
When to Perform 3754
Calibration Order 3754
Why Perform 3754
How to Perform 3754
Proc_Cal_006: Tilt Back Valve Output Threshold 3757
When to Perform 3757
Calibration Order 3757
Why Perform 3757
How to Perform 3757
Proc_Cal_007: Tilt Forward Valve Output Threshold 3760
When to Perform 3760
Calibration Order 3760
Why Perform 3760
How to Perform 3760
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3763
When to Perform 3763
Calibration Order 3763
Why Perform 3763
How to Perform 3763
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3766
When to Perform 3766
Calibration Order 3766
Why Perform 3766
How to Perform 3766
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3769
When to Perform 3769
Calibration Order 3769
Why Perform 3769
How to Perform 3769
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3772
When to Perform 3772
Calibration Order 3772
Why Perform 3772
How to Perform 3772
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3775
When to Perform 3775
Calibration Order 3775
Why Perform 3775
How to Perform 3775
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3778
When to Perform 3778
Calibration Order 3778
Why Perform 3778
How to Perform 3778
Proc_Cal_014: Load Weight Zero Point 3782
When to Perform 3782
Calibration Order 3782
Why Perform 3782
How to Perform 3782
Proc_Cal_015: Loaded Weight Calibration 3784
When to Perform 3784
Calibration Order 3784
Why Perform 3784
How to Perform 3784
Proc_Cal_016: Transmission Valve Calibration 3787
Applicable System/Option 3787
When to Perform 3787
Calibration Order 3787
Why Perform 3787
How to Perform 3787
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3789
Applicable System/Option 3789
When to Perform 3789
Calibration Order 3789
Why Perform 3789
How to Perform 3789
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3791
Applicable System/Option 3791
When to Perform 3791
Calibration Order 3791
Why Perform 3791
How to Perform 3792
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3793
Required Tools 3793
When to Perform 3793
Calibration Order 3793
Why Perform 3794
How to Perform 3794
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3795
When to Perform 3795
Why Perform 3795
How to Perform 3795
Proc_Cal_026: Travel Speed Calibration 3797
When to Perform 3797
Calibration Order 3797
Why Perform 3797
How to Perform 3797
524223780-8000YRM1134-(05-2022)-US-EN 3801
Series Code / Model Designation Reference Table 3807
Description 3810
Proc_Cal_001: Service Password Entry 3812
When to Perform 3812
Why Perform 3812
How to Perform 3812
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3813
When to Perform 3813
Calibration Order 3813
Why Perform 3813
How to Perform 3813
Proc_Cal_003: Save and Exit 3815
When to Perform 3815
Why Perform 3815
How to Perform 3815
Proc_Cal_004: Lift Valve Output Threshold 3816
When to Perform 3816
Calibration Order 3816
Why Perform 3816
How to Perform 3816
Proc_Cal_005: Lower Valve Output Threshold 3819
When to Perform 3819
Calibration Order 3819
Why Perform 3819
How to Perform 3819
Proc_Cal_006: Tilt Back Valve Output Threshold 3822
When to Perform 3822
Calibration Order 3822
Why Perform 3822
How to Perform 3822
Proc_Cal_007: Tilt Forward Valve Output Threshold 3825
When to Perform 3825
Calibration Order 3825
Why Perform 3825
How to Perform 3825
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3828
When to Perform 3828
Calibration Order 3828
Why Perform 3828
How to Perform 3828
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3831
When to Perform 3831
Calibration Order 3831
Why Perform 3831
How to Perform 3831
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3834
When to Perform 3834
Calibration Order 3834
Why Perform 3834
How to Perform 3834
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3837
When to Perform 3837
Calibration Order 3837
Why Perform 3837
How to Perform 3837
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3840
When to Perform 3840
Calibration Order 3840
Why Perform 3840
How to Perform 3840
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3843
When to Perform 3843
Calibration Order 3843
Why Perform 3843
How to Perform 3843
Proc_Cal_014: Load Weight Zero Point 3846
When to Perform 3846
Calibration Order 3846
Why Perform 3846
How to Perform 3846
Proc_Cal_015: Loaded Weight Calibration 3848
When to Perform 3848
Calibration Order 3848
Why Perform 3848
How to Perform 3848
Proc_Cal_016: Transmission Valve Calibration 3851
Applicable System/Option 3851
When to Perform 3851
Calibration Order 3851
Why Perform 3851
How to Perform 3851
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3853
Applicable System/Option 3853
When to Perform 3853
Calibration Order 3853
Why Perform 3853
How to Perform 3853
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3856
Applicable System/Option 3856
When to Perform 3856
Calibration Order 3856
Why Perform 3856
How to Perform 3856
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3859
Required Tools 3859
When to Perform 3859
Calibration Order 3859
Why Perform 3859
How to Perform 3859
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3861
When to Perform 3861
Why Perform 3861
How to Perform 3861
Proc_Cal_026: Travel Speed Calibration 3863
When to Perform 3863
Calibration Order 3863
Why Perform 3863
How to Perform 3863
524262279-1800YRM1247-(06-2021)-US-EN 3867
General 3871
Dry Brake System 3871
Wet Brake System 3871
Service Brakes Repair (Dry Brake) 3875
Remove and Disassemble 3875
Clean 3877
Inspect 3878
Assemble and Install 3879
Adjust 3882
Parking Brake Repair 3883
Dry Brake System 3883
Remove and Disassembly 3883
Assemble and Install 3885
Wet Brake System 3885
Remove and Install 3885
Assemble and Install 3892
Adjust 3892
Dry Brake System 3892
Wet Brake System 3893
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3893
Master Cylinder Repair 3895
Remove 3895
Disassemble 3899
Clean and Inspect 3900
Assemble 3901
Install and Adjust 3901
Accumulator 3904
Pre-Charge Check 3904
Remove 3905
Install 3907
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3908
Remove 3908
Modulating Brake Valve 3910
Disassemble 3910
Clean and Inspect 3911
Assemble 3911
Accumulator Charge Valve 3912
Disassemble 3912
Clean and Inspect 3914
Assemble 3914
Install 3915
Pressure Checks 3916
Accumulator Charge Valve Check 3916
Accumulator Check 3916
Service Brakes Adjustment (Dry Brake) 3917
Service Brakes Adjustment 3917
Brake System Air Removal 3919
Using Pressure Bleed System 3919
Using Brake Pedal Pressure 3919
Lift Truck Models with Master Cylinder 3919
Lift Truck Models with Modulating Brake Valve 3920
Brake Pedal Adjustment 3921
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) 3921
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3922
Free Pedal Adjustment 3924
Torque Specifications 3925
524262279-1800YRM1247-(09-2018)-UK-EN 3927
General 3931
Dry Brake System 3931
Wet Brake System 3932
Service Brakes Repair (Dry Brake) 3936
Remove and Disassemble 3936
Clean 3938
Inspect 3939
Assemble and Install 3939
Adjust 3943
Parking Brake Repair 3943
Dry Brake System 3944
Remove and Disassembly 3944
Assemble and Install 3946
Wet Brake System 3946
Remove and Install 3947
Assemble and Install 3953
Adjust 3953
Dry Brake System 3953
Wet Brake System 3954
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3954
Master Cylinder Repair 3955
Remove 3955
Disassemble 3960
Clean and Inspect 3961
Assemble 3962
Install and Adjust 3962
Accumulator 3964
Pre-Charge Check 3965
Remove 3966
Install 3968
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3968
Remove 3969
Modulating Brake Valve 3970
Disassemble 3970
Clean and Inspect 3972
Assemble 3972
Accumulator Charge Valve 3973
Disassemble 3973
Clean and Inspect 3975
Assemble 3975
Install 3976
Pressure Checks 3977
Accumulator Charge Valve Check 3977
Accumulator Check 3977
Service Brakes Adjustment (Dry Brake) 3978
Service Brakes Adjustment 3978
Brake System Air Removal 3979
Using Pressure Bleed System 3979
Using Brake Pedal Pressure 3980
Lift Truck Models with Master Cylinder 3980
Lift Truck Models with Modulating Brake Valve 3980
Brake Pedal Adjustment 3981
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) 3981
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3982
Free Pedal Adjustment 3984
Torque Specifications 3985
524265337-0600YRM1251-(09-2015)-US-EN 3989
General 3995
Engine Removal and Installation 3995
Cylinder Head Repair 3995
Remove and Disassemble 3995
Clean and Inspect 3997
Valve Oil Seals 4000
Remove and Disassemble 4000
Cylinder Leak Down Test 4000
Clean and Inspect 4001
Assemble and Install 4001
Valve Guides and Seats, Repairs 4003
Valves, Repair 4003
Valve Seats, Repair 4004
Valve Springs 4005
Assemble and Install 4006
Engine Block Cleaning and Inspection 4009
Clean and Inspect 4010
Piston Bore Preparation 4012
Engine Mounts Installation 4012
Remove 4012
Clean and Inspect 4013
Install 4013
Lubrication System Repair 4014
Oil Pump, Remove and Disassemble 4014
Clean and Inspect 4015
Oil Pump, Assemble and Install 4016
Oil Pan, Install 4018
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4020
Timing Cover 4020
Remove 4020
Install 4022
Timing Sprockets 4022
Remove 4022
Install 4022
Camshaft 4022
Remove 4022
Inspect 4023
Install 4023
Balance Shaft 4024
Remove 4024
Install 4025
Valve Lifters 4026
Remove 4026
Clean and Inspect 4026
Install 4027
Crankshaft Repair 4027
Remove 4028
Inspect and Repair 4028
How to Check Clearance Between Main Bearings and Their Journals 4029
Install 4030
Piston and Connecting Rod Assemblies Repair 4032
Connecting Rod Bearings, Replace 4032
Piston and Connecting Rod Assemblies, Remove 4033
Disassemble 4033
Piston, Clean and Inspect 4034
Cylinder Bores, Inspect and Repair 4034
Piston Rings 4035
Assemble 4036
Piston and Connecting Rod Assemblies, Install 4036
Flywheel and Flywheel Housing Repair 4036
Flywheel, Remove 4037
Clean 4037
Inspect 4037
Flywheel, Install 4038
Coolant Pump Repair 4038
Remove 4038
Clean and Inspect 4039
Install 4039
Thermostat Replacement 4039
Remove 4040
Thermostat Operation Check 4040
Install 4040
Starter Replacement 4041
4041
Remove 4041
Install 4044
Fan Assembly Replacement 4045
Remove 4045
Inspect 4047
Install 4047
Drive Belt Installation 4048
Remove 4048
Clean 4048
Inspect 4048
Installation 4049
Compression Check 4050
Engine Specifications 4050
Engine Data 4050
Cylinder Head 4050
Hydraulic Valve Lifter 4051
Camshaft 4051
Pistons 4051
Crankshaft 4052
Connecting Rods 4052
Balance Shaft 4053
Cooling System 4053
Lubrication System 4053
Torque Specifications 4054
524265342-4000YRM1250-(06-2021)-US-EN 4059
Safety Procedures When Working Near Mast 4065
Fork Replacement 4068
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4068
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4069
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) 4071
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4072
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4073
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) 4074
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4074
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) 4075
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4076
Fixed Carriage Replacement 4078
Remove, Carriage With Hook Forks 4078
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4086
Install, Carriage With Hook Forks 4087
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4087
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4088
Connecting Attachment Hydraulic Quick Disconnect Hoses 4088
Integral Sideshift Carriage Repair 4089
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) 4089
Disassemble 4089
Clean and Inspect 4092
Assemble 4092
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) 4093
Hang On Sideshift Carriage Repair 4094
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) 4094
Disassemble 4106
Clean and Inspect 4115
Assemble 4116
Install 4117
Hang-On Sideshift Carriage Repair 4119
Remove 4119
Disassemble Carriage 4121
Clean and Inspect 4124
Assemble 4124
Install 4127
Fork Positioner 4130
Two-Stage Mast With Limited Free-Lift Repair 4131
Remove 4131
Disassemble 4134
Clean and Inspect 4137
Assemble 4155
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) 4157
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) 4159
Header Hose Alignment 4170
Two-Stage Mast With Full Free-Lift Repair 4181
Remove 4181
Disassemble 4183
Clean and Inspect 4194
Assemble 4195
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) 4197
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) 4200
Header Hose Installation and Adjustment 4204
Installation 4204
Adjustment 4205
Three-Stage Mast With Full Free-Lift Repair 4206
Remove 4206
Disassemble 4208
Clean and Inspect 4238
Assemble 4240
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) 4243
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) 4248
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) 4255
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) 4262
Mast Operation Check 4266
Tilt Cylinder Adjustment 4267
Lift Chains Adjustment 4267
Mast Adjustments 4269
Load Roller Adjustment 4269
Mast Side Kicking Adjustment 4271
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4272
Carriage Adjustments 4274
Series Code / Model Designation Reference Table 4275
524265342-4000YRM1250-(09-2018)-UK-EN 4279
Safety Procedures When Working Near Mast 4285
Fork Replacement 4287
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4287
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4289
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) 4290
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4291
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4292
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) 4293
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4293
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) 4295
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4295
Fixed Carriage Replacement 4297
Remove, Carriage With Hook Forks 4297
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4306
Install, Carriage With Hook Forks 4307
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4307
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4308
Connecting Attachment Hydraulic Quick Disconnect Hoses 4308
Integral Sideshift Carriage Repair 4309
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) 4309
Disassemble 4309
Clean and Inspect 4312
Assemble 4312
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) 4313
Hang On Sideshift Carriage Repair 4313
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) 4313
Disassemble 4325
Clean and Inspect 4334
Assemble 4335
Install 4336
Bolzoni Hang-On Sideshift Carriage Repair 4338
Remove 4338
Disassemble Carriage 4340
Clean and Inspect 4343
Assemble 4343
Install 4346
Fork Positioner 4348
Two-Stage Mast With Limited Free-Lift Repair 4349
Remove 4349
Disassemble 4353
Clean and Inspect 4356
Assemble 4373
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) 4375
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) 4376
Header Hose Alignment 4388
Two-Stage Mast With Full Free-Lift Repair 4398
Remove 4398
Disassemble 4400
Clean and Inspect 4412
Assemble 4413
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) 4415
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) 4418
Header Hose Installation and Adjustment 4422
Installation 4422
Adjustment 4422
Three-Stage Mast With Full Free-Lift Repair 4423
Remove 4423
Disassemble 4425
Clean and Inspect 4455
Assemble 4456
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) 4460
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) 4465
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) 4472
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) 4478
Mast Operation Check 4482
Tilt Cylinder Adjustment 4482
Lift Chains Adjustment 4483
Mast Adjustments 4484
Load Roller Adjustment 4484
Mast Side Kicking Adjustment 4486
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4487
Carriage Adjustments 4490
524288189-0100YRM1316-(01-2022)-US-EN 4493
General 4497
Description 4498
Hood, Seat, Dash, and Side Covers Replacement 4500
Remove 4500
Install 4506
Steering Column 4510
Description 4510
Steering Column Repair 4510
Remove 4510
Disassemble 4511
Clean 4513
Inspect 4513
Assemble 4513
Install 4513
LPG Tank and Bracket Replacement 4513
Counterweight Replacement 4514
Remove 4514
Install 4515
Tow Pin, Remove and Install 4517
Overhead Guard Replacement 4518
Remove 4518
Install 4519
LED Tail, Backup, and Brake Lights, Replace 4520
Operator Restraint System Replacement 4521
Description 4521
Engine Replacement 4523
Remove Engine Only 4523
Install Engine only 4549
Remove Engine and Transmission 4552
Install Engine and Transmission 4554
Electronic Throttle Replacement 4558
Cummins 4 5L Diesel Engine With Electronic Throttle 4558
Remove 4558
Install 4562
Pull Actuator Linkage Adjustment 4564
Low Idle Adjustment 4564
Throttle Pedal and Cable Adjustment 4565
Cummins 4 5L Diesel Engine 4565
Exhaust System Repair 4567
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4567
PSI 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4567
Cummins QSB 3 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4567
Remove 4567
Inspect 4567
Install 4570
Cummins 4 5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4570
Remove 4570
Inspect 4572
Install 4572
Kubota 3 8L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 4572
Remove 4572
Inspect 4575
Install 4575
Kubota 3 8L Diesel Engine w/DPF for Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) 4575
Remove 4575
Inspect 4578
Install 4578
Kubota 3 8L Diesel Engine w/DOC for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) 4578
Remove 4578
Inspect 4581
Install 4581
Cooling System 4582
Description 4582
Hydraulic Filter Assembly Repair 4583
Remove 4583
Disassemble 4583
Clean 4584
Inspect 4584
Assemble 4584
Install 4584
Fuel and Hydraulic Tanks Repair 4585
Inspect 4585
Clean 4585
Steam Method of Cleaning 4585
Chemical Solution Method of Cleaning 4586
Additional Preparations for Repair 4587
Small Leaks, Repair 4587
Large Leaks, Repair 4587
Preparations for Use After Repair 4587
Safety Labels 4588
524288189-0100YRM1316-(11-2017)-UK-EN 4595
General 4599
Description 4599
Hood, Seat, Dash, and Side Covers Replacement 4600
Remove 4601
Install 4606
Steering Column 4609
Description 4609
Steering Column Repair 4609
Remove 4609
Disassemble 4611
Clean 4612
Inspect 4612
Assemble 4612
Install 4612
LPG Tank and Bracket Replacement 4612
Counterweight Replacement 4612
Remove 4613
Install 4614
Tow Pin, Remove and Install 4616
Overhead Guard Replacement 4616
Remove 4616
Install 4617
LED Tail, Backup, and Brake Lights, Replace 4618
Operator Restraint System Replacement 4618
Description 4619
Engine Replacement 4620
Remove Engine Only 4620
Install Engine only 4642
Remove Engine and Transmission 4646
Install Engine and Transmission 4649
Electronic Throttle Replacement 4651
Cummins 4 5L Diesel Engine With Electronic Throttle 4651
Remove 4651
Install 4655
Pull Actuator Linkage Adjustment 4657
Low Idle Adjustment 4657
Throttle Pedal and Cable Adjustment 4657
Cummins 4 5L Diesel Engine 4658
Exhaust System Repair 4659
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4660
PSI 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4660
Cummins QSB 3 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4660
Remove 4660
Inspect 4660
Install 4662
Cummins 4 5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 4662
Remove 4662
Inspect 4663
Install 4663
Kubota 3 8L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 4665
Remove 4665
Inspect 4665
Install 4666
Kubota 3 8L Diesel Engine w/DPF for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4667
Remove 4667
Inspect 4669
Install 4669
Kubota 3 8L Diesel Engine w/DOC for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4669
Remove 4669
Inspect 4670
Install 4670
Cooling System 4673
Description 4674
Hydraulic Filter Assembly Repair 4674
Remove 4674
Disassemble 4674
Clean 4674
Inspect 4675
Assemble 4675
Install 4675
Fuel and Hydraulic Tanks Repair 4675
Inspect 4676
Clean 4676
Steam Method of Cleaning 4676
Chemical Solution Method of Cleaning 4677
Additional Preparations for Repair 4678
Small Leaks, Repair 4678
Large Leaks, Repair 4678
Preparations for Use After Repair 4678
Safety Labels 4678
524288194-1300YRM1317-(03-2020)-UK-EN 4685
Transmission Repair 4689
Remove 4689
Torque Converter, Remove 4689
Disassemble 4690
Clean and Inspect 4739
Housings 4739
Oil Seals and Gaskets 4739
Bearings 4739
Gears and Shafts 4740
Assemble 4740
Torque Converter, Install 4781
Install 4782
Control Valve Repair 4783
Remove 4783
Disassemble 4783
Clean 4785
Inspect 4785
Assemble 4785
Install 4786
Torque Specification 4787
524288194-1300YRM1317-(06-2021)-US-EN 4789
Transmission Repair 4793
Remove 4793
Torque Converter, Remove 4793
Disassemble 4794
Clean and Inspect 4845
Housings 4845
Oil Seals and Gaskets 4845
Bearings 4845
Gears and Shafts 4846
Assemble 4846
Torque Converter, Install 4888
Install 4889
Control Valve Repair 4890
Remove 4890
Disassemble 4890
Clean 4892
Inspect 4892
Assemble 4892
Install 4893
Torque Specification 4894
524288199-1400YRM1318-(06-2021)-US-EN 4897
General 4901
Identification Plate 4901
Drive Axle Removal 4901
Planetary Reduction Gear Repair 4909
Clean and Inspect 4916
Brake Repair 4924
Clean and Inspect 4931
Wet Brake Noise Reduction 4942
General 4942
Adding Additive To Transmission 4942
Differential Repair 4944
Clean and Inspect 4953
Bevel Pinion 4965
Clean and Inspect 4969
Drive Axle Installation 4980
Special Tools 4988
Torque Specifications 4989
524288199-1400YRM1318-(09-2018)-UK-EN 4991
General 4995
Identification Plate 4995
Drive Axle Removal 4995
Planetary Reduction Gear Repair 5002
Clean and Inspect 5010
Brake Repair 5017
Clean and Inspect 5025
Wet Brake Noise Reduction 5035
General 5035
Adding Additive To Transmission 5035
Differential Repair 5036
Clean and Inspect 5046
Bevel Pinion 5058
Clean and Inspect 5062
Drive Axle Installation 5072
Special Tools 5079
Torque Specifications 5079
524294873-1300YRM1343-(06-2021)-US-EN 5083
Transmission Repair 5087
Remove 5087
Torque Converter, Remove 5087
Disassemble 5089
Clean and Inspect 5130
Housings 5130
Oil Seals and Gaskets 5130
Bearings 5130
Gears and Shafts 5131
Assemble 5131
Torque Converter, Install 5169
Install 5170
Control Valve Repair 5171
Remove 5171
Disassemble 5171
Control Valve Assembly 5171
Control Valve Body 5171
Clean 5174
Inspect 5174
Assemble 5174
Control Valve Body 5174
Control Valve Assembly 5175
Install 5175
Torque Specification 5177
524294873-1300YRM1343-(11-2019)-UK-EN 5179
Transmission Repair 5183
Remove 5183
Torque Converter, Remove 5183
Disassemble 5184
Clean and Inspect 5224
Housings 5224
Oil Seals and Gaskets 5224
Bearings 5225
Gears and Shafts 5225
Assemble 5225
Torque Converter, Install 5263
Install 5264
Control Valve Repair 5265
Remove 5265
Disassemble 5265
Control Valve Assembly 5265
Control Valve Body 5265
Clean 5268
Inspect 5268
Assemble 5268
Control Valve Body 5268
Control Valve Assembly 5268
Install 5269
Torque Specification 5271
524294878-2100YRM1328-(06-2021)-US-EN 5273
General 5277
Safety Procedures When Working Near Mast 5277
Tilt Cylinder Repair 5280
Remove 5280
Disassemble 5284
Clean 5286
Inspect 5286
Assemble 5286
Install 5288
Tilt Cylinders, Adjust 5290
Tilt Cylinder Leak Check 5292
Lift Cylinder Repair 5293
Remove 5293
Disassemble 5302
Clean 5305
Inspect 5305
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 5305
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5305
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 5306
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5306
Free-Lift Cylinder Repair 5308
Remove 5308
Disassemble 5314
Clean 5316
Inspect 5316
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 5317
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5317
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 5317
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5318
Sideshift Cylinder Repair 5319
Remove 5319
Disassemble 5320
Clean 5323
Inspect 5323
Assemble 5324
Install 5325
Bolzoni Sideshift Cylinder Repair 5326
Remove 5326
Disassemble 5326
Clean 5327
Inspect 5327
Assemble 5328
Install 5328
Fork Positioner Cylinder Repair 5329
Remove 5329
Disassemble 5332
Clean 5336
Inspect 5336
Assemble 5337
Install 5338
Lift Cylinder Leak Check 5340
Seal Kit Installation 5341
External Installation (Seal and Back-Up Ring) 5341
Internal Installation (Piston Rod Assembly) 5341
Special Tools 5342
Torque Specifications 5343
For Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5343
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5343
524294878-2100YRM1328-(09-2018)-UK-EN 5345
General 5349
Safety Procedures When Working Near Mast 5349
Tilt Cylinder Repair 5351
Remove 5351
Disassemble 5356
Clean 5358
Inspect 5358
Assemble 5358
Install 5360
Tilt Cylinders, Adjust 5362
Tilt Cylinder Leak Check 5363
Lift Cylinder Repair 5364
Remove 5364
Disassemble 5374
Clean 5377
Inspect 5377
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 5377
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5377
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 5378
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5378
Free-Lift Cylinder Repair 5379
Remove 5379
Disassemble 5385
Clean 5387
Inspect 5387
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 5388
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5388
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 5388
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5389
Sideshift Cylinder Repair 5390
Remove 5390
Disassemble 5391
Clean 5394
Inspect 5394
Assemble 5395
Install 5396
Bolzoni Sideshift Cylinder Repair 5397
Remove 5397
Disassemble 5397
Clean 5398
Inspect 5398
Assemble 5399
Install 5399
Fork Positioner Cylinder Repair 5399
Remove 5400
Disassemble 5403
Clean 5407
Inspect 5407
Assemble 5408
Install 5409
Lift Cylinder Leak Check 5410
Seal Kit Installation 5410
External Installation (Seal and Back-Up Ring) 5410
Internal Installation (Piston Rod Assembly) 5411
Special Tools 5412
Torque Specifications 5413
For Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5413
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 5413
550043871-0900YRM1556-(04-2018)-US-EN 5417
General 5421
LPG Tank and Bracket 5421
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) 5421
Remove 5421
Install 5429
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) 5430
Remove 5430
Install 5432
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 5432
Remove 5432
Install 5434
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 5434
Remove 5434
Install 5434
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) 5435
Remove 5435
Install 5437
Fuel Filter Unit 5437
Fuel Filter Element 5438
Remove 5438
Clean and Inspect 5438
Install 5439
Fuel Filter Housing with LP Vapor Sensor 5439
Remove 5439
Disassemble 5441
Clean and Inspect 5442
Assemble 5442
Install 5443
Throttle Body 5444
Remove 5444
Clean 5448
Install 5448
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 5449
Remove 5449
Install 5450
Control System 5450
Engine Control Unit (ECU) 5451
Remove 5451
Install 5452
Low Pressure Switch 5452
Remove 5452
Install 5452
Low Fuel Sensor 5453
Remove 5453
Install 5453
LP Converter 5454
Remove and Disassemble 5454
Assemble and Install 5455
LPG Lock-Off 5455
Remove 5456
Install 5457
Exhaust System 5458
Counterweight Exhaust 5458
Remove and Disassemble 5458
Inspect 5460
Assemble and Install 5460
Overhead Exhaust 5461
Remove and Disassemble 5461
Inspect 5463
Assemble and Install 5463
Exhaust Manifold 5463
Remove 5463
Install 5465
Oxygen (HEGO) Sensor 5465
Remove 5465
Install 5465
LPG Fuel Testing 5466
General 5466
Available Fuel Tests 5466
Composition Test (ASTM D-2163) 5466
Ammonia Test (ASTM D-4490) 5466
Basic Nitrogen Test (ASTM UOP269-90) 5466
Residues Test (ASTM D-2158) 5466
Vapor Pressure Test (ASTM D-2598) 5466
Sulfur Compounds Test (ASTM D-5623) 5466
Methanol Test (ASTM D-4864) 5467
Copper Corrosion (ASTM D-1838) 5467
Where To Send LPG Fuel Samples For Testing 5467
550048401-0900YRM1570-(03-2015)-US-EN 5471
550048607-0600YRM1557-(07-2019)-UK-EN 5501
General 5507
Engine Identification 5507
Major Engine Component Identification 5507
Location of Labels 5507
Crankcase Description 5508
Engine Removal and Installation 5509
Cylinder Head Assembly Repair 5510
Valve Covers and Fuel Injectors 5510
Remove 5510
Clean and Inspect 5516
Install 5516
Rocker Arm Assembly 5517
Remove 5517
Disassemble 5518
Clean and Inspect 5519
Push Rods 5519
Rocker Arm Assembly 5519
Assemble 5519
Install 5520
Valve Clearance Adjustments 5520
Cylinder Head Assembly 5521
Remove 5521
Disassemble 5533
Valves and Valve Springs, Remove 5533
Valve Guides, Remove 5534
Clean and Inspect 5534
Cylinder Head 5535
Valve Guides 5535
Valves 5535
Valve Sink 5535
Valve Seat 5536
Valve Springs 5536
Assemble 5537
Valve Guides, Install 5537
Valves and Valve Springs, Install 5538
Install 5539
Timing Gear Case and Timing Gears Repair 5543
Timing Gear Case Cover 5543
Remove 5543
Clean and Inspect 5544
Install 5544
Timing Gears 5545
Crankshaft Gear 5546
Remove 5546
Install 5546
Idler Gear 5546
Remove 5546
Inspect 5547
Install 5547
Camshaft Gear 5547
Remove 5547
Install 5548
Timing Gear Case 5548
Remove 5548
Clean and Inspect 5549
Install 5549
Drive Train, Camshaft, and Cylinder Block Repair 5550
Remove 5550
Disassemble 5550
Pistons and Connecting Rods 5550
Crankshaft 5551
Camshaft 5553
Clean and Inspect 5555
Cylinder Block 5555
Honing and Boring 5557
Cylinder Correction (Oversize) 5558
Pistons 5558
Piston Pin 5559
Connecting Rod 5559
Tappets 5560
Crankshaft 5560
Camshaft 5562
Camshaft Bushing 5563
Assemble 5563
Camshaft 5563
Crankshaft 5563
Pistons and Connecting Rods 5564
Install 5566
Angular Deviation Procedure 5566
Lubrication System Repair 5569
Engine Oil and Oil Filter Change 5569
Oil Pan 5570
Remove 5570
Install 5571
Oil Suction Tube 5571
Remove 5571
Clean 5572
Install 5572
Oil Pump 5572
Remove 5572
Clean and Inspect 5573
Outer Rotor Outside Clearance 5573
Outer Rotor to Inner Rotor Tip Clearance 5573
Outer Rotor Side Clearance 5574
Rotor Shaft Clearance 5574
Install 5574
Fuel System Repair 5575
Fuel Injectors 5575
Remove 5575
Inspect 5575
Clean 5575
Replace 5575
Install 5576
Test 5576
Fuel Injection Pump 5576
Remove 5576
Clean and Inspect 5581
Install 5581
Cooling System Repair 5582
Serpentine Belt 5582
Remove 5582
Inspect 5582
Install 5582
Serpentine Belt, Adjustment 5583
Water Pump 5583
Remove 5583
Install 5586
Thermostat 5588
Remove 5588
Inspect 5588
Install 5589
Flywheel and Flywheel Housing 5590
Flywheel 5590
Remove 5590
Install 5590
Flywheel Housing 5590
Remove 5590
Install 5590
Electrical Equipment Repair 5591
Alternator 5591
Remove 5591
Install 5592
Starter 5593
Remove 5593
Install 5593
Engine Specifications 5594
Engine Data For Lift Truck Models and GLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (H813)GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (E879) 5594
Engine Data For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (J813, K813) 5595
Engine Data For Lift Truck Models GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (F879) 5596
Engine Tuning 5597
Cylinder Head 5597
Intake/Exhaust Valve and Guide 5598
Valve Spring 5598
Rocker Arm and Shaft 5598
Push Rod 5598
Gear Train and Camshaft 5599
Camshaft 5599
Idle Gear Shaft and Bushing 5599
Backlash of Each Gear 5599
Cylinder Block 5599
Crankshaft 5599
Piston 5600
Piston Ring 5600
Connecting Rod 5600
Rod Small End 5600
Tappet 5601
Oil Pump 5601
Engine Oil Pressure 5601
Outer Rotor Outside Clearance 5601
Outer Rotor Side Clearance 5601
Inner Rotor to Cover 5601
Standard Torque Specifications 5602
Standard Torque Chart 5602
Special Torque Specifications 5602
Special Tools 5604
550048607-0600YRM1557-(11-2021)-US-EN 5617
General 5623
Engine Identification 5623
Major Engine Component Identification 5623
Location of Labels 5624
Crankcase Description 5625
Engine Removal and Installation 5626
Cylinder Head Assembly Repair 5626
Valve Covers and Fuel Injectors 5626
Remove 5626
Clean and Inspect 5633
Install 5633
Rocker Arm Assembly 5635
Remove 5635
Disassemble 5635
Clean and Inspect 5636
Push Rods 5636
Rocker Arm Assembly 5636
Assemble 5637
Install 5637
Valve Clearance Adjustments 5637
Cylinder Head Assembly 5638
Remove 5638
Disassemble 5649
Valves and Valve Springs, Remove 5649
Valve Guides, Remove 5650
Clean and Inspect 5650
Cylinder Head 5651
Valve Guides 5651
Valves 5651
Valve Sink 5651
Valve Seat 5652
Valve Springs 5652
Assemble 5653
Valve Guides, Install 5653
Valves and Valve Springs, Install 5654
Install 5654
Timing Gear Case and Timing Gears Repair 5658
Timing Gear Case Cover 5658
Remove 5658
Clean and Inspect 5659
Install 5659
Timing Gears 5660
Crankshaft Gear 5660
Remove 5660
Install 5660
Idler Gear 5661
Remove 5661
Inspect 5661
Install 5661
Camshaft Gear 5661
Remove 5661
Install 5662
Timing Gear Case 5662
Remove 5662
Clean and Inspect 5663
Install 5663
Drive Train, Camshaft, and Cylinder Block Repair 5664
Remove 5664
Disassemble 5664
Pistons and Connecting Rods 5664
Crankshaft 5665
Camshaft 5667
Clean and Inspect 5669
Cylinder Block 5669
Honing and Boring 5671
Cylinder Correction (Oversize) 5672
Pistons 5672
Piston Pin 5673
Connecting Rod 5673
Tappets 5674
Crankshaft 5674
Camshaft 5676
Camshaft Bushing 5677
Assemble 5677
Camshaft 5677
Crankshaft 5678
Pistons and Connecting Rods 5678
Install 5680
Angular Deviation Procedure 5680
Lubrication System Repair 5684
Engine Oil and Oil Filter Change 5684
Oil Pan 5685
Remove 5685
Install 5686
Oil Suction Tube 5686
Remove 5686
Clean 5687
Install 5687
Oil Pump 5687
Remove 5687
Clean and Inspect 5688
Outer Rotor Outside Clearance 5688
Outer Rotor to Inner Rotor Tip Clearance 5688
Outer Rotor Side Clearance 5689
Rotor Shaft Clearance 5689
Install 5689
Fuel System Repair 5691
Fuel Injectors 5691
Remove 5691
Inspect 5691
Clean 5691
Replace 5691
Install 5691
Test 5691
Fuel Injection Pump 5691
Remove 5691
Clean and Inspect 5696
Install 5696
Cooling System Repair 5698
Serpentine Belt 5698
Remove 5698
Inspect 5698
Install 5698
Serpentine Belt, Adjustment 5698
Water Pump 5699
Remove 5699
Install 5702
Thermostat 5704
Remove 5704
Inspect 5704
Install 5705
Flywheel and Flywheel Housing 5707
Flywheel 5707
Remove 5707
Install 5707
Flywheel Housing 5707
Remove 5707
Install 5707
Electrical Equipment Repair 5708
Alternator 5708
Remove 5708
Install 5709
Starter 5710
Remove 5710
Install 5710
Engine Specifications 5711
Engine Data For Lift Truck Models and GLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (H813)GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (E879) 5711
Engine Data For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (J813, K813) 5712
Engine Data For Lift Truck Models GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (F879, G879) 5713
Engine Tuning 5714
Cylinder Head 5714
Intake/Exhaust Valve and Guide 5715
Valve Spring 5715
Rocker Arm and Shaft 5715
Push Rod 5715
Gear Train and Camshaft 5716
Camshaft 5716
Idle Gear Shaft and Bushing 5716
Backlash of Each Gear 5716
Cylinder Block 5716
Crankshaft 5716
Piston 5717
Piston Ring 5717
Connecting Rod 5717
Rod Small End 5717
Tappet 5718
Oil Pump 5718
Engine Oil Pressure 5718
Outer Rotor Outside Clearance 5718
Outer Rotor Side Clearance 5718
Inner Rotor to Cover 5718
Standard Torque Specifications 5719
Standard Torque Chart 5719
Special Torque Specifications 5720
Special Tools 5721
550055283-8000YRM1585-(06-2021)-US-EN 5735
General Information About Diagrams and Schematics 5739
Symbol Definitions 5739
Diagrams Manual Applications 5740
Diagrams and Schematics 5742
550055283-8000YRM1585-(07-2020)-UK-EN 5831
General Information About Diagrams and Schematics 5835
Symbol Definitions 5835
Diagrams Manual Applications 5836
Diagrams and Schematics 5838
550059479-0600YRM1590-(07-2019)-US-EN 5927
General 5933
Engine Identification 5933
Major Engine Component Identification 5933
Location of Labels 5934
Crankcase Description 5934
Precautions Before Beginning Repair 5935
Exhaust System and DPF 5936
Engine Removal and Installation 5936
Cylinder Head Assembly Repair 5937
Valve Covers and Fuel Injectors 5937
Remove 5937
Clean and Inspect 5940
Install 5940
Rocker Arm Assembly 5941
Remove 5941
Disassemble 5942
Clean and Inspect 5942
Push Rods 5942
Rocker Arm Assembly 5942
Assemble 5943
Install 5943
Valve Clearance Adjustments 5943
Cylinder Head Assembly 5944
Remove 5944
Disassemble 5953
Valves and Valve Springs, Remove 5953
Valve Guides, Remove 5954
Clean and Inspect 5954
Cylinder Head 5955
Valve Guides 5955
Valves 5955
Valve Sink 5956
Valve Seat 5956
Valve Springs 5957
Assemble 5957
Valve Guides, Install 5957
Valves and Valve Springs, Install 5958
Install 5959
Timing Gear Case and Timing Gears Repair 5961
Timing Gear Case Cover 5961
Remove 5961
Clean and Inspect 5962
Install 5962
Timing Gears 5963
Crankshaft Gear 5964
Remove 5964
Install 5964
Idler Gear 5964
Remove 5964
Inspect 5965
Install 5966
Camshaft Gear 5966
Remove 5966
Install 5966
Drive Train, Camshaft, and Cylinder Block Repair 5966
Remove 5966
Disassemble 5967
Pistons and Connecting Rods 5967
Crankshaft 5968
Camshaft 5970
Clean and Inspect 5972
Cylinder Block 5972
Honing and Boring 5974
Cylinder Correction (Oversize) 5975
Pistons 5975
Piston Pin 5976
Connecting Rod 5976
Tappets 5977
Crankshaft 5977
Camshaft 5979
Camshaft Bushing 5980
Assemble 5980
Camshaft 5980
Crankshaft 5980
Pistons and Connecting Rods 5981
Install 5983
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 5983
Lubrication System Repair 5986
Engine Oil and Oil Filter Change 5986
Oil Pan 5987
Remove 5987
Install 5988
Oil Suction Tube 5989
Remove 5989
Clean 5989
Install 5989
Oil Pump 5989
Remove 5989
Clean and Inspect 5990
Outer Rotor Outside Clearance 5991
Outer Rotor to Inner Rotor Tip Clearance 5991
Outer Rotor Side Clearance 5991
Rotor Shaft Clearance 5992
Install 5992
Fuel System Repair 5993
Fuel Injectors 5993
Remove 5993
Inspect 5993
Clean 5993
Replace 5993
Install 5993
Test 5993
Fuel Injection Pump 5994
Remove 5994
Clean and Inspect 5995
Install 5995
Cooling System Repair 5996
Serpentine Belt 5996
Remove 5996
Inspect 5997
Install 5997
Adjust 5997
Water Pump 5998
Remove 5998
Install 5999
Thermostat 6000
Remove 6000
Inspect 6001
Install 6001
Flywheel and Flywheel Housing 6002
Flywheel 6002
Remove 6002
Install 6003
Flywheel Housing 6003
Remove 6003
Install 6003
Electrical Equipment Repair 6004
Alternator 6004
Remove 6004
Install 6005
Starter 6006
Remove 6006
Install 6006
Engine Specifications 6008
Engine Data 6008
Engine Tuning 6012
Cylinder Head 6012
Intake/Exhaust Valve and Guide 6012
Valve Spring 6013
Rocker Arm and Shaft 6013
Push Rod 6013
Gear Train and Camshaft 6013
Camshaft 6013
Idle Gear Shaft and Bushing 6013
Backlash of Each Gear 6014
Cylinder Block 6014
Crankshaft 6014
Piston 6014
Piston Ring 6015
Connecting Rod 6015
Rod Small End 6015
Tappet 6015
Oil Pump 6016
Engine Oil Pressure 6016
Outer Rotor Outside Clearance 6016
Outer Rotor Side Clearance 6016
Inner Rotor to Cover 6016
Standard Torque Specifications 6017
Standard Torque Chart 6017
Special Torque Specifications 6017
Special Tools 6019
550068794-8000YRM1606-(08-2019)-US-EN 6033
General 6039
Serial Number Data 6039
How to Move Disabled Lift Truck 6039
How to Tow Lift Truck 6039
How to Put Lift Truck on Blocks 6040
How to Raise Drive Tires 6040
How to Raise Steering Tires 6041
How to Clean a Lift Truck 6042
Maintenance Schedule 6043
Maintenance Procedures Every 8 Hours or Daily 6058
How to Make Checks With Engine Stopped 6058
Tires and Wheels 6058
Safety Labels 6059
Mast, Carriage, Lift Chains, Header Hoses, Attachment 6059
Operator Restraint System 6060
Emergency Locking Retractor (ELR) 6060
Adjust Seat – Full Suspension 6061
Adjust Seat – Internal Suspension 6062
Hood and Seat Latches 6063
Engine Compartment 6063
Paper Application 6063
Fuel, Oil, and Coolant Leaks, Check 6064
Hydraulic Hoses 6064
Coolant Hoses 6064
Steering Column Gas Cylinder 6064
Transmission 6065
Hydraulic System Oil 6065
Engine Oil 6066
Air Filter 6071
Forks 6071
General 6071
Inspect 6072
Remove 6073
Install 6073
Adjust 6073
Hang On Sideshift Carriage 6074
How to Make Checks With Engine Running 6075
Indicator Lights, Horn, Fuses, and Relays 6075
Service Brakes 6077
Brake Oil Level 6077
Operation, Check 6078
Parking Brake 6078
Engine Oil Pressure 6078
Cooling System 6078
Steering System 6079
Control Levers and Pedals 6079
Lift System, Operate 6080
Air Filter 6080
Fuel/Water Separator Filter, Kubota 3 8L Diesel Engine 6080
First Service After First 100 Hours of Operation 6081
4 3L Engine Oil and Oil Filter 6081
Kubota 3 8L Engine Oil and Oil Filter 6081
Bolzoni Hang on Sideshift Carriage Checks 6082
Maintenance Procedures Every 250 Hours or 6 Months 6083
GM 4 3L Engine Oil and Oil Filter Change 6083
Drive Belt 6084
GM 4 3L Engine 6084
Fan and Alternator Drive Belt 6084
Drain Tar From LPG Regulator 6085
Drain Tar From LPG Converter 6086
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine 6087
Maintenance Procedures Every 500 Hours or 6 Months 6089
Hydraulic System Oil 6089
Hydraulic Tank Breather 6090
Inspect 6090
Battery 6091
Kubota 3 8L Engine Oil and Oil Filter 6091
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 6092
Remove 6092
Install 6092
Priming the Fuel System (Kubota 3 8L Engine) 6093
Drive Belt 6094
Kubota 3 8L Diesel Engine 6094
Fan and Alternator Drive Belt 6094
Clean Debris From Radiator Core 6094
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 6095
Wet Brake Center Body Oil Level Check 6096
Forks 6098
Inspect 6098
Mast Lubrication 6100
Bolzoni Hang on Sideshift Carriage Checks 6105
Header Hose Checks 6106
Lift Chain Lubrication 6106
Tilt Cylinder Lubrication 6107
Master Brake Cylinder Rod End Pin Lubrication 6107
Manual Hydraulic Levers Lubrication 6108
Brake Oil 6108
Tie Rod Lubrication 6109
Parking Brake Adjustment 6110
Maintenance Procedures Every 1000 Hours or 6 Months 6111
Valve Clearance, Check and Adjust 6111
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 6111
Ignition System 6111
4 3L Engine 6111
Gasoline Fuel Filter, GM 4 3L Engine 6111
Remove and Replace 6111
In-Line Strainer Replacement, Kubota 3 8L Engine 6112
Remove 6112
Install 6112
Lift Chains Wear Check 6114
Lift Chain Lubrication 6114
Hang On Sideshift Carriage, Check Sliding Surfaces 6114
Bolzoni Hang on Sideshift Carriage Checks 6115
Steering Axle Spindle Bearings 6118
Control Levers and Pedals 6119
Inspect Engine Electrical System, Connectors 6119
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 6119
Parking Brake Lever Lubrication, Wet Brake Axle 6123
Normal Operating Environment 6123
Heavy Duty or Contaminated Environment 6123
Remove 6123
Clean and Inspect 6124
Install 6125
Crankcase Breather Element 6125
Remove 6125
Clean and Inspect 6126
Install 6126
Maintenance Procedures Every 2000 Hours or Annually 6126
Hydraulic System 6126
Hydraulic Filter Assembly, Replace 6126
Hydraulic Tank Breather, Replace 6127
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 6128
Cooling System Check 6128
Air Filter 6129
LPG Fuel Filter Element Replace, GM 4 3L and GM 4 3L With PSI Engine 6131
Remove 6131
Install 6132
Fuel Injector, Kubota 3 8L Engine 6132
Forks, Inspect 6132
Bolzoni Hang on Sideshift Carriage Checks 6134
Brake Oil (Master Cylinder), Change 6136
Check Throttle Shaft for Sticking 6137
Inspect Exhaust Manifold and Piping for Leaks 6137
Transmission Automatic Clutch Calibration 6137
Brake System Accumulator 6137
Wheel Bearings 6137
Steer Wheels, Lubrication 6137
Maintenance Procedures Every 4000 Hours or 2 Years 6138
Hydraulic Oil, Replace 6138
Safety Procedures When Working Near Mast 6140
Fuel Filter Water Removal 6142
Hood Latch Check 6143
Lift Chain Adjustments 6144
Jump-Starting the Lift Truck 6145
Jump-Starting Using a Battery Charger 6145
Jump-Starting a Lift Truck Using Another Lift Truck 6145
Welding Repairs 6146
Overhead Guard Changes 6146
Wheel and Tire Replacement 6146
General 6146
Solid Rubber Tire, Change 6146
Remove and Install Tire on Wheel 6147
Adhesives and Sealants 6148
550068797-8000YRM1606-(08-2019)-UK-EN 6151
General 6157
Serial Number Data 6157
How to Move Disabled Lift Truck 6157
How to Tow Lift Truck 6157
How to Put Lift Truck on Blocks 6158
How to Raise Drive Tires 6158
How to Raise Steering Tires 6159
How to Clean a Lift Truck 6160
Maintenance Schedule 6161
Maintenance Procedures Every 8 Hours or Daily 6175
How to Make Checks With Engine Stopped 6175
Tires and Wheels 6175
Safety Labels 6176
Mast, Carriage, Lift Chains, Header Hoses, Attachment 6176
Operator Restraint System 6177
Emergency Locking Retractor (ELR) 6177
Adjust Seat – Full Suspension 6178
Adjust Seat – Internal Suspension 6179
Hood and Seat Latches 6179
Engine Compartment 6179
Paper Application 6180
Fuel, Oil, and Coolant Leaks, Check 6180
Hydraulic Hoses 6181
Coolant Hoses 6181
Steering Column Gas Cylinder 6181
Transmission 6181
Hydraulic System Oil 6181
Engine Oil 6182
Air Filter 6186
Forks 6186
General 6186
Inspect 6187
Remove 6188
Install 6188
Adjust 6188
Hang On Sideshift Carriage 6189
How to Make Checks With Engine Running 6190
Indicator Lights, Horn, Fuses, and Relays 6190
Service Brakes 6192
Brake Oil Level 6192
Operation, Check 6193
Parking Brake 6193
Engine Oil Pressure 6193
Cooling System 6193
Steering System 6194
Control Levers and Pedals 6194
Lift System, Operate 6195
Air Filter 6195
Fuel/Water Separator Filter, Kubota 3 8L Diesel Engine 6195
First Service After First 100 Hours of Operation 6196
4 3L Engine Oil and Oil Filter 6196
Kubota 3 8L Engine Oil and Oil Filter 6196
Bolzoni Hang on Sideshift Carriage Checks 6197
Maintenance Procedures Every 500 Hours or 1 Year 6198
Hydraulic System Oil 6198
Hydraulic Tank Breather 6199
Inspect 6199
Battery 6200
Kubota 3 8L Engine Oil and Oil Filter 6200
4 3L Engine Oil and Oil Filter 6201
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 6202
Remove 6202
Install 6202
Priming the Fuel System (Kubota 3 8L Engine) 6203
Drain Tar From LPG Converter 6204
Drive Belt 6205
Kubota 3 8L Diesel Engine 6205
Fan and Alternator Drive Belt 6205
Clean Debris From Radiator Core 6205
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 6206
Wet Brake Center Body Oil Level Check 6207
Forks 6209
Inspect 6209
Bolzoni Hang on Sideshift Carriage Checks 6211
Mast Lubrication 6213
Header Hose Checks 6218
Lift Chain Lubrication 6218
Tilt Cylinder Lubrication 6218
Master Brake Cylinder Rod End Pin Lubrication 6219
Manual Hydraulic Levers Lubrication 6220
Brake Oil 6220
Tie Rod Lubrication 6221
Parking Brake Adjustment 6221
Maintenance Procedures Every 1000 Hours or 1 Year 6222
Valve Clearance, Check and Adjust 6222
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 6222
Ignition System 6222
4 3L Engine 6222
In-Line Strainer Replacement, Kubota 3 8L Engine 6223
Remove 6223
Install 6223
Lift Chains Wear Check 6225
Lift Chain Lubrication 6225
Hang On Sideshift Carriage, Check Sliding Surfaces 6225
Bolzoni Hang on Sideshift Carriage Checks 6226
Steering Axle Spindle Bearings 6229
Control Levers and Pedals 6230
Inspect Engine Electrical System, Connectors 6230
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 6230
Parking Brake Lever Lubrication, Wet Brake Axle 6234
Normal Operating Environment 6234
Heavy Duty or Contaminated Environment 6234
Remove 6234
Clean and Inspect 6235
Install 6236
Crankcase Breather Element 6236
Remove 6236
Clean and Inspect 6237
Install 6237
Maintenance Procedures Every 2000 Hours or Annually 6237
Hydraulic System 6237
Hydraulic Filter Assembly, Replace 6237
Hydraulic Tank Breather, Replace 6238
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 6239
Cooling System Check 6239
Air Filter 6240
LPG Fuel Filter Element Replace, GM 4 3L and GM 4 3L With PSI Engine 6242
Remove 6242
Install 6243
Fuel Injector, Kubota 3 8L Engine 6243
Forks, Inspect 6243
Bolzoni Hang on Sideshift Carriage Checks 6245
Brake Oil (Master Cylinder), Change 6247
Check Throttle Shaft for Sticking 6248
Inspect Exhaust Manifold and Piping for Leaks 6248
Transmission Automatic Clutch Calibration 6248
Brake System Accumulator 6248
Wheel Bearings 6248
Steer Wheels, Lubrication 6248
Maintenance Procedures Every 3000 Hours 6249
Diesel Particulate Filter 6249
Remove 6249
Disassemble 6251
Servicing the Diesel Particulate Filter 6252
Assemble 6252
Install 6253
Maintenance Procedures Every 4000 Hours or 2 Years 6254
Hydraulic Oil, Replace 6254
Safety Procedures When Working Near Mast 6256
Fuel Filter Water Removal 6258
Hood Latch Check 6259
Lift Chain Adjustments 6260
Jump-Starting the Lift Truck 6261
Jump-Starting Using a Battery Charger 6261
Jump-Starting a Lift Truck Using Another Lift Truck 6261
Welding Repairs 6262
Overhead Guard Changes 6262
Wheel and Tire Replacement 6262
General 6262
Solid Rubber Tire, Change 6262
Remove and Install Tire on Wheel 6263
Adhesives and Sealants 6264
550068802-8000YRM1607-(08-2019)-US-EN 6267
Lift Truck Lifting Capacity 6271
Counterweight Weights 6271
Tire Sizes 6271
Capacities 6271
Electrical System 6275
Transmission Oil Pressures 6276
Hydraulic System Relief Pressures 6277
Steering System 6278
Stall Speeds (in RPM ±100 rpm) 6278
GM 4 3L Gas 6278
GM/PSI 4 3L LPG 6278
Kubota Diesel 6278
Tilt Angles 6279
Front End Equipment – Mast Creep 6279
Mast Creep 6279
Engine Specifications 6280
Diesel Fuel Cleanliness Levels 6281
Torque Specifications 6282
Frame 6282
Mast 6282
Hang On Sideshift Carriage With Fork Positioner 6282
Steering System 6282
Transmission 6282
Engine – GM/PSI 4 3L 6283
Engine – Kubota 3 8L Diesel 6284
550073240-1900YRM1620-(01-2023)-US-EN 6287
Proper Flushing after Major Hydraulic Repairs 6293
Introduction 6293
The Phases of Wear 6293
Causes of Hydraulic System Failure 6293
Progression of Contaminant Caused Hydraulic System Failure 6294
Hydraulic System Flushing Techniques 6294
Double Oil and Filter Change 6294
Mechanical Cleaning 6295
Cleaning of Components 6295
How to Clean Tubes and Hoses 6295
Filter Caddy 6295
Start-Up Procedure for Cleaned System 6296
Contaminated Oil Coolers 6296
Additional Filter Caddy Functions 6297
How to Handle Different Fluids 6297
Water Removal Filters 6297
Fluid Conditioning and System Flushing Procedures 6298
Operation of the Filter Caddy 6298
Filter Caddy operation 6298
Fluid Conditioning Procedure 6298
Filter Caddy Start-Up 6299
System Flushing Procedure 6299
Component Cleaning Procedure 6300
Reservoir Cleaning Procedure 6300
Cylinder Cleaning Procedure 6300
Hose and Tube Cleaning Procedure 6300
Valve Cleaning Procedure 6301
Front-End Attachment Cleaning Procedure 6302
System Flushing Procedure 6302
Filter Caddy Start-Up 6303
System Start-Up and Flushing 6303
Reservoir Fluid Cleaning Times 6304
Dealing With Different Fluid Types 6305
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 6305
Filter Caddy Maintenance 6305
Servicing the Strainer 6305
DC Motor 6305
Hydraulic Oil Sampling Method and Procedure 6306
Hydraulic Oil Sampling Method 6306
Objective 6306
General Guidelines 6306
Synopsis 6307
Hydraulic Oil Analysis Report Guidelines 6308
Sampling Conditions 6308
Equipment 6308
Sampling Procedure 6309
Hydraulic Oil Sampling 6309
Sample Labeling 6309
Results Documentation 6309
550073240-1900YRM1620-(03-2020)-UK-EN 6311
Proper Flushing after Major Hydraulic Repairs 6315
Introduction 6315
The Phases of Wear 6315
Causes of Hydraulic System Failure 6315
Progression of Contaminant Caused Hydraulic System Failure 6316
Hydraulic System Flushing Techniques 6316
Double Oil and Filter Change 6316
Mechanical Cleaning 6317
Cleaning of Components 6317
How to Clean Tubes and Hoses 6317
Filter Caddy 6317
Start-Up Procedure for Cleaned System 6318
Contaminated Oil Coolers 6318
Additional Filter Caddy Functions 6318
How to Handle Different Fluids 6318
Water Removal Filters 6319
Fluid Conditioning and System Flushing Procedures 6319
Operation of the Filter Caddy 6319
Filter Caddy operation 6319
Fluid Conditioning Procedure 6320
Filter Caddy Start-Up 6320
System Flushing Procedure 6321
Component Cleaning Procedure 6321
Reservoir Cleaning Procedure 6321
Cylinder Cleaning Procedure 6321
Hose and Tube Cleaning Procedure 6322
Valve Cleaning Procedure 6322
Front-End Attachment Cleaning Procedure 6323
System Flushing Procedure 6323
Filter Caddy Start-Up 6324
System Start-Up and Flushing 6324
Reservoir Fluid Cleaning Times 6325
Dealing With Different Fluid Types 6325
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 6325
Filter Caddy Maintenance 6326
Servicing the Strainer 6326
DC Motor 6326
Hydraulic Oil Sampling Method and Procedure 6326
Hydraulic Oil Sampling Method 6326
Objective 6326
General Guidelines 6326
Synopsis 6327
Hydraulic Oil Analysis Report Guidelines 6328
Sampling Conditions 6329
Equipment 6329
Sampling Procedure 6329
Hydraulic Oil Sampling 6329
Sample Labeling 6330
Results Documentation 6330
550096331-8000YRM1689-(03-2020)-UK-EN 6333
General Information About Diagrams and Schematics 6337
Symbol Definitions 6337
Diagrams Manual Applications 6338
Diagrams and Schematics 6340
550096331-8000YRM1689-(06-2021)-US-EN 6443
General Information About Diagrams and Schematics 6447
Symbol Definitions 6447
Diagrams Manual Applications 6448
Diagrams and Schematics 6450
550118411-1900YRM1894-(06-2016)-US-EN 6535
General 6539
Description 6541
Hydraulic Fan Drive Replacement 6548
Lift Truck Models GC/GLC60VX, GC/GLC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 6549
Remove 6549
Disassemble 6551
Clean and Inspect 6552
Assemble 6552
Install 6552
Lift Truck Models GLC40, 45, 55VX; GLC55SVX (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (G818) 6553
Remove 6553
Disassemble 6554
Clean and Inspect 6556
Assemble 6556
Install 6556
Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (K813) 6557
Remove 6557
Disassemble 6558
Clean and Inspect 6560
Assemble 6560
Install 6560
Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (K813) with Kubota 3 8L Diesel Engine (Tier 4), 55kw with DOC 6560
Remove 6560
Disassemble 6562
Clean and Inspect 6563
Assemble 6563
Install 6563
Hydraulic Fan Drive Manifold 6563
Remove 6563
Install 6565
550118420-8000YRM1904-(05-2022)-US-EN 6569
General Information About Diagrams and Schematics 6575
Symbol Definitions 6575
Diagrams Manual Applications 6576
Diagrams and Schematics 6578
550118420-8000YRM1904-(10-2020)-UK-EN 6687
General Information About Diagrams and Schematics 6691
Symbol Definitions 6692
Diagrams Manual Applications 6693
Diagrams and Schematics 6695
550131848-0600YRM1961-(03-2020)-US-EN 6805
General 6811
Engine Identification 6812
Major Engine Component Identification 6812
Location of Labels 6814
Cylinder Block Description 6815
Precautions Before Beginning Repair 6816
Exhaust System and DPF 6817
Engine Removal and Installation 6817
Cylinder Head Assembly Repair 6817
Valve Covers and Fuel Injectors 6817
Remove 6817
Clean and Inspect 6820
Install 6820
Rocker Arm Assembly 6821
Remove 6821
Disassemble 6821
Clean and Inspect 6822
Push Rods 6822
Rocker Arm Assembly 6822
Assemble 6823
Install 6823
Valve Clearance Adjustments 6823
Cylinder Head Assembly 6824
Remove 6824
Disassemble 6832
Valves and Valve Springs, Remove 6832
Valve Guides, Remove 6833
Clean and Inspect 6833
Cylinder Head 6834
Valve Guides 6834
Valves 6835
Valve Sink 6835
Valve Seat 6835
Valve Springs 6836
Assemble 6836
Valve Guides, Install 6836
Valves and Valve Springs, Install 6837
Install 6838
Timing Gear Case and Timing Gears Repair 6840
Timing Gear Case Cover 6840
Remove 6840
Clean and Inspect 6841
Install 6841
Timing Gears 6842
Crankshaft Gear 6842
Remove 6842
Install 6843
Idler Gear 1 and Idler Gear 2 6843
Remove 6843
Inspect 6844
Install 6845
Idler Gear 3 6845
Remove 6845
Inspect 6845
Install 6845
Camshaft Gear 6845
Remove 6845
Install 6845
Drive Train, Camshaft, and Cylinder Block Repair 6846
Remove 6846
Disassemble 6846
Pistons and Connecting Rods 6846
Crankshaft 6847
Camshaft 6849
Clean and Inspect 6851
Cylinder Block 6851
Honing and Boring 6853
Cylinder Correction (Oversize) 6854
Pistons 6854
Piston Pin 6855
Connecting Rod 6855
Tappets 6856
Crankshaft 6856
Camshaft 6858
Camshaft Bushing 6859
Assemble 6859
Camshaft 6859
Crankshaft 6859
Pistons and Connecting Rods 6860
Install 6862
Angular Deviation Procedure 6862
Lubrication System Repair 6865
Engine Oil and Oil Filter Change 6865
Oil Pan 6866
Remove 6866
Install 6866
Oil Suction Tube 6866
Remove 6866
Clean 6867
Install 6867
Oil Pump 6867
Remove 6867
Clean and Inspect 6868
Inner Rotor and Outer Rotor Clearance 6868
Outer Rotor and Pump Body Clearance 6869
Rotor and Cover Clearance 6869
Rotor Shaft Clearance 6869
Install 6870
Fuel System Repair 6870
Fuel Injectors 6870
Remove 6870
Inspect 6870
Clean 6871
Replace 6871
Install 6871
Test 6871
Fuel Injection Pump 6871
Remove 6871
Clean and Inspect 6874
Install 6874
Cooling System Repair 6875
Serpentine Belt 6875
Remove 6875
Inspect 6875
Install 6875
Adjust 6875
Water Pump 6876
Remove 6876
Install 6878
Thermostat 6878
Remove 6878
Inspect 6879
Install 6879
Flywheel and Flywheel Housing 6880
Flywheel 6880
Remove 6880
Install 6881
Flywheel Housing 6881
Remove 6881
Install 6881
Electrical Equipment Repair 6882
Alternator 6882
Remove 6882
Install 6883
Starter 6884
Remove 6884
Install 6884
Engine Specifications 6886
Engine Data 6886
Engine Tuning 6888
Cylinder Head 6888
Intake/Exhaust Valve and Guide 6889
Valve Spring 6889
Rocker Arm and Shaft 6889
Push Rod 6889
Gear Train and Camshaft 6890
Camshaft 6890
Idle Gear Shaft and Bushing 6890
Backlash of Each Gear 6890
Cylinder Block 6890
Crankshaft 6891
Piston 6891
Piston Ring 6891
Connecting Rod 6892
Rod Small End 6892
Tappet 6892
Oil Pump 6892
Engine Oil Pressure 6892
Inner and Outer Rotor Clearance 6892
Outer Rotor and Pump Body 6892
Rotor and Cover 6893
Standard Torque Specifications 6893
Standard Torque Chart 6893
Special Torque Specifications 6893
Special Tools 6895
550148125-9000YRM2010-(05-2016)-US-EN 6909
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 6915
Group 05 – Operational Checkout 6917
SECTION 9020 ENGINE 6923
Group 10 – Principles of Operation 6925
Group 03 – General Maintenance and Diagnostic Data 6935
Group 30 – Observed Symptoms 6939
SECTION 9030 ELECTRICAL SYSTEM 6945
Group 03 – General Maintenance and Diagnostic Data 6949
Group 10 – Principles of Operation 6955
Group 20 – Diagnostic Trouble Codes 6963
SECTION 9080 SUPPLEMENTARY DATA 7025
Group 50 – Abbreviations and Acronyms 7027
Group 60 – Special Tools List 7035
Group 70 – Fault Mode Indicator Reference 7037
550152438-0600YRM1949-(07-2023)-US-EN 7041
General 7047
Engine Removal and Installation 7047
Cylinder Head Repair 7047
Remove and Disassemble 7047
Clean and Inspect 7049
Valve Oil Seals 7051
Remove and Disassemble 7051
Cylinder Leak Down Test 7051
Clean and Inspect 7052
Assemble and Install 7052
Valve Guides and Seats, Repairs 7054
Valves, Repair 7055
Valve Seats, Repair 7055
Valve Springs 7056
Assemble and Install 7057
Engine Block Cleaning and Inspection 7061
Clean and Inspect 7061
Piston Bore Preparation 7063
Engine Mounts Installation 7064
Remove 7064
Clean and Inspect 7064
Install 7064
Lubrication System Repair 7065
Oil Pump, Remove and Disassemble 7065
Clean and Inspect 7066
Oil Pump, Assemble and Install 7067
Oil Pan, Install 7069
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 7071
Timing Cover 7071
Remove 7071
Install 7072
Timing Chain and Sprockets 7072
Remove 7072
Install 7073
Camshaft 7073
Remove 7073
Inspect 7074
Install 7074
Balance Shaft 7075
Remove 7075
Install 7076
Valve Lifters 7077
Remove 7077
Clean and Inspect 7077
Install 7077
Crankshaft Repair 7079
Remove 7079
Inspect and Repair 7079
How to Check Clearance Between Main Bearings and Their Journals 7080
Install 7081
Piston and Connecting Rod Assemblies Repair 7083
Connecting Rod Bearings, Replace 7083
Piston and Connecting Rod Assemblies, Remove 7084
Disassemble 7084
Piston, Clean and Inspect 7085
Cylinder Bores, Inspect and Repair 7085
Piston Rings 7086
Assemble 7087
Piston and Connecting Rod Assemblies, Install 7087
Flywheel and Flywheel Housing Repair 7088
Flywheel, Remove 7088
Clean 7088
Inspect 7088
Flywheel, Install 7089
Coolant Pump Repair 7090
Remove 7090
Clean and Inspect 7091
Install 7091
Thermostat Replacement 7092
Remove 7092
Thermostat Operation Check 7092
Install 7092
Starter Replacement 7093
Fan Assembly Replacement 7097
Remove 7097
Inspect 7099
Install 7099
Drive Belt Installation 7100
Remove 7100
Clean 7100
Inspect 7100
Installation 7100
Compression Check 7102
Engine Specifications 7103
Engine Data 7103
Cylinder Head 7103
Hydraulic Valve Lifter 7103
Camshaft 7103
Pistons 7104
Crankshaft 7104
Connecting Rods 7105
Balance Shaft 7105
Cooling System 7105
Lubrication System 7105
Torque Specifications 7106
550152438-0600YRM1949-(11-2019)-UK-EN 7109
General 7113
Engine Removal and Installation 7113
Cylinder Head Repair 7113
Remove and Disassemble 7113
Clean and Inspect 7115
Valve Oil Seals 7117
Remove and Disassemble 7117
Cylinder Leak Down Test 7117
Clean and Inspect 7118
Assemble and Install 7118
Valve Guides and Seats, Repairs 7120
Valves, Repair 7121
Valve Seats, Repair 7121
Valve Springs 7122
Assemble and Install 7123
Engine Block Cleaning and Inspection 7126
Clean and Inspect 7126
Piston Bore Preparation 7128
Engine Mounts Installation 7129
Remove 7129
Clean and Inspect 7129
Install 7129
Lubrication System Repair 7129
Oil Pump, Remove and Disassemble 7129
Clean and Inspect 7131
Oil Pump, Assemble and Install 7132
Oil Pan, Install 7133
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 7135
Timing Cover 7135
Remove 7135
Install 7136
Timing Chain and Sprockets 7136
Remove 7136
Install 7137
Camshaft 7138
Remove 7138
Inspect 7138
Install 7138
Balance Shaft 7139
Remove 7139
Install 7140
Valve Lifters 7141
Remove 7141
Clean and Inspect 7141
Install 7142
Crankshaft Repair 7142
Remove 7142
Inspect and Repair 7143
How to Check Clearance Between Main Bearings and Their Journals 7144
Install 7145
Piston and Connecting Rod Assemblies Repair 7146
Connecting Rod Bearings, Replace 7146
Piston and Connecting Rod Assemblies, Remove 7147
Disassemble 7148
Piston, Clean and Inspect 7148
Cylinder Bores, Inspect and Repair 7149
Piston Rings 7149
Assemble 7150
Piston and Connecting Rod Assemblies, Install 7151
Flywheel and Flywheel Housing Repair 7152
Flywheel, Remove 7152
Clean 7152
Inspect 7152
Flywheel, Install 7153
Coolant Pump Repair 7154
Remove 7154
Clean and Inspect 7154
Install 7155
Thermostat Replacement 7156
Remove 7156
Thermostat Operation Check 7156
Install 7156
Starter Replacement 7157
Fan Assembly Replacement 7160
Remove 7160
Inspect 7162
Install 7162
Drive Belt Installation 7163
Remove 7163
Clean 7163
Inspect 7163
Installation 7163
Compression Check 7164
Engine Specifications 7165
Engine Data 7165
Cylinder Head 7165
Hydraulic Valve Lifter 7165
Camshaft 7165
Pistons 7166
Crankshaft 7166
Connecting Rods 7167
Balance Shaft 7167
Cooling System 7167
Lubrication System 7167
Torque Specifications 7167
550152439-0900YRM1951-(11-2019)-US-EN 7171
General 7177
LPG Tank and Bracket 7177
LPG Tank, Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080-120VX) (K813) and GLC60-70VX (GLC135-155VX) (F879) 7177
Remove 7177
Install 7182
LPG Tank Bracket, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813), and GLC60-70VX (GLC135-155VX) (F879) 7183
Remove 7183
Install 7184
LPG Tank, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878) and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 7185
Remove 7185
Install 7187
LPG Tank Bracket, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 7187
Remove 7187
Install 7187
LPG Tank Bracket Alignment Pin, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813) and GLC60-70VX (GLC135-155VX) (F879) 7188
Remove 7188
Install 7189
Fuel Filter Unit 7190
Fuel Filter Element 7190
Remove 7190
Clean and Inspect 7191
Install 7191
Fuel Filter Housing, Lift Truck Models GLP60-70VX (GLP135-155VX) (F878), GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878), GLC60-70VX (GLC135-155VX) (F879), and GLP40VX5, GLP40-45VX6, GLP45SVX5, GLP50-55VX (GLP80-120VX) (K813) 7192
Remove 7192
Disassemble 7193
Clean and Inspect 7193
Assemble 7194
Install 7194
Fuel Filter Housing, Lift Truck Models GLP60-70VX (E878) 7194
Remove 7194
Disassemble 7196
Clean and Inspect 7197
Assemble 7197
Install 7198
Throttle Body 7198
Remove 7198
Clean 7200
Install 7200
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 7201
Remove 7201
Install 7202
Control System 7203
Engine Control Unit (ECU) 7203
Remove 7203
Install 7204
Low Pressure Switch 7204
Remove 7204
Install 7205
Low Fuel Sensor 7205
Remove 7205
Install 7206
LP Converter 7206
Remove and Disassemble 7206
Assemble and Install 7208
LPG Lock-Off 7209
Remove 7209
Install 7210
Exhaust System 7210
Counterweight Exhaust 7210
Remove and Disassemble Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 7210
Inspect 7212
Assemble and Install Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 7213
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 7213
Inspect 7214
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 7214
Overhead Exhaust 7215
Remove and Disassemble Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 7215
Inspect 7216
Assemble and Install Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 7217
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 7217
Inspect 7219
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 7219
Exhaust Manifold 7219
Remove 7219
Install 7220
Oxygen (HEGO) Sensor 7221
Remove 7221
Install 7221
LPG Fuel Testing 7221
General 7221
Available Fuel Tests 7222
Composition Test (ASTM D-2163) 7222
Ammonia Test (ASTM D-4490) 7222
Basic Nitrogen Test (ASTM UOP269-90) 7222
Residues Test (ASTM D-2158) 7222
Vapor Pressure Test (ASTM D-2598) 7222
Sulfur Compounds Test (ASTM D-5623) 7222
Methanol Test (ASTM D-4864) 7222
Copper Corrosion (ASTM D-1838) 7222
Where To Send LPG Fuel Samples For Testing 7222
550152440-2200YRM1955-(11-2019)-US-EN 7225
Description 7229
Distributor Ignition (DI) System 7229
Crankshaft Position (CKP) Sensor 7229
Camshaft Position (CMP) Sensor 7229
Ignition Coil and Ignition Control Module (ICM) 7229
Secondary Ignition Components 7229
Spark Plugs and Wires 7229
Spark Plug Wire Inspection 7229
Spark Plug Wire Replacement 7229
Remove 7229
Install 7230
Spark Plug Inspection 7230
Usage 7230
Inspection 7230
Visual Inspection 7232
Spark Plug Replacement 7233
Remove 7233
Install 7233
Distributor Repair 7233
Inspect 7233
Overhaul 7234
Disassemble 7234
Assemble 7236
Replace 7237
Remove 7237
Install Procedure 1 7239
Install Procedure 2 7240
Ignition Coil Replacement 7242
Remove 7242
Install 7242
Ignition Control Module Replacement 7243
Remove 7243
Install 7243
Starter Replacement 7244
Remove 7244
Install 7247
Sensors and Switches 7248
LPG Trucks 7248
Crankshaft Position (CKP) Sensor 7248
Remove 7248
Install 7248
Camshaft Position (CMP) Sensor 7249
Remove 7249
Install 7250
Oil Pressure Sensor 7251
Remove 7251
Install 7251
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 7252
Remove 7252
Install 7252
Engine Coolant Temperature (ECT) Sensor 7252
Remove 7252
Install 7253
Air Flow Restriction Switch 7253
Remove 7253
Install 7254
Specifications and Special Tools 7254
550166584-2040YRM2041-(06-2017)-US-EN 7257
General 7261
Description 7261
Precautions 7261
7262
Center of Gravity and Lift Truck Capacity 7267
Net Capacity Rating 7267
The Effects of Loading 7267
Choosing The Right Equipment 7268
Choosing the Right Clamp 7268
Choosing the Right Truck 7268
Choosing the Right Contact Pads 7269
Clamping Force 7269
Description 7270
CLAMPING FORCE 7270
Clamping Force Too High 7270
Clamping Force Too Low 7270
Clamping Operation 7271
Lever Functions 7271
Two-Motion Controls 7271
Bilge Position 7271
Damage Prevention 7272
Description 7272
ROLL DAMAGE 7272
Edge Damage 7272
End Damage 7273
Belly Damage 7273
Out-of-Roundness 7274
Inspection and Maintenance 7274
Daily Checks 7274
Pad Inspection 7274
Inspection and Service (6 Months / 300 hours) 7275
Rotation Bearing 7275
Rack and Pinion 7275
Arm Pivots (Pins/Bushings/Seats) 7275
Rotation Mechanism (Rack and Pinion) 7275
550166585-2040YRM2040-(12-2016)-US-EN 7279
General 7283
Description 7283
Precautions 7283
Clamp Assembly Installation 7285
Hydraulic Hose Flush 7285
Clamp Installation (With Lifting Device) 7286
Clamp Installation (Without Lifting Device) 7287
Hose Connections 7287
AR Series Clamp 7287
ARC Series Clamp 7288
Connecting The Hoses 7288
Two-Motion Controls 7289
Operating Checks 7289
Set Flow Rate 7290
Hydraulic Adjustments 7291
E-Hydraulics 7291
Clamping Pressure 7291
Clamping Force Test 7292
7292
Clamping Force 7292
Testing Clamping Force with the Test Pad 7293
Test Procedures 7294
Testing Clamping force with the Test Stand 7294
Test Procedures 7295
Testing Clamping Force with the Test Cylinder 7295
Test Procedures 7295
Hydraulic Adjustments 7296
E-Hydraulics 7296
Bolzoni Force-Matic 7297
General Description 7297
Installation 7297
Operation 7300
Troubleshooting 7300
General 7300
Hydraulic Schematics 7303
550210540-0600YRM2190-(03-2020)-UK-EN 7309
General 7315
Engine Identification 7315
Major Engine Component Identification 7315
Location of Labels 7319
Cylinder Block Description 7319
Precautions Before Beginning Repair 7320
Exhaust System and DPF 7321
Engine Removal and Installation 7321
Cylinder Head Assembly Repair 7321
Valve Covers and Fuel Injectors 7321
Remove 7321
Clean and Inspect 7324
Install 7324
Rocker Arm Assembly 7325
Remove 7325
Disassemble 7325
Clean and Inspect 7326
Push Rods 7326
Rocker Arm Assembly 7326
Assemble 7327
Install 7327
Valve Clearance Adjustments 7327
Cylinder Head Assembly 7328
Remove 7328
Disassemble 7338
Valves and Valve Springs, Remove 7338
Valve Guides, Remove 7339
Clean and Inspect 7339
Cylinder Head 7340
Valve Guides 7340
Valves 7340
Valve Sink 7341
Valve Seat 7341
Valve Springs 7342
Assemble 7342
Valve Guides, Install 7342
Valves and Valve Springs, Install 7343
Install 7344
Timing Gear Case and Timing Gears Repair 7346
Timing Gear Case Cover 7346
Remove 7346
Clean and Inspect 7347
Install 7348
Timing Gears 7348
Crankshaft Gear 7349
Remove 7349
Install 7349
Idler Gear 1 and Idler Gear 2 7349
Remove 7349
Inspect 7350
Install 7351
Idler Gear 3 7351
Remove 7351
Inspect 7351
Install 7351
Camshaft Gear 7351
Remove 7351
Install 7351
Drive Train, Camshaft, and Cylinder Block Repair 7352
Remove 7352
Disassemble 7352
Pistons and Connecting Rods 7352
Crankshaft 7353
Camshaft 7355
Clean and Inspect 7357
Cylinder Block 7357
Honing and Boring 7359
Cylinder Correction (Oversize) 7360
Pistons 7360
Piston Pin 7361
Connecting Rod 7361
Tappets 7362
Crankshaft 7362
Camshaft 7364
Camshaft Bushing 7365
Assemble 7365
Camshaft 7365
Crankshaft 7366
Pistons and Connecting Rods 7366
Install 7368
Angular Deviation Procedure 7368
Lubrication System Repair 7371
Engine Oil and Oil Filter Change 7371
Oil Pan 7372
Remove 7372
Install 7372
Oil Suction Tube 7372
Remove 7372
Clean 7373
Install 7373
Oil Pump 7373
Remove 7373
Clean and Inspect 7374
Inner Rotor and Outer Rotor Clearance 7374
Outer Rotor and Pump Body Clearance 7375
Rotor and Cover Clearance 7375
Rotor Shaft Clearance 7375
Install 7376
Fuel System Repair 7377
Fuel Injectors 7377
Remove 7377
Inspect 7377
Clean 7377
Replace 7377
Install 7377
Test 7377
Fuel Injection Pump 7378
Remove 7378
Clean and Inspect 7380
Install 7380
Cooling System Repair 7381
Serpentine Belt 7381
Remove 7381
Inspect 7381
Install 7381
Adjust 7381
Water Pump 7382
Remove 7382
Install 7384
Thermostat 7385
Remove 7385
Inspect 7386
Install 7387
Flywheel and Flywheel Housing 7388
Flywheel 7388
Remove 7388
Install 7389
Flywheel Housing 7389
Remove 7389
Install 7389
Electrical Equipment Repair 7390
Alternator 7390
Remove 7390
Install 7391
Starter 7391
Remove 7391
Install 7392
Engine Specifications 7393
Engine Data 7393
Engine Tuning 7395
Cylinder Head 7396
Intake/Exhaust Valve and Guide 7396
Valve Spring 7397
Rocker Arm and Shaft 7397
Push Rod 7397
Gear Train and Camshaft 7397
Camshaft 7397
Idle Gear Shaft and Bushing 7397
Backlash of Each Gear 7398
Cylinder Block 7398
Crankshaft 7398
Piston 7398
Piston Ring 7399
Connecting Rod 7399
Rod Small End 7399
Tappet 7399
Oil Pump 7400
Engine Oil Pressure 7400
Inner and Outer Rotor Clearance 7400
Outer Rotor and Pump Body 7400
Rotor and Cover 7400
Standard Torque Specifications 7401
Standard Torque Chart 7401
Special Torque Specifications 7402
Special Tools 7403

S.V 06/24