Yale Forklift G818 (GLC080-120 VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) Service Manual PDF

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Yale Forklift G818 (GLC080-120 VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) Service Manual – PDF DOWNLOAD

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Yale Forklift G818 (GLC080-120 VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5112
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift G818 (GLC080-120 VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524221866-9000YRM1112-(10-2020)-US-EN 43
SECTION 9010 Operational Diagnostic Procedures 59
Group 05 – Operational Checkout 61
SECTION 9020 Engine 79
Group 10 – Principles of Operation 89
Group 30 – Observed Symptoms 287
Group 40 – Tests and Adjustments 389
SECTION 9030 Electrical System 421
Group 03 – General Maintenance and Diagnostic Data 445
Group 10 – Principles of Operation 539
Group 20 – Diagnostic Trouble Codes 563
Group 30 – Observed Symptoms 1535
SECTION 9040 Drive Train 1591
Group 10 – Principles of Operation 1595
Group 30 – Observed Symptoms 1651
Group 40 – Tests and Adjustments 1701
SECTION 9050 Hydraulic Systems 1711
Group 10 – Principles of Operation 1715
Group 30 – Observed Symptoms 1773
Group 33 – Observed Symptoms-Gear Pump 1775
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1863
Group 40 – Tests and Adjustments 1907
Group 43 – Tests and Adjustments-Gear Pump 1909
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1933
SECTION 9060 Operators Station 1951
Group 10 – Principles of Operation 1953
SECTION 9070 Front End (Mast) and Chassis 1989
Group 10 – Principles of Operation 1991
Group 30 – Observed Symptoms 2013
SECTION 9080 Supplementary Data 2071
Group 50 – Abbreviations and Acronyms 2073
Group 60 – Special Tools List 2081
Group 70 – Fault Mode Indicator Reference 2091
Group 80 – Supplier Specification Data 2093
524223769-2200YRM1128-(01-2023)-US-EN 2097
Series Code / Model Designation Reference Table 2105
General 2107
Deutsch Crimping Tool 2108
How to Strip a Wire for Use With Deutsch Crimping Tool 2108
How to Crimp With the Deutsch Crimping Tool 2109
Calibration Test for the Deutsch Crimping Tool 2111
Deutsch Connectors 2113
DT, DTM, and DTP Series Connectors 2113
HD Series Connectors 2156
Metri-Pack Connectors 2178
Remove and Install 2178
Micro-Pack Connectors 2181
Weather-Pack Connectors 2182
AMPSEAL Crimping Tools 2184
AMP Hand Crimping Tool With Certi-Crimp 2184
Description 2184
Stripping Wire for Use with AMP Hand Crimping Tool 2185
Insulation Crimp Adjustment 2186
Maintenance and Inspection for AMP Hand Crimping Tool 2186
AMP Hand Crimping Tool 2186
Crimp Height Inspection 2186
How to use AMP Hand Crimping Tool 2187
AMP Pro-Crimper II Tool 2187
Description 2187
Remove and Install Die Set and Locator Assembly 2188
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2188
Contact Support Adjustment 2189
Crimp Height Adjustment 2190
Maintenance and Inspection Procedures 2190
PRO-CRIMPER II Tool 2190
Crimp Height Inspection 2190
How to Use AMP PRO-CRIMPER II Tool 2191
AMPSEAL Connector Assemblies 2192
Description for Plug Connector Assembly 2192
Seal Plug 2193
Contact Crimping 2193
Description for Plug Connector and Header Assembly 2198
Voltage Reading 2201
Seal Plug 2201
Contact Crimping 2201
AMP Superseal 1 5 Crimping Tools 2208
Mini Mic Receptacle and Tab Contacts 2208
Description 2208
Crimping Conditions and Measurements 2208
Insertion of Rubber Seal on Cable 2210
AMP Hand Application Tool 2215
Description 2215
Maintenance and Inspection 2215
Crimp Height Inspection 2215
Crimp Height Adjustment 2216
How to Use AMP Hand Application Tool 2216
AMP Pro-Crimper II Tool 2217
Description 2217
Remove and Install Die Set and Locator Assembly 2217
Adjustments 2218
Contact Support 2218
Crimp Height 2219
Inspections and Maintenance 2220
Crimp Height Inspection 2220
Visual Inspection 2220
Maintenance 2221
How to Use Pro-Crimper II Tool 2221
AMP Superseal 1 5 Connector Assemblies 2222
Description 2222
Repair and Maintenance 2229
Panel Mount Option 2229
AMP Fastin-Faston Hand Tools 2230
Description – AMP Double Action Hand Tool 2230
Maintenance and Inspection Procedures 2230
Daily Maintenance 2230
Periodic Tool Inspection 2231
Lubrication 2231
Visual Inspection 2231
Crimp Height Inspection 2231
Certi-Crimp Ratchet Inspection 2232
How to Use AMP Double Action Hand Tool 2233
Description – AMP Extraction Tool 2234
Maintenance and Inspection 2235
How to Use AMP Extraction Tool 2235
AMP Fastin-Faston Receptacles and Housings 2237
Description 2237
Wire Repair 2245
Wire Splicing Requirements 2245
Deutsch Jiffy Splice 2246
Twisted/Shielded Cable and Leads Repair 2252
Special Tools 2254
524223769-2200YRM1128-(07-2020)-US-EN 2263
Series Code / Model Designation Reference Table 2269
General 2272
Deutsch Crimping Tool 2272
How to Strip a Wire for Use With Deutsch Crimping Tool 2272
How to Crimp With the Deutsch Crimping Tool 2273
Calibration Test for the Deutsch Crimping Tool 2275
Deutsch Connectors 2277
DT, DTM, and DTP Series Connectors 2277
HD Series Connectors 2319
Metri-Pack Connectors 2342
Remove and Install 2342
Micro-Pack Connectors 2344
Weather-Pack Connectors 2345
AMPSEAL Crimping Tools 2347
AMP Hand Crimping Tool With Certi-Crimp 2347
Description 2347
Stripping Wire for Use with AMP Hand Crimping Tool 2347
Insulation Crimp Adjustment 2348
Maintenance and Inspection for AMP Hand Crimping Tool 2348
AMP Hand Crimping Tool 2348
Crimp Height Inspection 2348
How to use AMP Hand Crimping Tool 2349
AMP Pro-Crimper II Tool 2349
Description 2349
Remove and Install Die Set and Locator Assembly 2350
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2351
Contact Support Adjustment 2351
Crimp Height Adjustment 2352
Maintenance and Inspection Procedures 2352
PRO-CRIMPER II Tool 2352
Crimp Height Inspection 2352
How to Use AMP PRO-CRIMPER II Tool 2353
AMPSEAL Connector Assemblies 2354
Description for Plug Connector Assembly 2354
Seal Plug 2355
Contact Crimping 2355
Description for Plug Connector and Header Assembly 2360
Voltage Reading 2362
Seal Plug 2362
Contact Crimping 2362
AMP Superseal 1 5 Crimping Tools 2369
Mini Mic Receptacle and Tab Contacts 2369
Description 2369
Crimping Conditions and Measurements 2369
Insertion of Rubber Seal on Cable 2371
AMP Hand Application Tool 2376
Description 2376
Maintenance and Inspection 2376
Crimp Height Inspection 2376
Crimp Height Adjustment 2377
How to Use AMP Hand Application Tool 2377
AMP Pro-Crimper II Tool 2378
Description 2378
Remove and Install Die Set and Locator Assembly 2379
Adjustments 2379
Contact Support 2379
Crimp Height 2380
Inspections and Maintenance 2381
Crimp Height Inspection 2381
Visual Inspection 2381
Maintenance 2382
How to Use Pro-Crimper II Tool 2382
AMP Superseal 1 5 Connector Assemblies 2383
Description 2383
Repair and Maintenance 2390
Panel Mount Option 2390
AMP Fastin-Faston Hand Tools 2391
Description – AMP Double Action Hand Tool 2391
Maintenance and Inspection Procedures 2391
Daily Maintenance 2391
Periodic Tool Inspection 2392
Lubrication 2392
Visual Inspection 2392
Crimp Height Inspection 2392
Certi-Crimp Ratchet Inspection 2393
How to Use AMP Double Action Hand Tool 2394
Description – AMP Extraction Tool 2395
Maintenance and Inspection 2395
How to Use AMP Extraction Tool 2396
AMP Fastin-Faston Receptacles and Housings 2397
Description 2397
Wire Repair 2404
Wire Splicing Requirements 2404
Deutsch Jiffy Splice 2405
Twisted/Shielded Cable and Leads Repair 2410
Special Tools 2413
524223770-2200YRM1130-(03-2020)-US-EN 2421
General 2425
Description 2425
Dash Display Menu Access 2425
Menu Navigation 2426
Standard Display 2426
Main Menu 2426
Passwords Menu 2427
Password Administration 2427
Add Password 2427
Delete Password 2428
Edit Password 2428
Other Password Functions 2429
Operator Passwords – Enable/Disable 2429
Password Time-Out Delay 2429
Passwords – Number Wrong to Disable 2430
Lockout Reset Password 2430
View Password Log 2431
View Versions 2432
VSM Versions 2432
Dash Display Versions 2433
Engine Controller Version 2434
Transmission (Xmsn) Controller Version 2435
Truck Serial Number 2436
Diagnostics 2437
View Fault Log 2437
Set Travel and Braking 2438
Speed Limit 2438
Acceleration Rate 2439
Auto-Deceleration Rate 2439
Set Power Reversal Rate 2440
Set Inching/Brake Overlap 2441
Setup Display Menu 2442
Set Operator Language 2442
Set Units 2443
Set Time Format (12/24 Hour) 2443
Set Daylight Saving Time 2443
Set Time 2446
Set Date Format 2447
Set Date 2447
Setup Hydraulics 2448
Return to Set Tilt Delay/On/Off 2448
Setup General Items 2449
Light Shutdown Time-Out 2449
Impact Sensor – Enable/Disable 2450
Impact Sensor – Soft Impact Settings 2451
Impact Sensor – Hard Impact Settings 2452
Adjust Impact Sensor Settings 2452
Initial Adjustment of Soft and Hard Impact Settings 2454
Readjustment of Soft and Hard Impact Settings 2454
Impact Sensor – Impact Alarm/Shutdown Reset 2455
Impact Sensor – Alarm Time Duration and Deactivation 2456
Impact Sensor – View Impact Event Log 2457
Engine Mode Indicator 2458
Generation 1 (ECO-eLo ONLY) 2458
Generation 2 2459
Operator Checklist 2460
Operator Checklist Off-On Mode 2460
Edit Operator Checklist 2460
Set Operator Checklist Expiration 2461
View Checklist Log 2461
Clear Operator Checklist Log 2462
Clear Operator Checklist Fault 2462
Calibrations 2463
Set Tilt Stop Point 2463
Calibrate Loaded Weight 2463
524223770-2200YRM1130-(05-2021)-US-EN 2465
General 2469
Description 2469
Dash Display Menu Access 2469
Menu Navigation 2470
Standard Display 2470
Main Menu 2470
Passwords Menu 2471
Password Administration 2471
Add Password 2471
Delete Password 2471
Edit Password 2472
Other Password Functions 2473
Operator Passwords – Enable/Disable 2473
Password Time-Out Delay 2473
Passwords – Number Wrong to Disable 2473
Lockout Reset Password 2474
View Password Log 2474
View Versions 2475
VSM Versions 2475
Dash Display Versions 2476
Engine Controller Version 2477
Transmission (Xmsn) Controller Version 2478
Truck Serial Number 2479
Diagnostics 2480
View Fault Log 2480
Set Travel and Braking 2481
Speed Limit 2481
Acceleration Rate 2482
Auto-Deceleration Rate 2482
Set Power Reversal Rate 2483
Set Inching/Brake Overlap 2484
Setup Display Menu 2485
Set Operator Language 2485
Set Units 2486
Set Time Format (12/24 Hour) 2486
Set Daylight Saving Time 2487
Set Time 2490
Set Date Format 2490
Set Date 2491
Setup Hydraulics 2492
Return to Set Tilt Delay/On/Off 2492
Setup General Items 2493
Light Shutdown Time-Out 2493
Impact Sensor – Enable/Disable 2494
Impact Sensor – Soft Impact Settings 2495
Impact Sensor – Hard Impact Settings 2495
Adjust Impact Sensor Settings 2496
Initial Adjustment of Soft and Hard Impact Settings 2498
Readjustment of Soft and Hard Impact Settings 2498
Impact Sensor – Impact Alarm/Shutdown Reset 2499
Impact Sensor – Alarm Time Duration and Deactivation 2500
Impact Sensor – View Impact Event Log 2501
Engine Mode Indicator 2501
Generation 1 (ECO-eLo ONLY) 2501
Generation 2 2502
Operator Checklist 2503
Operator Checklist Off-On Mode 2503
Edit Operator Checklist 2503
Set Operator Checklist Expiration 2503
View Checklist Log 2504
Clear Operator Checklist Log 2505
Clear Operator Checklist Fault 2505
Calibrations 2506
Set Tilt Stop Point 2506
Calibrate Loaded Weight 2506
524223771-2200YRM1131-(03-2020)-US-EN 2509
Series Code / Model Designation Reference Table 2515
General 2517
Description 2517
Dash Display Menu Access 2517
Menu Navigation 2518
Main Menu 2518
Passwords 2519
Adding Passwords 2519
Hourmeters 2521
View Versions 2522
VSM Versions 2522
Dash Display Versions 2523
Engine Controller Version 2524
Transmission (Xmsn) Controller Version 2525
Truck Serial Number 2526
Truck Configuration 2527
Diagnostics 2528
Clear Fault Log 2528
View Fault Log 2529
No-Run Data Display 2530
Engine Accelerator and Throttle Data Display 2530
Engine Speeds and Governor Data Display 2531
Engine Fuel and Emissions Data Display 2532
Engine General Data Display 2534
XMSN/Brake Data Display 2535
Hydraulic Data Display 2538
General Truck Data Display 2540
Set Travel and Braking 2541
Speed Limit 2541
Acceleration Rate 2542
Auto-Deceleration Rate 2543
Set Power Reversal Rate 2543
Set Inching/Brake Overlap 2544
Setup Hydraulics 2544
Lift Maximum Speed 2545
Lower Maximum Speed 2545
Tilt Maximum Speed 2546
Auxiliary Function One, Direction A, Maximum Speed 2548
Auxiliary Function One, Direction B, Maximum Speed 2550
Auxiliary Function Two, Direction A, Maximum Speed 2550
Auxiliary Function Two, Direction B, Maximum Speed 2551
Auxiliary Function Three, Direction A, Maximum Speed 2552
Auxiliary Function Three, Direction B, Maximum Speed 2552
Lift/Lower Ramp Rate 2553
Hydraulic Auxiliary Ramp Rate 2553
Return to Set Tilt Delay/On/Off 2554
Hydraulic Input Device 2555
Auxiliary Solenoid 2555
Dual Function 2556
Setup Display 2557
Set Service Language 2557
Setup General Items 2557
Motion Alarm Activation Type 2558
Light Shutdown Time-Out 2559
Restore Default Settings 2559
Restore Engine Controller Default Calibration 2560
Impact Sensor – Enable/Disable 2560
Impact Sensor – Soft Impact Settings 2561
Impact Sensor – Hard Impact Settings 2562
Adjust Impact Sensor Settings 2563
Initial Adjustment of Soft and Hard Impact Settings 2565
Readjustment of Soft and Hard Impact Settings 2565
Impact Sensor – Impact Alarm/Shutdown Reset 2566
Impact Sensor – Alarm Time Duration and Deactivation 2567
Impact Sensor – View Impact Event Log 2568
Engine Mode Indicator 2568
Generation 1 (ECO-eLo ONLY) 2568
Generation 2 2569
Diesel Particulate Filter (DPF) Display 2570
General Description 2570
Passive Regeneration Only 2570
Regeneration Level 0 2570
Auto/Active Regeneration Inhibited 2571
Auto/Active Regeneration 2571
Regeneration Level 1 2571
Parked Regeneration Request 2572
Regeneration Level 2 2572
Warning Level 2572
Regeneration Level 3 2572
Service Level 2573
Regeneration Level 4 2573
Display, Diesel Particulate Filter (DPF), Revised 2573
Operator Interface 2573
Refer to Operator Manual 2573
CAN Communication Lost 2574
Passive Regeneration Only 2574
Regeneration Level 0 2574
Auto/Active Regeneration Inhibited 2574
Auto/Active Regeneration 2575
Regeneration Level 1 2575
Idle-up Auto/Active Regeneration 2575
Parked Regeneration Request 2575
Regeneration Level 2 2575
Warning Level 2577
Regeneration Level 3 2577
Service Level 2577
Regeneration Level 4 2577
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2577
Display, Diesel Particulate Filter (DPF), Stage V Engine 2577
Operator Interface 2578
Refer to Operator Manual 2578
CAN Communication Lost 2578
Passive Regeneration Only 2578
Regeneration Level 0 2578
Auto/Active Regeneration Inhibited 2579
Auto/Active Regeneration 2579
Regeneration Level 1 2579
Idle-up Auto/Active Regeneration 2580
Parked Regeneration Request 2580
Regeneration Level 2 2580
Warning Level 2581
Regeneration Level 3 2581
Service Level 2582
Regeneration Level 4 2582
Stage V Content 2582
Emissions System Malfunction 2582
Ash Load 2582
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2583
Operator Interface 2583
Refer to Operator Manual 2583
CAN Communication Lost 2584
Passive Regeneration Only 2584
Regeneration Level 0 2584
Auto/Active Regeneration Inhibited 2584
Auto/Active Regeneration 2585
Regeneration Level 1 2585
Idle-up Auto/Active Regeneration 2585
Parked Regeneration Request 2585
Regeneration Level 2 2585
Warning Level 2587
Regeneration Level 3 2587
Service Level 2587
Regeneration Level 4 2587
Calibrations 2588
Calibrate Transmission Valve 2590
Set Tilt Stop Point 2590
Calibrate Loaded Weight 2590
Calibrate Travel Speed Sensor 2591
Calibrate Mazda LP and Gas Accelerator Pedal 2591
524223771-2200YRM1131-(05-2021)-US-EN 2593
Series Code / Model Designation Reference Table 2599
General 2601
Description 2601
Dash Display Menu Access 2601
Menu Navigation 2602
Main Menu 2603
Passwords 2603
Adding Passwords 2603
Hourmeters 2605
View Versions 2606
VSM Versions 2606
Dash Display Versions 2607
Engine Controller Version 2608
Transmission (Xmsn) Controller Version 2609
Truck Serial Number 2610
Truck Configuration 2611
Diagnostics 2612
Clear Fault Log 2612
View Fault Log 2613
No-Run Data Display 2614
Engine Accelerator and Throttle Data Display 2615
Engine Speeds and Governor Data Display 2617
Engine Fuel and Emissions Data Display 2618
Engine General Data Display 2620
XMSN/Brake Data Display 2621
Hydraulic Data Display 2623
General Truck Data Display 2626
Set Travel and Braking 2628
Speed Limit 2628
Acceleration Rate 2629
Auto-Deceleration Rate 2629
Set Power Reversal Rate 2630
Set Inching/Brake Overlap 2630
Setup Hydraulics 2631
Lift Maximum Speed 2631
Lower Maximum Speed 2632
Tilt Maximum Speed 2632
Auxiliary Function One, Direction A, Maximum Speed 2634
Auxiliary Function One, Direction B, Maximum Speed 2637
Auxiliary Function Two, Direction A, Maximum Speed 2637
Auxiliary Function Two, Direction B, Maximum Speed 2638
Auxiliary Function Three, Direction A, Maximum Speed 2639
Auxiliary Function Three, Direction B, Maximum Speed 2639
Lift/Lower Ramp Rate 2640
Hydraulic Auxiliary Ramp Rate 2640
Return to Set Tilt Delay/On/Off 2641
Hydraulic Input Device 2642
Auxiliary Solenoid 2642
Dual Function 2643
Setup Display 2644
Set Service Language 2644
Setup General Items 2644
Motion Alarm Activation Type 2645
Light Shutdown Time-Out 2646
Restore Default Settings 2646
Restore Engine Controller Default Calibration 2647
Impact Sensor – Enable/Disable 2647
Impact Sensor – Soft Impact Settings 2648
Impact Sensor – Hard Impact Settings 2648
Adjust Impact Sensor Settings 2649
Initial Adjustment of Soft and Hard Impact Settings 2651
Readjustment of Soft and Hard Impact Settings 2651
Impact Sensor – Impact Alarm/Shutdown Reset 2652
Impact Sensor – Alarm Time Duration and Deactivation 2653
Impact Sensor – View Impact Event Log 2654
Engine Mode Indicator 2654
Generation 1 (ECO-eLo ONLY) 2654
Generation 2 2655
Diesel Particulate Filter (DPF) Display 2656
General Description 2656
Passive Regeneration Only 2656
Regeneration Level 0 2656
Auto/Active Regeneration Inhibited 2657
Auto/Active Regeneration 2657
Regeneration Level 1 2657
Parked Regeneration Request 2658
Regeneration Level 2 2658
Warning Level 2659
Regeneration Level 3 2659
Service Level 2659
Regeneration Level 4 2659
Display, Diesel Particulate Filter (DPF), Revised 2659
Operator Interface 2660
Refer to Operator Manual 2660
CAN Communication Lost 2660
Passive Regeneration Only 2660
Regeneration Level 0 2660
Auto/Active Regeneration Inhibited 2661
Auto/Active Regeneration 2661
Regeneration Level 1 2661
Idle-up Auto/Active Regeneration 2661
Parked Regeneration Request 2662
Regeneration Level 2 2662
Warning Level 2663
Regeneration Level 3 2663
Service Level 2663
Regeneration Level 4 2663
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2664
Display, Diesel Particulate Filter (DPF), Stage V Engine 2664
Operator Interface 2664
Refer to Operator Manual 2664
CAN Communication Lost 2665
Passive Regeneration Only 2665
Regeneration Level 0 2665
Auto/Active Regeneration Inhibited 2665
Auto/Active Regeneration 2666
Regeneration Level 1 2666
Idle-up Auto/Active Regeneration 2666
Parked Regeneration Request 2666
Regeneration Level 2 2666
Warning Level 2668
Regeneration Level 3 2668
Service Level 2668
Regeneration Level 4 2668
Stage V Content 2668
Emissions System Malfunction 2668
Ash Load 2669
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2670
Operator Interface 2670
Refer to Operator Manual 2670
CAN Communication Lost 2671
Passive Regeneration Only 2671
Regeneration Level 0 2671
Auto/Active Regeneration Inhibited 2671
Auto/Active Regeneration 2672
Regeneration Level 1 2672
Idle-up Auto/Active Regeneration 2672
Parked Regeneration Request 2672
Regeneration Level 2 2672
Warning Level 2674
Regeneration Level 3 2674
Service Level 2674
Regeneration Level 4 2674
Calibrations 2675
Calibrate Transmission Valve 2677
Set Tilt Stop Point 2677
Calibrate Loaded Weight 2678
Calibrate Travel Speed Sensor 2678
Calibrate Mazda LP and Gas Accelerator Pedal 2679
524223780-8000YRM1134-(03-2020)-US-EN 2681
Series Code / Model Designation Reference Table 2687
Description 2689
Proc_Cal_001: Service Password Entry 2691
When to Perform 2691
Why Perform 2691
How to Perform 2691
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2692
When to Perform 2692
Calibration Order 2692
Why Perform 2692
How to Perform 2693
Proc_Cal_003: Save and Exit 2694
When to Perform 2694
Why Perform 2694
How to Perform 2694
Proc_Cal_004: Lift Valve Output Threshold 2695
When to Perform 2695
Calibration Order 2695
Why Perform 2695
How to Perform 2696
Proc_Cal_005: Lower Valve Output Threshold 2698
When to Perform 2698
Calibration Order 2698
Why Perform 2698
How to Perform 2698
Proc_Cal_006: Tilt Back Valve Output Threshold 2701
When to Perform 2701
Calibration Order 2701
Why Perform 2701
How to Perform 2701
Proc_Cal_007: Tilt Forward Valve Output Threshold 2704
When to Perform 2704
Calibration Order 2704
Why Perform 2704
How to Perform 2704
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2707
When to Perform 2707
Calibration Order 2707
Why Perform 2707
How to Perform 2707
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2710
When to Perform 2710
Calibration Order 2710
Why Perform 2710
How to Perform 2710
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2713
When to Perform 2713
Calibration Order 2713
Why Perform 2713
How to Perform 2713
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2716
When to Perform 2716
Calibration Order 2716
Why Perform 2716
How to Perform 2716
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2719
When to Perform 2719
Calibration Order 2719
Why Perform 2719
How to Perform 2719
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2722
When to Perform 2722
Calibration Order 2722
Why Perform 2722
How to Perform 2722
Proc_Cal_014: Load Weight Zero Point 2726
When to Perform 2726
Calibration Order 2726
Why Perform 2726
How to Perform 2726
Proc_Cal_015: Loaded Weight Calibration 2728
When to Perform 2728
Calibration Order 2728
Why Perform 2728
How to Perform 2728
Proc_Cal_016: Transmission Valve Calibration 2731
Applicable System/Option 2731
When to Perform 2731
Calibration Order 2731
Why Perform 2731
How to Perform 2731
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2733
Applicable System/Option 2733
When to Perform 2733
Calibration Order 2733
Why Perform 2733
How to Perform 2733
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2735
Applicable System/Option 2735
When to Perform 2735
Calibration Order 2735
Why Perform 2735
How to Perform 2736
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2737
Required Tools 2737
When to Perform 2737
Calibration Order 2737
Why Perform 2738
How to Perform 2738
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2739
When to Perform 2739
Why Perform 2739
How to Perform 2739
Proc_Cal_026: Travel Speed Calibration 2741
When to Perform 2741
Calibration Order 2741
Why Perform 2741
How to Perform 2741
524223780-8000YRM1134-(05-2022)-US-EN 2745
Series Code / Model Designation Reference Table 2751
Description 2754
Proc_Cal_001: Service Password Entry 2756
When to Perform 2756
Why Perform 2756
How to Perform 2756
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2757
When to Perform 2757
Calibration Order 2757
Why Perform 2757
How to Perform 2757
Proc_Cal_003: Save and Exit 2759
When to Perform 2759
Why Perform 2759
How to Perform 2759
Proc_Cal_004: Lift Valve Output Threshold 2760
When to Perform 2760
Calibration Order 2760
Why Perform 2760
How to Perform 2760
Proc_Cal_005: Lower Valve Output Threshold 2763
When to Perform 2763
Calibration Order 2763
Why Perform 2763
How to Perform 2763
Proc_Cal_006: Tilt Back Valve Output Threshold 2766
When to Perform 2766
Calibration Order 2766
Why Perform 2766
How to Perform 2766
Proc_Cal_007: Tilt Forward Valve Output Threshold 2769
When to Perform 2769
Calibration Order 2769
Why Perform 2769
How to Perform 2769
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2772
When to Perform 2772
Calibration Order 2772
Why Perform 2772
How to Perform 2772
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2775
When to Perform 2775
Calibration Order 2775
Why Perform 2775
How to Perform 2775
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2778
When to Perform 2778
Calibration Order 2778
Why Perform 2778
How to Perform 2778
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2781
When to Perform 2781
Calibration Order 2781
Why Perform 2781
How to Perform 2781
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2784
When to Perform 2784
Calibration Order 2784
Why Perform 2784
How to Perform 2784
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2787
When to Perform 2787
Calibration Order 2787
Why Perform 2787
How to Perform 2787
Proc_Cal_014: Load Weight Zero Point 2790
When to Perform 2790
Calibration Order 2790
Why Perform 2790
How to Perform 2790
Proc_Cal_015: Loaded Weight Calibration 2792
When to Perform 2792
Calibration Order 2792
Why Perform 2792
How to Perform 2792
Proc_Cal_016: Transmission Valve Calibration 2795
Applicable System/Option 2795
When to Perform 2795
Calibration Order 2795
Why Perform 2795
How to Perform 2795
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2797
Applicable System/Option 2797
When to Perform 2797
Calibration Order 2797
Why Perform 2797
How to Perform 2797
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2800
Applicable System/Option 2800
When to Perform 2800
Calibration Order 2800
Why Perform 2800
How to Perform 2800
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2803
Required Tools 2803
When to Perform 2803
Calibration Order 2803
Why Perform 2803
How to Perform 2803
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2805
When to Perform 2805
Why Perform 2805
How to Perform 2805
Proc_Cal_026: Travel Speed Calibration 2807
When to Perform 2807
Calibration Order 2807
Why Perform 2807
How to Perform 2807
524262278-1400YRM1246-(02-2018)-US-EN 2811
General 2815
Identification Plate 2816
Drive Axle Removal 2816
Hub Seal Replacement 2828
Planetary Reduction Repair 2837
Clean and Inspect 2846
Brake Repair 2859
Clean and Inspect 2875
Wet Brake Noise Reduction 2891
General 2891
Adding Additive To Transmission 2892
Bevel Pinion 2893
Clean and Inspect 2898
Differential Unit 2910
Disassemble 2921
Clean and Inspect 2927
Assemble 2928
Drive Axle Installation 2951
Special Tools 2961
Torque Specifications 2961
524262279-1800YRM1247-(06-2021)-US-EN 2965
General 2969
Dry Brake System 2969
Wet Brake System 2969
Service Brakes Repair (Dry Brake) 2973
Remove and Disassemble 2973
Clean 2975
Inspect 2976
Assemble and Install 2977
Adjust 2980
Parking Brake Repair 2981
Dry Brake System 2981
Remove and Disassembly 2981
Assemble and Install 2983
Wet Brake System 2983
Remove and Install 2983
Assemble and Install 2990
Adjust 2990
Dry Brake System 2990
Wet Brake System 2991
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 2991
Master Cylinder Repair 2993
Remove 2993
Disassemble 2997
Clean and Inspect 2998
Assemble 2999
Install and Adjust 2999
Accumulator 3002
Pre-Charge Check 3002
Remove 3003
Install 3005
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3006
Remove 3006
Modulating Brake Valve 3008
Disassemble 3008
Clean and Inspect 3009
Assemble 3009
Accumulator Charge Valve 3010
Disassemble 3010
Clean and Inspect 3012
Assemble 3012
Install 3013
Pressure Checks 3014
Accumulator Charge Valve Check 3014
Accumulator Check 3014
Service Brakes Adjustment (Dry Brake) 3015
Service Brakes Adjustment 3015
Brake System Air Removal 3017
Using Pressure Bleed System 3017
Using Brake Pedal Pressure 3017
Lift Truck Models with Master Cylinder 3017
Lift Truck Models with Modulating Brake Valve 3018
Brake Pedal Adjustment 3019
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) 3019
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3020
Free Pedal Adjustment 3022
Torque Specifications 3023
524262279-1800YRM1247-(09-2018)-US-EN 3025
General 3029
Dry Brake System 3029
Wet Brake System 3030
Service Brakes Repair (Dry Brake) 3034
Remove and Disassemble 3034
Clean 3036
Inspect 3037
Assemble and Install 3037
Adjust 3041
Parking Brake Repair 3041
Dry Brake System 3042
Remove and Disassembly 3042
Assemble and Install 3044
Wet Brake System 3044
Remove and Install 3045
Assemble and Install 3051
Adjust 3051
Dry Brake System 3051
Wet Brake System 3052
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3052
Master Cylinder Repair 3053
Remove 3053
Disassemble 3058
Clean and Inspect 3059
Assemble 3060
Install and Adjust 3060
Accumulator 3062
Pre-Charge Check 3063
Remove 3064
Install 3066
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3066
Remove 3067
Modulating Brake Valve 3068
Disassemble 3068
Clean and Inspect 3070
Assemble 3070
Accumulator Charge Valve 3071
Disassemble 3071
Clean and Inspect 3073
Assemble 3073
Install 3074
Pressure Checks 3075
Accumulator Charge Valve Check 3075
Accumulator Check 3075
Service Brakes Adjustment (Dry Brake) 3076
Service Brakes Adjustment 3076
Brake System Air Removal 3077
Using Pressure Bleed System 3077
Using Brake Pedal Pressure 3078
Lift Truck Models with Master Cylinder 3078
Lift Truck Models with Modulating Brake Valve 3078
Brake Pedal Adjustment 3079
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) 3079
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3080
Free Pedal Adjustment 3082
Torque Specifications 3083
524265342-4000YRM1250-(06-2021)-US-EN 3087
Safety Procedures When Working Near Mast 3093
Fork Replacement 3096
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3096
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3097
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) 3099
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3100
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3101
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) 3102
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3102
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) 3103
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3104
Fixed Carriage Replacement 3106
Remove, Carriage With Hook Forks 3106
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3114
Install, Carriage With Hook Forks 3115
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3115
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3116
Connecting Attachment Hydraulic Quick Disconnect Hoses 3116
Integral Sideshift Carriage Repair 3117
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) 3117
Disassemble 3117
Clean and Inspect 3120
Assemble 3120
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) 3121
Hang On Sideshift Carriage Repair 3122
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) 3122
Disassemble 3134
Clean and Inspect 3143
Assemble 3144
Install 3145
Hang-On Sideshift Carriage Repair 3147
Remove 3147
Disassemble Carriage 3149
Clean and Inspect 3152
Assemble 3152
Install 3155
Fork Positioner 3158
Two-Stage Mast With Limited Free-Lift Repair 3159
Remove 3159
Disassemble 3162
Clean and Inspect 3165
Assemble 3183
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) 3185
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) 3187
Header Hose Alignment 3198
Two-Stage Mast With Full Free-Lift Repair 3209
Remove 3209
Disassemble 3211
Clean and Inspect 3222
Assemble 3223
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) 3225
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) 3228
Header Hose Installation and Adjustment 3232
Installation 3232
Adjustment 3233
Three-Stage Mast With Full Free-Lift Repair 3234
Remove 3234
Disassemble 3236
Clean and Inspect 3266
Assemble 3268
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) 3271
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) 3276
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) 3283
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) 3290
Mast Operation Check 3294
Tilt Cylinder Adjustment 3295
Lift Chains Adjustment 3295
Mast Adjustments 3297
Load Roller Adjustment 3297
Mast Side Kicking Adjustment 3299
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 3300
Carriage Adjustments 3302
Series Code / Model Designation Reference Table 3303
524265342-4000YRM1250-(09-2018)-US-EN 3307
Safety Procedures When Working Near Mast 3313
Fork Replacement 3315
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3315
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3317
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) 3318
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3319
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3320
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) 3321
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3321
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) 3323
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3323
Fixed Carriage Replacement 3325
Remove, Carriage With Hook Forks 3325
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3334
Install, Carriage With Hook Forks 3335
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3335
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3336
Connecting Attachment Hydraulic Quick Disconnect Hoses 3336
Integral Sideshift Carriage Repair 3337
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) 3337
Disassemble 3337
Clean and Inspect 3340
Assemble 3340
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) 3341
Hang On Sideshift Carriage Repair 3341
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) 3341
Disassemble 3353
Clean and Inspect 3362
Assemble 3363
Install 3364
Bolzoni Hang-On Sideshift Carriage Repair 3366
Remove 3366
Disassemble Carriage 3368
Clean and Inspect 3371
Assemble 3371
Install 3374
Fork Positioner 3376
Two-Stage Mast With Limited Free-Lift Repair 3377
Remove 3377
Disassemble 3381
Clean and Inspect 3384
Assemble 3401
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) 3403
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) 3404
Header Hose Alignment 3416
Two-Stage Mast With Full Free-Lift Repair 3426
Remove 3426
Disassemble 3428
Clean and Inspect 3440
Assemble 3441
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) 3443
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) 3446
Header Hose Installation and Adjustment 3450
Installation 3450
Adjustment 3450
Three-Stage Mast With Full Free-Lift Repair 3451
Remove 3451
Disassemble 3453
Clean and Inspect 3483
Assemble 3484
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) 3488
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) 3493
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) 3500
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) 3506
Mast Operation Check 3510
Tilt Cylinder Adjustment 3510
Lift Chains Adjustment 3511
Mast Adjustments 3512
Load Roller Adjustment 3512
Mast Side Kicking Adjustment 3514
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 3515
Carriage Adjustments 3518
550048681-1300YRM1569-(11-2018)-US-EN 3521
General 3525
Serial Number 3525
Charge Pump Repair 3525
Lift Trucks Manufactured Before July, 2013 3525
Remove 3525
Inspect 3526
Install 3526
Lift Trucks Manufactured After July, 2013 3526
Remove 3526
Inspect 3527
Install 3527
Torque Converter Replace 3527
Remove 3527
Install 3533
Housings and Chain Drive Repair 3538
Remove 3539
Clean 3547
Inspect 3547
Install 3547
Clutch Packs Repair- 1 Speed Transmission 3553
Remove and Disassemble 3553
Transmission, Remove and Disassemble 3553
Clean 3565
Inspect 3565
Assemble and Install 3566
Transmission, Assemble and Install 3574
Clutch Packs Repair- 2 Speed Transmission 3577
Remove and Disassemble 3578
Transmission, Remove and Disassemble 3578
Clean 3592
Inspect 3592
Assemble and Install 3593
Transmission, Assemble and Install 3602
Control Valve Repair 3604
Remove and Disassemble 3605
Clean 3608
Inspect 3608
Assemble and Install 3608
Foot Directional Control Pedal Repair 3609
Remove and Disassemble 3609
Assemble and Install 3613
Direction Control Lever 3614
Remove 3614
Install 3614
550055280-1400YRM1582-(01-2019)-US-EN 3619
General 3623
Identification Plate 3623
Drive Axle Removal 3624
Reduction Gear Assembly 3629
Remove 3629
Disassemble 3632
Clean and Inspect 3636
Assemble 3636
Install 3645
Wet Disc Brake Repair 3648
General 3648
Remove 3649
Clean and Inspect 3652
Install 3653
Initial Steps For Install 3653
Final Steps For Install 3660
Wet Brake Noise Reduction 3663
General 3663
Adding Additive To Transmission 3663
Piston Housing 3665
Remove 3665
Disassemble 3666
Clean and Inspect 3667
Assemble 3667
Install 3668
Parking Brake Control Lever 3669
Remove 3669
Clean and Inspect 3670
Install 3670
Differential Repair 3672
Initial Removal Steps for Differential Housing and drive axle trumpet arm (right side) 3672
Input Pinion Carrier 3672
Remove 3673
Disassemble 3673
Clean and Inspect 3674
Assemble 3674
Preload Pinion Bearings 3676
Differential Housing and Drive Axle Trumpet Arm (Right Side) 3676
Remove 3678
Disassemble 3678
Clean and Inspect 3679
Assemble 3679
Install 3681
Ring Gear Backlash 3681
Final Installation Steps for Differential Housing and drive axle trumpet arm (right side) 3682
Pinion and Motor Carrier 3683
Install 3683
Drive Axle Installation 3686
Special Tools 3691
Special Tools 3691
Torque specifications 3693
550064329-1800YRM1597-(03-2017)-US-EN 3697
Wet Brake System 3701
Service Brake Repair 3702
Parking Brake Repair 3702
Remove and Disassemble 3702
Assemble and Install 3703
Adjust 3704
Lift Trucks With a Foot Directional Control Pedal or Forward Reverse Lever 3704
Master Cylinder and Booster 3704
Remove 3704
Disassemble 3706
Clean and Inspect 3707
Assemble 3707
Install and Adjust 3707
Brake System Air Removal 3709
Using Pressure Bleed System 3709
Using Brake Pedal Pressure 3710
Lift Truck Models with Master Cylinder 3710
Brake Pedal Adjustment 3711
Free Pedal Adjustment 3712
Torque Specifications 3712
550073240-1900YRM1620-(01-2023)-US-EN 3715
Proper Flushing after Major Hydraulic Repairs 3721
Introduction 3721
The Phases of Wear 3721
Causes of Hydraulic System Failure 3721
Progression of Contaminant Caused Hydraulic System Failure 3722
Hydraulic System Flushing Techniques 3722
Double Oil and Filter Change 3722
Mechanical Cleaning 3723
Cleaning of Components 3723
How to Clean Tubes and Hoses 3723
Filter Caddy 3723
Start-Up Procedure for Cleaned System 3724
Contaminated Oil Coolers 3724
Additional Filter Caddy Functions 3725
How to Handle Different Fluids 3725
Water Removal Filters 3725
Fluid Conditioning and System Flushing Procedures 3726
Operation of the Filter Caddy 3726
Filter Caddy operation 3726
Fluid Conditioning Procedure 3726
Filter Caddy Start-Up 3727
System Flushing Procedure 3727
Component Cleaning Procedure 3728
Reservoir Cleaning Procedure 3728
Cylinder Cleaning Procedure 3728
Hose and Tube Cleaning Procedure 3728
Valve Cleaning Procedure 3729
Front-End Attachment Cleaning Procedure 3730
System Flushing Procedure 3730
Filter Caddy Start-Up 3731
System Start-Up and Flushing 3731
Reservoir Fluid Cleaning Times 3732
Dealing With Different Fluid Types 3733
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 3733
Filter Caddy Maintenance 3733
Servicing the Strainer 3733
DC Motor 3733
Hydraulic Oil Sampling Method and Procedure 3734
Hydraulic Oil Sampling Method 3734
Objective 3734
General Guidelines 3734
Synopsis 3735
Hydraulic Oil Analysis Report Guidelines 3736
Sampling Conditions 3736
Equipment 3736
Sampling Procedure 3737
Hydraulic Oil Sampling 3737
Sample Labeling 3737
Results Documentation 3737
550073240-1900YRM1620-(03-2020)-US-EN 3739
Proper Flushing after Major Hydraulic Repairs 3743
Introduction 3743
The Phases of Wear 3743
Causes of Hydraulic System Failure 3743
Progression of Contaminant Caused Hydraulic System Failure 3744
Hydraulic System Flushing Techniques 3744
Double Oil and Filter Change 3744
Mechanical Cleaning 3745
Cleaning of Components 3745
How to Clean Tubes and Hoses 3745
Filter Caddy 3745
Start-Up Procedure for Cleaned System 3746
Contaminated Oil Coolers 3746
Additional Filter Caddy Functions 3746
How to Handle Different Fluids 3746
Water Removal Filters 3747
Fluid Conditioning and System Flushing Procedures 3747
Operation of the Filter Caddy 3747
Filter Caddy operation 3747
Fluid Conditioning Procedure 3748
Filter Caddy Start-Up 3748
System Flushing Procedure 3749
Component Cleaning Procedure 3749
Reservoir Cleaning Procedure 3749
Cylinder Cleaning Procedure 3749
Hose and Tube Cleaning Procedure 3750
Valve Cleaning Procedure 3750
Front-End Attachment Cleaning Procedure 3751
System Flushing Procedure 3751
Filter Caddy Start-Up 3752
System Start-Up and Flushing 3752
Reservoir Fluid Cleaning Times 3753
Dealing With Different Fluid Types 3753
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 3753
Filter Caddy Maintenance 3754
Servicing the Strainer 3754
DC Motor 3754
Hydraulic Oil Sampling Method and Procedure 3754
Hydraulic Oil Sampling Method 3754
Objective 3754
General Guidelines 3754
Synopsis 3755
Hydraulic Oil Analysis Report Guidelines 3756
Sampling Conditions 3757
Equipment 3757
Sampling Procedure 3757
Hydraulic Oil Sampling 3757
Sample Labeling 3758
Results Documentation 3758
550118409-0100YRM1891-(05-2017)-US-EN 3761
General 3765
Description 3766
Hood, Seat, and Side Covers Replacement 3769
Remove 3769
Install 3776
Hood Latch and Striker Bolt Adjustment 3782
Steering Column 3782
Description 3782
Steering Column Repair 3783
Remove 3783
Disassemble 3784
Clean 3786
Inspect 3786
Assemble 3786
Install 3786
LPG Tank and Bracket Replacement 3787
Counterweight Replacement 3787
Remove 3787
Install 3790
Tow Pin 3794
Operator Restraint System Replacement 3795
Description 3795
Emergency Locking Retractor (ELR) 3796
Overhead Guard Replacement 3797
Remove 3798
Install 3799
LED Tail, Backup, and Brake Lights, Replace 3799
Engine Replacement 3800
Remove Engine Only 3800
Install Engine only 3825
Remove Engine and Transmission 3828
Install Engine and Transmission 3832
Throttle Pedal and Cable Adjustment 3835
Kubota 3 6L Diesel Engine 3835
Exhaust System Repair 3837
4 3L Engine for Lift Truck Models GP/GLP080, 090, 100, 110, 120VX (K813) 3837
Kubota 3 8L LPG Engine for Lift Truck Models GLC40, 45, 55VX; GLC55SVX (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (G818) and GLP40VX5/VX6; GLP45SVX5, GLP/45VX6; GLP50-55VX (GLP080, 090, 100, 110, 120VX) (K813) 3837
Kubota 3 6L Diesel Engine for Lift Truck Models GDP40VX5/VX6; GDP45SVX5, GDP45VX6; GDP50-55VX (GDP080, 090, 100, 110, 120VX) (K813) 3837
Remove 3837
Inspect 3839
Install 3839
Kubota 3 8L Diesel Engine W/DOC for Lift Truck Models GDP40VX5/VX6; GDP45SVX5, GDP45VX6; GDP50-55VX (GDP080, 090, 100, 110, 120VX) (K813) 3839
Remove 3839
Inspect 3844
Install 3844
Kubota 3 8L Diesel Engine W/DPF for Lift Truck Models GDP40VX5/VX6; GDP45SVX5, GDP45VX6; GDP50-55VX (GDP080, 090, 100, 110, 120VX) (K813) 3845
Remove 3845
Inspect 3850
Diesel Particulate Filter (DPF) 3850
Disassemble 3850
Clean and Inspect 3851
Differential Pressure Pipes and Hoses 3852
Assembly 3852
Install 3852
Heavy Duty Pre-Cleaner, Kubota 3 6L and 3 8L Diesel Engines 3854
Remove 3854
Clean 3854
Inspect 3854
Install 3854
Cooling System 3854
Description 3854
Hydraulic Fan Drive 3855
Description 3855
Hydraulic Filter Assembly Repair 3855
Remove 3856
Disassemble 3856
Clean 3857
Inspect 3857
Assemble 3857
Install 3857
Fuel and Hydraulic Tanks Repair 3857
Inspect 3857
Clean 3858
Steam Method of Cleaning 3858
Chemical Solution Method of Cleaning 3859
Additional Preparations for Repair 3859
Small Leaks, Repair 3859
Large Leaks, Repair 3859
Preparations for Use After Repair 3859
Safety Labels 3859
550118410-0600YRM1893-(01-2022)-US-EN 3867
General 3875
Engine Identification 3875
Major Engine Component Identification 3875
Major Engine Component Identification 3876
Location of Labels 3877
Location of Labels 3878
Crankcase Description 3879
Engine Removal and Installation 3880
Cylinder Head Assembly Repair 3880
Valve Covers and Ignition Coils 3880
Remove 3880
Clean and Inspect 3885
Install 3885
Rocker Arm Assembly 3886
Remove 3886
Disassemble 3888
Clean and Inspect 3888
Push Rods 3888
Rocker Arm Assembly 3888
Assemble 3889
Install 3889
Valve Clearance Adjustments 3889
Cylinder Head Assembly 3890
Remove 3890
Disassemble 3896
Valves and Valve Springs, Remove 3896
Valve Guides, Remove 3897
Clean and Inspect 3897
Cylinder Head 3898
Valve Guides 3898
Valves 3899
Valve Sink 3899
Valve Seat 3899
Valve Springs 3900
Assemble 3900
Valve Guides, Install 3900
Valves and Valve Springs, Install 3901
Install 3902
Timing Gear Case and Timing Gears Repair 3905
Timing Gear Case Cover 3905
Remove 3905
Clean and Inspect 3905
Install 3905
Timing Gears 3906
Crankshaft Gear 3906
Remove 3906
Install 3907
Idler Gear 3907
Remove 3907
Inspect 3907
Install 3908
Camshaft Gear 3908
Remove 3908
Install 3908
Timing Gear Case 3909
Remove 3909
Clean and Inspect 3909
Install 3909
Drive Train, Camshaft, and Cylinder Block Repair 3910
Remove 3910
Disassemble 3910
Pistons and Connecting Rods 3910
Crankshaft 3911
Camshaft 3913
Clean and Inspect 3914
Cylinder Block 3914
Honing and Boring 3917
Cylinder Correction (Oversize) 3918
Pistons 3918
Piston Pin 3919
Connecting Rod 3919
Tappets 3920
Crankshaft 3920
Camshaft 3922
Camshaft Bushing 3923
Assemble 3923
Camshaft 3923
Crankshaft 3923
Pistons and Connecting Rods 3923
Install 3925
Lubrication System Repair 3927
Engine Oil and Oil Filter Change 3927
Oil Pan 3928
Remove 3928
Install 3928
Oil Suction Tube 3928
Remove 3928
Clean 3929
Install 3929
Oil Pump 3929
Remove 3929
Clean and Inspect 3930
Outer Rotor Outside Clearance 3930
Outer Rotor to Inner Rotor Tip Clearance 3930
Outer Rotor Side Clearance 3930
Rotor Shaft Clearance 3931
Install 3931
Fuel System Repair 3932
Cooling System Repair 3932
Serpentine Belt 3932
Remove 3932
Inspect 3932
Install 3932
Serpentine Belt, Adjustment 3932
Water Pump 3934
Remove 3934
Install 3936
Thermostat 3937
Remove 3937
Inspect 3938
Install 3938
Flywheel and Flywheel Housing 3940
Flywheel 3940
Remove 3940
Install 3940
Flywheel Housing 3940
Remove 3940
Install 3940
Electrical Equipment Repair 3941
Alternator 3941
Remove 3941
Install 3942
Starter 3943
Remove 3943
Install 3943
Engine Specifications 3944
Engine Data 3944
Engine Tuning 3949
Cylinder Head 3949
Intake/Exhaust Valve and Guide 3949
Valve Spring 3950
Rocker Arm and Shaft 3950
Push Rod 3950
Gear Train and Camshaft 3950
Camshaft 3950
Idle Gear Shaft and Bushing 3951
Backlash of Each Gear 3951
Cylinder Block 3951
Crankshaft 3951
Piston 3952
Piston Ring 3952
Connecting Rod 3952
Rod Small End 3952
Tappet 3953
Oil Pump 3953
Engine Oil Pressure 3953
Outer Rotor Outside Clearance 3953
Outer Rotor Side Clearance 3953
Inner Rotor to Cover 3953
Standard Torque Specifications 3954
Standard Torque Chart 3954
Special Torque Specifications 3955
Special Tools 3956
550118410-0600YRM1893-(07-2019)-US-EN 3965
General 3971
Engine Identification 3971
Major Engine Component Identification 3971
Location of Labels 3971
Crankcase Description 3972
Engine Removal and Installation 3973
Cylinder Head Assembly Repair 3974
Valve Covers and Ignition Coils 3974
Remove 3974
Clean and Inspect 3977
Install 3978
Rocker Arm Assembly 3978
Remove 3978
Disassemble 3979
Clean and Inspect 3980
Push Rods 3980
Rocker Arm Assembly 3980
Assemble 3981
Install 3981
Valve Clearance Adjustments 3981
Cylinder Head Assembly 3982
Remove 3982
Disassemble 3987
Valves and Valve Springs, Remove 3987
Valve Guides, Remove 3988
Clean and Inspect 3988
Cylinder Head 3989
Valve Guides 3989
Valves 3989
Valve Sink 3990
Valve Seat 3990
Valve Springs 3991
Assemble 3991
Valve Guides, Install 3991
Valves and Valve Springs, Install 3992
Install 3993
Timing Gear Case and Timing Gears Repair 3995
Timing Gear Case Cover 3995
Remove 3995
Clean and Inspect 3995
Install 3995
Timing Gears 3996
Crankshaft Gear 3996
Remove 3996
Install 3996
Idler Gear 3996
Remove 3996
Inspect 3997
Install 3997
Camshaft Gear 3997
Remove 3997
Install 3998
Timing Gear Case 3998
Remove 3998
Clean and Inspect 3998
Install 3998
Drive Train, Camshaft, and Cylinder Block Repair 3999
Remove 3999
Disassemble 3999
Pistons and Connecting Rods 3999
Crankshaft 4000
Camshaft 4002
Clean and Inspect 4003
Cylinder Block 4003
Honing and Boring 4006
Cylinder Correction (Oversize) 4007
Pistons 4007
Piston Pin 4008
Connecting Rod 4008
Tappets 4009
Crankshaft 4009
Camshaft 4011
Camshaft Bushing 4012
Assemble 4012
Camshaft 4012
Crankshaft 4012
Pistons and Connecting Rods 4012
Install 4014
Lubrication System Repair 4015
Engine Oil and Oil Filter Change 4015
Oil Pan 4015
Remove 4015
Install 4016
Oil Suction Tube 4016
Remove 4016
Clean 4016
Install 4016
Oil Pump 4017
Remove 4017
Clean and Inspect 4017
Outer Rotor Outside Clearance 4017
Outer Rotor to Inner Rotor Tip Clearance 4018
Outer Rotor Side Clearance 4018
Rotor Shaft Clearance 4018
Install 4018
Fuel System Repair 4019
Cooling System Repair 4019
Serpentine Belt 4019
Remove 4019
Inspect 4019
Install 4019
Serpentine Belt, Adjustment 4020
Water Pump 4021
Remove 4021
Install 4023
Thermostat 4024
Remove 4024
Inspect 4025
Install 4025
Flywheel and Flywheel Housing 4026
Flywheel 4026
Remove 4026
Install 4027
Flywheel Housing 4027
Remove 4027
Install 4027
Electrical Equipment Repair 4027
Alternator 4027
Remove 4027
Install 4028
Starter 4029
Remove 4029
Install 4029
Engine Specifications 4030
Engine Data 4030
Engine Tuning 4031
Cylinder Head 4031
Intake/Exhaust Valve and Guide 4032
Valve Spring 4032
Rocker Arm and Shaft 4032
Push Rod 4032
Gear Train and Camshaft 4033
Camshaft 4033
Idle Gear Shaft and Bushing 4033
Backlash of Each Gear 4033
Cylinder Block 4033
Crankshaft 4034
Piston 4034
Piston Ring 4034
Connecting Rod 4035
Rod Small End 4035
Tappet 4035
Oil Pump 4035
Engine Oil Pressure 4035
Outer Rotor Outside Clearance 4035
Outer Rotor Side Clearance 4035
Inner Rotor to Cover 4036
Standard Torque Specifications 4036
Standard Torque Chart 4036
Special Torque Specifications 4037
Special Tools 4038
550118411-1900YRM1894-(06-2016)-US-EN 4049
General 4053
Description 4055
Hydraulic Fan Drive Replacement 4062
Lift Truck Models GC/GLC60VX, GC/GLC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 4063
Remove 4063
Disassemble 4065
Clean and Inspect 4066
Assemble 4066
Install 4066
Lift Truck Models GLC40, 45, 55VX; GLC55SVX (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (G818) 4067
Remove 4067
Disassemble 4068
Clean and Inspect 4070
Assemble 4070
Install 4070
Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (K813) 4071
Remove 4071
Disassemble 4072
Clean and Inspect 4074
Assemble 4074
Install 4074
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 4074
Remove 4074
Disassemble 4076
Clean and Inspect 4077
Assemble 4077
Install 4077
Hydraulic Fan Drive Manifold 4077
Remove 4077
Install 4079
550118412-0700YRM1895-(08-2016)-US-EN 4083
General 4087
Cooling System Checks 4088
Exhaust Leaks Into Cooling System 4088
Water Flow Restrictions in Radiator 4088
Radiator Hoses 4088
Water Pump 4088
Flushing the Cooling System 4088
Cooling System, Clean 4089
Radiator Replacement 4090
Lift Truck Models GLC40, 45, 55VX; GLC55SVX (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (G818) 4090
Remove 4090
Install 4096
Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (K813) 4097
Remove 4097
Install 4104
Fan Assembly Replacement 4105
Fan Removal 4105
Inspect 4110
Fan Installation 4110
550118413-1600YRM1896-(03-2015)-US-EN 4113
550118414-1900YRM1897-(03-2020)-US-EN 4135
Series Code / Model Designation Reference Table 4139
General 4139
Hydraulic Gear Pump Assembly Repair 4141
Remove 4141
Disassemble 4143
Clean 4145
Inspect 4145
Assemble 4145
Install 4145
Hydraulic Gear Pump Specifications 4147
Variable Displacement Pump Repair 4148
Remove 4148
Disassemble 4151
Clean 4153
Inspect 4153
Assemble 4153
Install 4153
Variable Displacement Pump Checks and Adjustments 4155
Margin Pressure Check 4155
Flow Compensator Adjustment 4156
Pressure Compensator Adjustment 4156
Variable Displacement Pump Specifications 4157
Torque Specifications 4158
Hydraulic Gear Pump 4158
Variable Displacement Pump 4158
550118414-1900YRM1897-(06-2021)-US-EN 4161
Series Code / Model Designation Reference Table 4167
General 4168
Hydraulic Gear Pump Assembly Repair 4170
Remove 4170
Disassemble 4173
Clean 4175
Inspect 4175
Assemble 4175
Install 4175
Hydraulic Gear Pump Specifications 4177
Variable Displacement Pump Repair 4179
Remove 4179
Disassemble 4182
Clean 4184
Inspect 4184
Assemble 4184
Install 4184
Variable Displacement Pump Checks and Adjustments 4187
Margin Pressure Check 4187
Flow Compensator Adjustment 4187
Pressure Compensator Adjustment 4188
Variable Displacement Pump Specifications 4190
Torque Specifications 4191
Hydraulic Gear Pump 4191
Variable Displacement Pump 4191
550118415-2000YRM1898-(03-2020)-US-EN 4193
Series Code / Model Designation Reference Table 4197
General 4198
Electro-Hydraulic Main Control Valve 4198
Description 4198
Remove 4204
Electro-Hydraulic Control Valve Sections 4207
General 4207
Outlet Control Valve Section 4207
Remove 4207
Disassemble 4207
Clean 4210
Inspect 4210
Assemble 4210
Install 4211
Auxiliary Control Valve Sections 4211
Remove 4211
Disassemble 4213
Clean 4213
Inspect 4214
Assemble 4214
Install 4215
Tilt Control Valve Section 4215
Remove 4215
Disassemble 4215
Clean 4216
Inspect 4216
Assemble 4217
Install 4217
Lift/Lower Control Valve Section 4217
Remove 4217
Disassemble 4217
Clean 4219
Inspect 4219
Assemble 4219
Install 4219
Transition Section 4219
Remove 4219
Disassemble 4220
Clean 4220
Inspect 4220
Assemble 4221
Install 4221
Install 4221
Manual Main Control Valve 4223
Description 4223
Remove 4225
OPS Solenoid Assembly 4229
General 4229
Remove 4230
Clean and Inspect 4232
Install 4232
Manual Control Valve Sections 4233
General 4233
Outlet Control Valve Section 4233
Remove 4233
Disassemble 4233
Clean 4235
Inspect 4235
Assemble 4235
Install 4235
Auxiliary Control Valve Sections 4236
Remove 4236
Disassemble 4236
Clean 4238
Inspect 4238
Assemble 4238
Install 4238
Lift/Tilt Control Valve Section 4239
Remove 4239
Disassemble 4239
Clean 4241
Inspect 4242
Assemble 4242
Install 4243
Install 4243
Pressure Relief Valve Check and Adjustment 4246
Primary Relief Valve 4246
Secondary Relief Valve 4247
Steering Control Unit Repair 4250
Steering Control Unit, Remove 4250
Steering Control Unit, Disassemble 4251
Steering Control Unit, Clean 4253
Steering Control Unit, Inspect 4253
Steering Control Unit, Assemble 4253
Relief Valve, Disassemble 4254
Relief Valve, Clean 4254
Relief Valve, Inspect 4255
Relief Valve, Assemble 4255
Steering Control Unit, Install 4255
550118415-2000YRM1898-(06-2021)-US-EN 4259
Series Code / Model Designation Reference Table 4265
General 4266
Electro-Hydraulic Main Control Valve 4267
Description 4267
Remove 4273
Electro-Hydraulic Control Valve Sections 4277
General 4277
Outlet Control Valve Section 4277
Remove 4277
Disassemble 4277
Clean 4279
Inspect 4279
Assemble 4279
Install 4280
Auxiliary Control Valve Sections 4280
Remove 4280
Disassemble 4282
Clean 4282
Inspect 4283
Assemble 4283
Install 4284
Tilt Control Valve Section 4284
Remove 4284
Disassemble 4284
Clean 4286
Inspect 4286
Assemble 4286
Install 4286
Lift/Lower Control Valve Section 4286
Remove 4286
Disassemble 4286
Clean 4288
Inspect 4288
Assemble 4288
Install 4288
Transition Section 4288
Remove 4288
Disassemble 4289
Clean 4289
Inspect 4289
Assemble 4290
Install 4290
Install 4290
Manual Main Control Valve 4293
Description 4293
Remove 4295
OPS Solenoid Assembly 4299
General 4299
Remove 4300
Clean and Inspect 4302
Install 4302
Manual Control Valve Sections 4303
General 4303
Outlet Control Valve Section 4303
Remove 4303
Disassemble 4303
Clean 4305
Inspect 4305
Assemble 4305
Install 4305
Auxiliary Control Valve Sections 4306
Remove 4306
Disassemble 4306
Clean 4308
Inspect 4308
Assemble 4308
Install 4308
Lift/Tilt Control Valve Section 4309
Remove 4309
Disassemble 4309
Clean 4311
Inspect 4312
Assemble 4312
Install 4313
Install 4313
Pressure Relief Valve Check and Adjustment 4316
Primary Relief Valve 4316
Secondary Relief Valve 4317
Steering Control Unit Repair 4321
Steering Control Unit, Remove 4321
Steering Control Unit, Disassemble 4322
Steering Control Unit, Clean 4324
Steering Control Unit, Inspect 4324
Steering Control Unit, Assemble 4324
Relief Valve, Disassemble 4325
Relief Valve, Clean 4325
Relief Valve, Inspect 4326
Relief Valve, Assemble 4326
Steering Control Unit, Install 4326
550118417-2200YRM1901-(01-2020)-US-EN 4329
General 4337
Display Switch Cluster 4339
Remove 4339
Install 4341
Direction Control and Turn Signal Levers 4341
Remove 4341
Install 4342
Key Switch 4343
Remove 4343
Install 4344
Display Switch Cluster Panel Bezel and Overlay 4344
Remove 4344
Install 4344
Steering Column Repair 4344
Remove 4344
Disassemble 4346
Assemble 4346
Install 4347
Sensors and Switches 4347
General 4347
Dash Panel, Kick Panel, and Seal Plate, Remove and Install 4347
Remove 4347
Install 4348
Accelerator (Throttle) Pedal Position Sensor 4348
Remove 4348
Install 4349
Brake Fluid Level Switch 4350
Remove 4350
Install 4351
Service Brake Pedal Position Sensor 4352
Remove 4352
Install 4353
Service Brake Pressure Sensor 4354
Remove 4354
Install 4354
Parking Brake Position Sensor 4354
Remove 4354
Install 4354
Sensor MicroswitchFoot Directional Control 4355
Remove 4355
Install 4357
Low Coolant Level Sensor 4357
Remove 4357
Install 4358
Fuel Level Sensor, Gas and Diesel Engines Only 4359
Remove 4359
Install 4359
Seat Sensor (Operator Presence System) 4360
Non-Suspension and Semi-Suspension Seats 4360
Remove 4360
Install 4361
Full Suspension Seats 4362
Remove 4362
Install 4363
Hood Shut Off Switch 4363
Remove 4363
Install 4363
Remote Key Switch 4363
Remove 4363
Install 4364
Hydraulic Filter Pressure Switch 4364
Remove 4364
Install 4364
Transmission Speed Sensors 4365
Remove 4365
Install 4365
Transmission Pressure Sensors 4365
Remove 4365
Install 4366
Transmission Temperature Sensor 4366
Remove 4366
Install 4366
Return To Set Tilt (Tilt Angle) Sensor 4366
Remove 4366
Install 4367
Rear Horn Button Switch 4367
Remove 4367
Install 4368
Impact Sensor 4368
Remove 4368
Install 4369
Load Weight Sensor 4370
Remove 4370
Install 4370
Hydraulic Fan Drive Push Button Switch 4371
Remove 4371
Install 4371
Engine and Fuel Sensors and Switches – GM 4 3L Gas and LPG Engines 4372
Engine and Fuel Sensors and Switches – PSI 4 3L LPG Engine 4372
Engine and Fuel Sensors and Switches – Kubota 3 8L LPG and Bi-Fuel Engine 4372
Crankshaft Position Sensor 4373
Remove 4373
Install 4373
Camshaft Position Sensor 4373
Remove 4373
Install 4373
Oil Pressure Sensor 4374
Remove 4374
Install 4374
Engine Coolant Temperature (ECT) Sensor 4374
Remove 4374
Install 4374
Temperature And Manifold Absolute Pressure (TMAP) Sensor 4374
Remove 4374
Install 4375
Knock Sensor 4375
Remove 4375
Install 4375
Oxygen Sensors 4376
Air Flow Restriction Switch 4376
Remove 4376
Install 4376
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without Diesel Particulate Filter (DPF) 4377
Intake Air Temperature Sensor 4377
Remove 4377
Install 4378
Intake Air Pressure Sensor 4378
Remove 4378
Install 4378
Air Inlet Heater 4378
Remove 4378
Install 4378
Engine Oil Pressure Sensor 4378
Remove 4378
Install 4379
Engine Coolant Temperature (ECT) Sensor 4379
Remove 4379
Install 4379
Crankshaft Position Sensor 4379
Remove 4379
Install 4379
Adjust Shim Procedure 4380
Camshaft Position Sensor 4381
Remove 4381
Install 4381
Air Flow Restriction Sensor 4382
Remove 4382
Install 4382
Fuel/Water Separator 4382
Remove 4382
Install 4383
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With Diesel Particulate Filter (DPF) And Kubota 3 8L Diesel Engine (Tier 4), 55kW With Diesel Oxidation Catalyst (DOC) 4383
Intake Air Temperature Sensor 4385
Remove 4385
Install 4385
Boost Sensor 4386
Remove 4386
Install 4386
Throttle Valve Assembly, Air Intake Adapter and Air Intake Heater 4388
Remove 4388
Install 4389
Engine Coolant Temperature (ECT) Sensor 4389
Remove 4389
Install 4389
Engine Oil Pressure Sensor 4390
Remove 4390
Install 4390
Crankshaft Position Sensor 4390
Remove 4390
Install 4390
Adjust Shim Procedure 4391
Camshaft Position Sensor 4392
Remove 4392
Install 4392
Differential Pressure Sensor 4392
Remove 4392
Install 4393
Mass Air flow Sensor 4393
Remove 4393
Install 4393
Fuel/Water Separator 4393
Remove 4393
Install 4394
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 4395
Engine Coolant Temperature (ECT) Sensor 4395
Remove 4395
Install 4395
Engine Oil Pressure Sensor 4396
Remove 4396
Install 4396
Throttle Position Sensor 4396
Engine Speed Sensor 4396
Remove 4396
Install 4396
Fuel Shut Off Solenoid 4396
Remove 4396
Install 4396
Vehicle System Manager (VSM) 4397
General 4397
VSM Replacement 4397
Remove 4397
Install 4397
Programming a New VSM and/or Display Switch Cluster (DSC) 4398
Data Transferring 4399
New VSM 4399
New (Blank) Display Switch Cluster 4399
Used (Non-Blank) Display Switch Cluster 4399
PC Service Tool Software 4400
Power Distribution Module (PDM) and Component Parts 4401
Remove 4401
PDM as a Unit 4401
Install 4403
PDM as a Unit 4403
Remove and Install 4403
PDM Component Parts 4403
Battery 4403
Remove 4403
Install 4403
Lights 4404
Work Lights (Front and Rear) 4404
Halogen Bulb Lights 4404
Remove 4404
Install 4404
LED Lights 4404
Remove 4404
Install 4405
Strobe Light 4405
Remove 4405
Install 4405
LED Tail, Backup, and Brake Lights 4406
Remove 4406
Install 4406
Front Marker/Turn Signal Lights 4407
Replacing Whole Front Marker/Turn Signal Light Assembly 4407
Remove 4407
Install 4407
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 4408
Remove 4408
Install 4408
Diesel Particulate Filter (DPF) Display 4409
Remove 4409
Clean and Inspect 4409
Install 4409
Electronic-Hydraulic Controls, Before January, 2020 4410
E-Hydraulic Controls – Test 4410
Mini-Levers 4410
Full Stroke Test 4410
Function Returns to Neutral Test 4410
Push (Override) Button 4411
General 4411
Mini-levers, Remove and Install 4411
Armrest Assembly 4412
Remove 4412
Install 4415
Horn Button 4415
Remove 4415
Install 4415
Direction Control Switch 4415
Remove 4415
Install 4416
Push (Override) Buttons 4416
Remove 4417
Install 4417
Electronic-Hydraulic Controls, After January, 2020 4418
E-Hydraulic Controls – TEST 4418
Mini-Levers 4418
Full Stroke Test 4418
Function Returns to Neutral Test 4418
Push (Override) Button 4418
General 4419
Mini-levers, Remove and Install 4419
Armrest Assembly 4420
Remove 4420
Install 4423
Horn Button 4423
Remove 4423
Install 4423
Direction Control Switch 4423
Remove 4423
Install 4424
Push (Override) Buttons 4424
Remove 4425
Install 4425
Push (Override) Buttons and Toggle Switch 4426
Remove 4426
Install 4428
Special Tools 4429
550118418-8000YRM1902-(12-2020)-US-EN 4433
General 4441
Serial Number Data 4441
How to Move Disabled Lift Truck 4442
How to Tow Lift Truck 4442
How to Put Lift Truck on Blocks 4443
How to Raise Drive Tires 4443
How to Raise Steering Tires 4444
How to Clean a Lift Truck 4445
Maintenance Schedule 4445
Maintenance Procedures Every 8 Hours or Daily 4478
How to Make Checks With Engine Stopped 4478
Tires and Wheels 4478
Safety Labels 4479
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4479
Operator Restraint System 4480
Emergency Locking Retractor (ELR) 4480
Hood and Seat Latches 4481
Engine Compartment 4481
Paper Application 4481
Fuel, Oil, and Coolant Leaks, Check 4482
Hydraulic Hoses 4482
Coolant Hoses 4482
Steering Column Gas Cylinder 4482
Transmission 4483
Hydraulic System Oil 4483
Engine Oil 4483
Air Filter 4491
Forks 4491
Forks, Inspect 4492
Forks, Remove 4493
Forks, Install 4493
Forks, Adjust 4493
Integral Sideshift Carriage 4494
Fork Positioner 4494
Forks, Inspect 4494
Forks, Remove 4495
Forks, Install 4496
Forks, Adjustments 4497
How to Make Checks With Engine Running 4497
Indicator Lights, Horn, Fuses, and Relays 4497
Service Brakes 4499
Brake Oil Level 4499
Operation, Check 4500
Parking Brake 4500
Engine Oil Pressure 4500
Cooling System 4500
Steering System 4501
Control Levers and Pedals 4501
Fuel/Water Separator Filter, Kubota Diesel Engine 4501
Lift System, Operate 4502
Air Filter 4502
First Service After First 100 Hours of Operation 4503
4 3L Engine Oil and Oil Filter 4503
Kubota Diesel Engine Oil and Oil Filter 4503
Kubota 3 8L LPG or Bi-Fuel Engine Oil and Oil Filter 4504
Maintenance Procedures Every 250 Hours or 6 Months 4504
4 3L Engine Oil and Oil Filter 4504
Kubota 3 6L Diesel Engine Oil and Oil Filter 4505
Drive Belt 4506
4 3L Engine 4506
Fan and Alternator Drive Belt 4506
Drain Tar From LPG Converter 4507
Cleaning Carbon Buildup From Intake Valves – GM 4 3L and Kubota 3 8L LPG Engines 4508
Maintenance Procedures Every 500 Hours or 6 Months 4510
Hydraulic System Oil 4510
Hydraulic Tank Breather 4511
Inspect 4511
Battery 4512
Kubota 3 8L Diesel Engine Oil and Oil Filter 4512
Kubota 3 8L LPG and Bi-Fuel Engine Oil and Oil Filter 4513
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 4513
Remove 4513
Install 4513
Priming the Fuel System (Kubota 3 8L Engine) 4514
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 4515
Remove 4515
Install 4515
Priming the Fuel System (Kubota 3 6L Engine) 4516
Drive Belt 4516
Kubota Diesel Engine 4516
Fan and Alternator Drive Belt 4516
Kubota LPG and Bi-Fuel Engine 4517
Fan and Alternator Drive Belt 4517
Clean Debris From Radiator Core 4518
Transmission Oil Level 4518
Wet Brake Center Body Oil Level Check (Dana Drive Axle) 4520
Wet Brake Oil Level Check (NMHG/HYG Drive Axle) 4521
Forks, Inspect 4522
Mast Lubrication 4524
Fork Positioner Lubrication 4526
Header Hose Checks 4527
Lift Chain Lubrication 4527
Tilt Cylinder Lubrication 4527
Master Brake Cylinder Rod End Pin Lubrication 4528
Manual Hydraulic Levers Lubrication 4529
Brake Oil 4529
Tie Rod Lubrication 4530
Parking Brake Adjustment 4530
Maintenance Procedures Every 1000 Hours or 6 Months 4531
Valve Clearance, Check and Adjust, 4 3L Engine 4531
Valve Clearance, Check and Adjust, Kubota 3 6L Diesel Engine 4531
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 4531
Valve Clearance, Check and Adjust for Kubota 3 8L LPG and Bi-Fuel Engine 4532
Ignition System 4532
4 3L Engine 4532
Kubota 3 8L LPG and Bi-Fuel Engine, Standard Spark Plugs 4532
Gasoline Fuel Filter, GM 4 3L Engine 4532
Remove and Replace 4532
LPG Fuel Filter Element Replace, 4 3L Engine 4532
Remove 4532
Install 4533
LPG Fuel Filter Element Replace, Kubota 3 8L LPG and Bi-Fuel Engine 4533
Remove 4533
Install 4534
In-Line Strainer Replacement, Kubota Diesel Engine 4536
Remove 4536
Install 4536
Lift Chains Wear Check 4538
Lift Chain Lubrication 4538
Integral Sideshift Carriage, Check Sliding Surfaces 4538
Steering Axle (Spindle Bearings) 4539
Control Levers and Pedals 4540
Parking Brake Lever Lubrication, Dana Wet Brake Axle 4540
Normal Operating Environment 4540
Heavy Duty or Contaminated Environment – Parking Brake Lever on Top of Drive Axle 4543
Remove 4543
Clean and Inspect 4544
Install 4545
Heavy Duty or Contaminated Environment – Parking Brake Lever on Right Side of Drive Axle 4545
Remove 4545
Clean and Inspect 4547
Install 4547
Inspect Engine Electrical System, Connectors 4549
Crankcase Breather Element, Kubota 3 8L Diesel 4550
Remove 4550
Clean and Inspect 4550
Install 4550
Maintenance Procedures Every 2000 Hours or Annually 4551
Hydraulic System 4551
Hydraulic Filter, Replace 4551
Hydraulic Tank Breather, Replace 4552
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 4553
Spark Plugs, 4 3L Engine 4553
Remove 4553
Install 4553
Long-Life Spark Plugs, Kubota 3 8L LPG and Bi-Fuel Engine 4554
Cooling System 4554
Air Filter 4554
4 3L Gasoline Fuel Filter 4556
Remove and Replace 4556
Kubota 3 8L Bi-Fuel Gasoline Fuel Filter 4557
Remove and Replace 4557
Fuel Injector, Kubota 3 8L Engine 4558
Fuel Injector, Kubota 3 6L Engine 4558
Forks, Inspect 4558
Transmission Oil and Filter, Replace 4559
Transmission and Wet Brake Planetary Carrier Housing Oil Change (Dana Drive Axle) 4560
Wet Brake Center Section Oil Change (Dana Drive Axle) 4563
Remove 4563
Install 4563
Wet Brake Oil Change (NMHG/HYG Drive Axle) 4564
Brake Oil (Master Cylinder), Change 4565
Check Throttle Shaft for Sticking 4566
Inspect Exhaust Manifold and Piping for Leaks 4566
Wheel Bearings 4566
Steer Wheels, Lubrication 4566
Maintenance Procedures Every 3000 Hours 4567
Diesel Particulate Filter 4567
Remove 4567
Inspect 4571
Disassemble 4571
Servicing the Diesel Particulate Filter,Pressure Tubes and Pressure Hoses 4572
Assemble 4572
Install 4573
Maintenance Procedures Every 4000 Hours or 2 Years 4574
Hydraulic Oil, Replace 4574
Weld Inspection 4576
Safety Procedures When Working Near Mast 4579
Fuel Filter Water Removal 4580
Kubota Diesel Engine 4580
3 8L Diesel Engine 4580
3 6L Diesel Engine 4581
Hood Latch Check 4582
Lift Chain Adjustments 4583
Jump-Starting the Lift Truck 4585
Jump-Starting Using a Battery Charger 4585
Jump-Starting a Lift Truck Using Another Lift Truck 4585
Welding Repairs 4585
Overhead Guard Changes 4586
Wheel and Tire Replacement 4586
General 4586
Pneumatic Tire With Tube, Repair ( Series)GP/GLP/GDP 4586
Remove Wheels From Lift Truck 4586
Remove Tire From Wheel 4587
Install Wheel in Tire 4589
Install Tire on Two-Piece Wheel 4591
Add Air to Pneumatic Tires With Tube 4592
Install the Wheels 4593
Dual Drive Wheels, Install 4593
Pneumatic Tubeless Tire, Repair ( Series)GP/GLP/GDP 4594
Remove Wheels From Lift Truck 4594
Add Air to Pneumatic Tubeless Tire 4599
Install the Wheels 4599
Dual Drive Wheels, Install 4600
Solid Rubber Tire , Change ( Series)GLC 4600
Remove and Install Tire on Wheel 4601
Dual Drive Wheels, Install 4601
Adhesives and Sealants 4602
550118419-8000YRM1903-(08-2019)-US-EN 4605
Lift Truck Lifting Capacity 4609
Counterweight Weights 4609
Tire Sizes 4610
Capacities 4610
Electrical System 4616
Transmission Oil Pressures 4618
Hydraulic System Relief Pressures 4620
Steering System 4621
Stall Speeds (in RPM ±100 rpm) 4622
GM/PSI 4 3L 4622
Kubota 3 6L Diesel 4622
Kubota 3 8L Diesel 4622
Kubota 3 8L LPG/Bi-Fuel 4623
Mast Speeds 4623
Tilt Angles 4627
Front End Equipment – Mast Creep 4627
Mast Creep 4627
Engine Specifications 4628
Diesel Fuel Cleanliness Levels 4630
Torque Specifications 4631
Frame 4631
Mast 4631
Steering System 4631
Steer Axle 4631
Drive Axle, Wet Brake
(Dana Spicer Axle) 4631
Drive Axle, Wet Brake
(NMHG/HYG Axle) 4631
Transmission 4632
Engine – GM/PSI 4 3L 4632
Engine – Kubota 3 6L Diesel 4633
Engine – Kubota 3 8L 4634
550118420-8000YRM1904-(05-2022)-US-EN 4637
General Information About Diagrams and Schematics 4643
Symbol Definitions 4643
Diagrams Manual Applications 4644
Diagrams and Schematics 4646
550118420-8000YRM1904-(10-2020)-US-EN 4755
General Information About Diagrams and Schematics 4759
Symbol Definitions 4760
Diagrams Manual Applications 4761
Diagrams and Schematics 4763
550118556-2000YRM1899-(03-2015)-US-EN 4873
550119576-0900YRM1905-(01-2022)-US-EN 4909
General 4915
LPG Tank and Bracket Replacement 4916
Remove LPG Tank, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 4916
Remove LPG Tank, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 4919
Install LPG Tank, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 4920
Install LPG Tank, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 4920
Remove LPG Bracket, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 4921
Remove LPG Bracket, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 4923
Install LPG Bracket, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 4924
Install LPG Bracket, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 4924
Remove LPG Tank Bracket Alignment Pin, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 4925
Remove LPG Tank Bracket Alignment Pin, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 4927
Install LPG Tank Bracket Alignment Pin, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 4927
Install LPG Tank Bracket Alignment Pin, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 4928
LPG Fuel Filter Unit Repair 4930
LPG Fuel Filter Element, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 4930
Remove/Disassemble 4930
Clean/Inspect 4932
Assemble/Install 4932
LPG Fuel Filter Element, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 4932
Remove/Disassemble 4932
Clean/Inspect 4933
Assemble/Install 4933
Fuel Filter Housing, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 4933
Remove 4933
Disassemble 4939
Clean and Inspect 4940
Assemble 4940
Install 4940
Fuel Filter Housing, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 4941
Remove 4941
Disassemble 4942
Clean and Inspect 4943
Assemble 4943
Install 4944
Electronic Throttle Body Repair 4945
Remove 4945
Install 4947
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 4948
Remove 4948
Install 4951
Control System 4952
Engine Control Unit (ECU) 4952
Remove 4952
Install 4952
LPG Low Level Sensor 4953
Remove 4953
Remove 4955
Install 4956
Exhaust System 4957
Counterweight Exhaust 4957
Remove and Disassemble 4957
Remove and Disassemble 4959
Inspect 4961
Assemble and Install 4961
Assemble and Install 4961
Exhaust Manifold 4961
Remove 4961
Install 4962
Oxygen (HEGO) Sensor 4962
Remove 4962
Install 4962
LPG Fuel Testing 4963
General 4963
Available Fuel Tests 4963
Composition Test (ASTM D-2163) 4963
Ammonia Test (ASTM D-4490) 4963
Basic Nitrogen Test (ASTM UOP269-90) 4963
Residues Test (ASTM D-2158) 4963
Vapor Pressure Test (ASTM D-2598) 4963
Sulfur Compounds Test (ASTM D-5623) 4963
Methanol Test (ASTM D-4864) 4964
Copper Corrosion (ASTM D-1838) 4964
Where To Send LPG Fuel Samples For Testing 4964
550119576-0900YRM1905-(04-2018)-US-EN 4967
General 4971
LPG Tank and Bracket Replacement 4971
Remove LPG Tank 4971
Install LPG Tank 4974
Remove LPG Bracket 4974
Install LPG Bracket 4975
Remove LPG Tank Bracket Alignment Pin 4977
Install LPG Tank Bracket Alignment Pin 4978
LPG Fuel Filter Unit Repair 4979
LPG Fuel Filter Element 4979
Remove/Disassemble 4979
Clean/Inspect 4979
Assemble/Install 4981
Fuel Filter Housing 4981
Remove 4981
Disassemble 4986
Clean and Inspect 4986
Assemble 4987
Install 4987
Electronic Throttle Body Repair 4988
Remove 4988
Install 4989
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 4991
Remove 4991
Install 4992
Control System 4993
Engine Control Unit (ECU) 4993
Remove 4993
Install 4993
LPG Low Level Sensor 4994
Remove 4994
Install 4994
Exhaust System 4996
Counterweight Exhaust 4996
Remove and Disassemble 4996
Inspect 4998
Assemble and Install 4998
Exhaust Manifold 4998
Remove 4998
Install 4998
Oxygen (HEGO) Sensor 4999
Remove 4999
Install 4999
LPG Fuel Testing 4999
General 4999
Available Fuel Tests 5000
Composition Test (ASTM D-2163) 5000
Ammonia Test (ASTM D-4490) 5000
Basic Nitrogen Test (ASTM UOP269-90) 5000
Residues Test (ASTM D-2158) 5000
Vapor Pressure Test (ASTM D-2598) 5000
Sulfur Compounds Test (ASTM D-5623) 5000
Methanol Test (ASTM D-4864) 5000
Copper Corrosion (ASTM D-1838) 5000
Where To Send LPG Fuel Samples For Testing 5000
550125043-2100YRM1947-(03-2015)-US-EN 5003
550158688-2040YRM2075-(06-2017)-US-EN 5045
General 5049
Description 5049
Precautions 5049
Clamp Assembly Installation 5049
Hydraulic Hose Flush 5050
Clamp Installation (With Lifting Device) 5050
Clamp Installation (Without Lifting Device) 5052
Hose Connections 5052
Clamp Series 5052
Connecting The Hoses 5053
Operating Checks 5053
Clamping Force Test 5053
Troubleshooting 5055
General 5055
Hydraulic Schematics 5057
550166584-2040YRM2041-(06-2017)-US-EN 5061
General 5065
Description 5065
Precautions 5065
5066
Center of Gravity and Lift Truck Capacity 5071
Net Capacity Rating 5071
The Effects of Loading 5071
Choosing The Right Equipment 5072
Choosing the Right Clamp 5072
Choosing the Right Truck 5072
Choosing the Right Contact Pads 5073
Clamping Force 5073
Description 5074
CLAMPING FORCE 5074
Clamping Force Too High 5074
Clamping Force Too Low 5074
Clamping Operation 5075
Lever Functions 5075
Two-Motion Controls 5075
Bilge Position 5075
Damage Prevention 5076
Description 5076
ROLL DAMAGE 5076
Edge Damage 5076
End Damage 5077
Belly Damage 5077
Out-of-Roundness 5078
Inspection and Maintenance 5078
Daily Checks 5078
Pad Inspection 5078
Inspection and Service (6 Months / 300 hours) 5079
Rotation Bearing 5079
Rack and Pinion 5079
Arm Pivots (Pins/Bushings/Seats) 5079
Rotation Mechanism (Rack and Pinion) 5079
550166585-2040YRM2040-(12-2016)-US-EN 5083
General 5087
Description 5087
Precautions 5087
Clamp Assembly Installation 5089
Hydraulic Hose Flush 5089
Clamp Installation (With Lifting Device) 5090
Clamp Installation (Without Lifting Device) 5091
Hose Connections 5091
AR Series Clamp 5091
ARC Series Clamp 5092
Connecting The Hoses 5092
Two-Motion Controls 5093
Operating Checks 5093
Set Flow Rate 5094
Hydraulic Adjustments 5095
E-Hydraulics 5095
Clamping Pressure 5095
Clamping Force Test 5096
5096
Clamping Force 5096
Testing Clamping Force with the Test Pad 5097
Test Procedures 5098
Testing Clamping force with the Test Stand 5098
Test Procedures 5099
Testing Clamping Force with the Test Cylinder 5099
Test Procedures 5099
Hydraulic Adjustments 5100
E-Hydraulics 5100
Bolzoni Force-Matic 5101
General Description 5101
Installation 5101
Operation 5104
Troubleshooting 5104
General 5104
Hydraulic Schematics 5107

S.V 06/24