Yale Forklift A909 (GDPGLP80-90VX, GDPGLP80VX9 Europe) Service Manual PDF

Yale Forklift A909 (GDPGLP80-90VX, GDPGLP80VX9 Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift A909 (GDPGLP80-90VX, GDPGLP80VX9 Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 3920
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift A909 (GDPGLP80-90VX, GDPGLP80VX9 Europe) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (03 2020) UK EN 1
General 5
Threaded Fasteners 5
Nomenclature, Threads 5
Strength Identification 6
Cotter (Split) Pins 7
Fastener Torque Tables 12
Conversion Table 14
524208014 2200YRM1097 (03 2020) UK EN 21
Series Code / Model Designation Reference Table 25
Description 26
Distributor Ignition (DI) System 26
Crankshaft Position (CKP) Sensor 26
Camshaft Position (CMP) Sensor 26
Ignition Coil and Ignition Control Module (ICM) 26
Secondary Ignition Components 26
Spark Plugs and Wires 27
Spark Plug Wire Inspection 27
Spark Plug Wire Replacement 27
Remove 27
Install 28
Spark Plug Inspection 28
Usage 28
Inspection 28
Visual Inspection 30
Spark Plug Replacement 30
Remove 30
Install 30
Distributor Repair 31
Inspect 31
Overhaul 31
Disassemble 31
Assemble 34
Replace 35
Remove 35
Install Procedure 1 37
Install Procedure 2 38
Ignition Coil Replacement 39
Remove 39
Install 39
Ignition Control Module Replacement 40
Remove 40
Install 40
Starter Replacement 41
Remove 41
Install 44
Sensors and Switches 45
Gas and LPG Trucks 45
Crankshaft Position (CKP) Sensor 45
Remove 45
Install 45
Camshaft Position (CMP) Sensor 46
Remove 46
Install 48
Oil Pressure Sensor 48
Remove 48
Install 49
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 50
Remove 50
Install 50
Engine Coolant Temperature (ECT) Sensor 51
Remove 51
Install 52
Air Flow Restriction Switch 52
Remove 52
Install 53
Specifications and Special Tools 54
524221866 9000YRM1112 (10 2020) UK EN 59
SECTION 9010 Operational Diagnostic Procedures 75
Group 05 – Operational Checkout 77
SECTION 9020 Engine 95
Group 10 – Principles of Operation 105
Group 30 – Observed Symptoms 303
Group 40 – Tests and Adjustments 405
SECTION 9030 Electrical System 437
Group 03 – General Maintenance and Diagnostic Data 461
Group 10 – Principles of Operation 555
Group 20 – Diagnostic Trouble Codes 579
Group 30 – Observed Symptoms 1551
SECTION 9040 Drive Train 1607
Group 10 – Principles of Operation 1611
Group 30 – Observed Symptoms 1667
Group 40 – Tests and Adjustments 1717
SECTION 9050 Hydraulic Systems 1727
Group 10 – Principles of Operation 1731
Group 30 – Observed Symptoms 1789
Group 33 – Observed Symptoms-Gear Pump 1791
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1879
Group 40 – Tests and Adjustments 1923
Group 43 – Tests and Adjustments-Gear Pump 1925
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1949
SECTION 9060 Operators Station 1967
Group 10 – Principles of Operation 1969
SECTION 9070 Front End (Mast) and Chassis 2005
Group 10 – Principles of Operation 2007
Group 30 – Observed Symptoms 2029
SECTION 9080 Supplementary Data 2087
Group 50 – Abbreviations and Acronyms 2089
Group 60 – Special Tools List 2097
Group 70 – Fault Mode Indicator Reference 2107
Group 80 – Supplier Specification Data 2109
524223757 0700YRM1123 (06 2016) UK EN 2113
General 2117
Cooling System Checks 2117
Exhaust Leaks Into Cooling System 2117
Water Flow Restrictions in Radiator 2117
Radiator Hoses 2117
Water Pump 2118
Flushing the Cooling System 2118
Cooling System, Clean 2118
Radiator Replacement 2119
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) 2120
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 2135
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2138
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) 2141
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) 2148
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 2153
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2155
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) 2158
Fan Assembly Replacement 2170
Fan Removal 2170
Inspect 2185
Fan Installation 2185
524223764 1600YRM1133 (07 2013) UK EN 2191
toc 2191
Steering Axle 2191
Safety Precautions Maintenance and Repair 2192
General 2195
Steering Axle Assembly Repair 2197
Remove 2197
Disassemble 2198
Clean 2206
Inspect 2206
Assemble 2206
Install 2212
Spindles, Bearings, and Tie Rods Repair 2214
Spindles and Bearings 2214
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2214
Remove 2214
Disassemble 2216
Clean 2217
Inspect 2217
Assemble 2217
Install 2218
Spindles and Bearings 2221
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2221
Remove and Disassemble 2221
Assemble and Install 2222
Tie Rods 2222
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2222
Remove 2222
Install 2223
Tie Rods 2224
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2224
Remove 2224
Install 2230
Steering Cylinder Repair 2230
Remove and Disassemble 2230
Clean and Inspect 2231
Assemble and Install 2231
Torque Specifications 2232
524223766 1900YRM1136 (11 2017) UK EN 2237
General 2241
Hydraulic Gear Pump Assembly 2242
Variable Displacement Pump Assembly 2243
Single Gear Pump Assembly Repair 2243
Remove 2243
Disassemble 2250
Clean 2250
Inspect 2252
Assemble 2252
Install 2252
Tandem Gear Pump Assembly 2256
Remove 2257
Disassemble 2259
Clean 2261
Inspect 2261
Assemble 2261
Install 2262
Gear Pump Specifications 2262
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2268
Remove 2268
Disassemble 2278
Clean 2281
Inspect 2281
Assemble 2281
Install 2282
63 0 cc/rev – Variable Displacement Pump Repair 2285
Remove 2285
Disassemble 2288
Clean 2288
Inspect 2288
Assemble 2290
Install 2290
Variable Displacement Pump Checks and Adjustments (Single Pump) 2292
Margin Pressure Check 2292
Flow Compensator Adjustment 2293
Pressure Compensator Adjustment 2293
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2294
Variable Displacement Pump Specifications 2297
Torque Specifications 2298
Hydraulic Gear Pump 2299
Variable Displacement Pump 2300
Special Tools 2300
524223767 2000YRM1137 (01 2017) UK EN 2305
General 2311
Electro-Hydraulic Main Control Valve 2312
Description 2312
Remove 2320
Electro-Hydraulic Control Valve Sections 2325
General 2325
Outlet Control Valve Section 2325
Remove 2325
Disassemble 2326
Clean 2328
Inspect 2328
Assemble 2328
Install 2329
Auxiliary Control Valve Sections 2329
Remove 2329
Disassemble 2336
Clean 2337
Inspect 2338
Assemble 2338
Install 2340
Tilt Control Valve Section 2341
Remove 2341
Disassemble 2341
Clean 2347
Inspect 2347
Assemble 2347
Install 2348
Lift/Lower Control Valve Section 2349
Remove 2349
Disassemble 2349
Clean 2358
Inspect 2358
Assemble 2358
Install 2359
Mid-Inlet Section 2359
Remove 2359
Clean 2360
Inspect 2360
Install 2360
Install 2360
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2365
Lift Pilot Pin 2365
Lower Pilot Pin 2369
Abnormal/Erroneous EHPV Adjustment 2371
Manual Main Control Valve 2372
Description 2372
Remove 2376
OPS Solenoid Assembly 2384
General 2384
Remove 2385
Clean and Inspect 2388
Install 2388
Manual Control Valve Sections 2389
General 2389
Outlet Control Valve Section 2389
Remove 2389
Disassemble 2389
Clean 2392
Inspect 2392
Assemble 2392
Install 2393
Auxiliary Control Valve Sections 2393
Remove 2393
Disassemble 2393
Clean 2396
Inspect 2396
Assemble 2396
Install 2397
Lift/Tilt Control Valve Section 2397
Remove 2397
Disassemble 2397
Clean 2404
Inspect 2404
Assemble 2405
Install 2406
Mid-Inlet Section 2407
Remove 2407
Clean 2407
Inspect 2407
Install 2407
Install 2408
Pressure Relief Valve Check and Adjustment 2414
Primary Relief Valve 2415
Secondary Relief Valve 2419
Steering Control Unit Repair 2426
Steering Control Unit, Remove 2426
Steering Control Unit, Disassemble 2430
Steering Control Unit, Clean 2432
Steering Control Unit, Inspect 2432
Steering Control Unit, Assemble 2432
Relief Valve, Disassemble 2433
Relief Valve, Clean 2433
Relief Valve, Inspect 2434
Relief Valve, Assemble 2434
Steering Control Unit, Install 2434
524223769 2200YRM1128 (07 2020) UK EN 2439
Series Code / Model Designation Reference Table 2445
General 2448
Deutsch Crimping Tool 2448
How to Strip a Wire for Use With Deutsch Crimping Tool 2448
How to Crimp With the Deutsch Crimping Tool 2449
Calibration Test for the Deutsch Crimping Tool 2451
Deutsch Connectors 2453
DT, DTM, and DTP Series Connectors 2453
HD Series Connectors 2495
Metri-Pack Connectors 2518
Remove and Install 2518
Micro-Pack Connectors 2520
Weather-Pack Connectors 2521
AMPSEAL Crimping Tools 2523
AMP Hand Crimping Tool With Certi-Crimp 2523
Description 2523
Stripping Wire for Use with AMP Hand Crimping Tool 2523
Insulation Crimp Adjustment 2524
Maintenance and Inspection for AMP Hand Crimping Tool 2524
AMP Hand Crimping Tool 2524
Crimp Height Inspection 2524
How to use AMP Hand Crimping Tool 2525
AMP Pro-Crimper II Tool 2525
Description 2525
Remove and Install Die Set and Locator Assembly 2526
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2527
Contact Support Adjustment 2527
Crimp Height Adjustment 2528
Maintenance and Inspection Procedures 2528
PRO-CRIMPER II Tool 2528
Crimp Height Inspection 2528
How to Use AMP PRO-CRIMPER II Tool 2529
AMPSEAL Connector Assemblies 2530
Description for Plug Connector Assembly 2530
Seal Plug 2531
Contact Crimping 2531
Description for Plug Connector and Header Assembly 2536
Voltage Reading 2538
Seal Plug 2538
Contact Crimping 2538
AMP Superseal 1 5 Crimping Tools 2545
Mini Mic Receptacle and Tab Contacts 2545
Description 2545
Crimping Conditions and Measurements 2545
Insertion of Rubber Seal on Cable 2547
AMP Hand Application Tool 2552
Description 2552
Maintenance and Inspection 2552
Crimp Height Inspection 2552
Crimp Height Adjustment 2553
How to Use AMP Hand Application Tool 2553
AMP Pro-Crimper II Tool 2554
Description 2554
Remove and Install Die Set and Locator Assembly 2555
Adjustments 2555
Contact Support 2555
Crimp Height 2556
Inspections and Maintenance 2557
Crimp Height Inspection 2557
Visual Inspection 2557
Maintenance 2558
How to Use Pro-Crimper II Tool 2558
AMP Superseal 1 5 Connector Assemblies 2559
Description 2559
Repair and Maintenance 2566
Panel Mount Option 2566
AMP Fastin-Faston Hand Tools 2567
Description – AMP Double Action Hand Tool 2567
Maintenance and Inspection Procedures 2567
Daily Maintenance 2567
Periodic Tool Inspection 2568
Lubrication 2568
Visual Inspection 2568
Crimp Height Inspection 2568
Certi-Crimp Ratchet Inspection 2569
How to Use AMP Double Action Hand Tool 2570
Description – AMP Extraction Tool 2571
Maintenance and Inspection 2571
How to Use AMP Extraction Tool 2572
AMP Fastin-Faston Receptacles and Housings 2573
Description 2573
Wire Repair 2580
Wire Splicing Requirements 2580
Deutsch Jiffy Splice 2581
Twisted/Shielded Cable and Leads Repair 2586
Special Tools 2589
524223770 2200YRM1130 (03 2020) UK EN 2597
General 2601
Description 2601
Dash Display Menu Access 2601
Menu Navigation 2602
Standard Display 2602
Main Menu 2602
Passwords Menu 2603
Password Administration 2603
Add Password 2603
Delete Password 2604
Edit Password 2604
Other Password Functions 2605
Operator Passwords – Enable/Disable 2605
Password Time-Out Delay 2605
Passwords – Number Wrong to Disable 2606
Lockout Reset Password 2606
View Password Log 2607
View Versions 2608
VSM Versions 2608
Dash Display Versions 2609
Engine Controller Version 2610
Transmission (Xmsn) Controller Version 2611
Truck Serial Number 2612
Diagnostics 2613
View Fault Log 2613
Set Travel and Braking 2614
Speed Limit 2614
Acceleration Rate 2615
Auto-Deceleration Rate 2615
Set Power Reversal Rate 2616
Set Inching/Brake Overlap 2617
Setup Display Menu 2618
Set Operator Language 2618
Set Units 2619
Set Time Format (12/24 Hour) 2619
Set Daylight Saving Time 2619
Set Time 2622
Set Date Format 2623
Set Date 2623
Setup Hydraulics 2624
Return to Set Tilt Delay/On/Off 2624
Setup General Items 2625
Light Shutdown Time-Out 2625
Impact Sensor – Enable/Disable 2626
Impact Sensor – Soft Impact Settings 2627
Impact Sensor – Hard Impact Settings 2628
Adjust Impact Sensor Settings 2628
Initial Adjustment of Soft and Hard Impact Settings 2630
Readjustment of Soft and Hard Impact Settings 2630
Impact Sensor – Impact Alarm/Shutdown Reset 2631
Impact Sensor – Alarm Time Duration and Deactivation 2632
Impact Sensor – View Impact Event Log 2633
Engine Mode Indicator 2634
Generation 1 (ECO-eLo ONLY) 2634
Generation 2 2635
Operator Checklist 2636
Operator Checklist Off-On Mode 2636
Edit Operator Checklist 2636
Set Operator Checklist Expiration 2637
View Checklist Log 2637
Clear Operator Checklist Log 2638
Clear Operator Checklist Fault 2638
Calibrations 2639
Set Tilt Stop Point 2639
Calibrate Loaded Weight 2639
524223771 2200YRM1131 (03 2020) UK EN 2641
Series Code / Model Designation Reference Table 2647
General 2649
Description 2649
Dash Display Menu Access 2649
Menu Navigation 2650
Main Menu 2650
Passwords 2651
Adding Passwords 2651
Hourmeters 2653
View Versions 2654
VSM Versions 2654
Dash Display Versions 2655
Engine Controller Version 2656
Transmission (Xmsn) Controller Version 2657
Truck Serial Number 2658
Truck Configuration 2659
Diagnostics 2660
Clear Fault Log 2660
View Fault Log 2661
No-Run Data Display 2662
Engine Accelerator and Throttle Data Display 2662
Engine Speeds and Governor Data Display 2663
Engine Fuel and Emissions Data Display 2664
Engine General Data Display 2666
XMSN/Brake Data Display 2667
Hydraulic Data Display 2670
General Truck Data Display 2672
Set Travel and Braking 2673
Speed Limit 2673
Acceleration Rate 2674
Auto-Deceleration Rate 2675
Set Power Reversal Rate 2675
Set Inching/Brake Overlap 2676
Setup Hydraulics 2676
Lift Maximum Speed 2677
Lower Maximum Speed 2677
Tilt Maximum Speed 2678
Auxiliary Function One, Direction A, Maximum Speed 2680
Auxiliary Function One, Direction B, Maximum Speed 2682
Auxiliary Function Two, Direction A, Maximum Speed 2682
Auxiliary Function Two, Direction B, Maximum Speed 2683
Auxiliary Function Three, Direction A, Maximum Speed 2684
Auxiliary Function Three, Direction B, Maximum Speed 2684
Lift/Lower Ramp Rate 2685
Hydraulic Auxiliary Ramp Rate 2685
Return to Set Tilt Delay/On/Off 2686
Hydraulic Input Device 2687
Auxiliary Solenoid 2687
Dual Function 2688
Setup Display 2689
Set Service Language 2689
Setup General Items 2689
Motion Alarm Activation Type 2690
Light Shutdown Time-Out 2691
Restore Default Settings 2691
Restore Engine Controller Default Calibration 2692
Impact Sensor – Enable/Disable 2692
Impact Sensor – Soft Impact Settings 2693
Impact Sensor – Hard Impact Settings 2694
Adjust Impact Sensor Settings 2695
Initial Adjustment of Soft and Hard Impact Settings 2697
Readjustment of Soft and Hard Impact Settings 2697
Impact Sensor – Impact Alarm/Shutdown Reset 2698
Impact Sensor – Alarm Time Duration and Deactivation 2699
Impact Sensor – View Impact Event Log 2700
Engine Mode Indicator 2700
Generation 1 (ECO-eLo ONLY) 2700
Generation 2 2701
Diesel Particulate Filter (DPF) Display 2702
General Description 2702
Passive Regeneration Only 2702
Regeneration Level 0 2702
Auto/Active Regeneration Inhibited 2703
Auto/Active Regeneration 2703
Regeneration Level 1 2703
Parked Regeneration Request 2704
Regeneration Level 2 2704
Warning Level 2704
Regeneration Level 3 2704
Service Level 2705
Regeneration Level 4 2705
Display, Diesel Particulate Filter (DPF), Revised 2705
Operator Interface 2705
Refer to Operator Manual 2705
CAN Communication Lost 2706
Passive Regeneration Only 2706
Regeneration Level 0 2706
Auto/Active Regeneration Inhibited 2706
Auto/Active Regeneration 2707
Regeneration Level 1 2707
Idle-up Auto/Active Regeneration 2707
Parked Regeneration Request 2707
Regeneration Level 2 2707
Warning Level 2709
Regeneration Level 3 2709
Service Level 2709
Regeneration Level 4 2709
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2709
Display, Diesel Particulate Filter (DPF), Stage V Engine 2709
Operator Interface 2710
Refer to Operator Manual 2710
CAN Communication Lost 2710
Passive Regeneration Only 2710
Regeneration Level 0 2710
Auto/Active Regeneration Inhibited 2711
Auto/Active Regeneration 2711
Regeneration Level 1 2711
Idle-up Auto/Active Regeneration 2712
Parked Regeneration Request 2712
Regeneration Level 2 2712
Warning Level 2713
Regeneration Level 3 2713
Service Level 2714
Regeneration Level 4 2714
Stage V Content 2714
Emissions System Malfunction 2714
Ash Load 2714
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2715
Operator Interface 2715
Refer to Operator Manual 2715
CAN Communication Lost 2716
Passive Regeneration Only 2716
Regeneration Level 0 2716
Auto/Active Regeneration Inhibited 2716
Auto/Active Regeneration 2717
Regeneration Level 1 2717
Idle-up Auto/Active Regeneration 2717
Parked Regeneration Request 2717
Regeneration Level 2 2717
Warning Level 2719
Regeneration Level 3 2719
Service Level 2719
Regeneration Level 4 2719
Calibrations 2720
Calibrate Transmission Valve 2722
Set Tilt Stop Point 2722
Calibrate Loaded Weight 2722
Calibrate Travel Speed Sensor 2723
Calibrate Mazda LP and Gas Accelerator Pedal 2723
524223772 2200YRM1142 (01 2020) UK EN 2725
General 2735
Display Switch Cluster 2738
Remove 2738
Install 2741
Direction Control and Turn Signal Levers 2741
Remove 2741
Install 2743
Key Switch 2743
Remove 2743
Install 2744
Display Switch Cluster Panel Bezel and Overlay 2744
Remove 2744
Install 2744
Steering Column Repair 2744
Remove 2744
Disassemble 2747
Assemble 2747
Install 2747
Sensors and Switches 2748
General 2748
Dash and Kick Panel, Remove and Install 2748
Remove 2748
Install 2749
Accelerator Pedal Position Sensor 2750
Remove 2750
Install 2753
Brake Fluid Level Switch 2754
Remove 2754
Install 2756
Service Brake Pedal Position Sensor 2757
Remove 2757
Install 2760
Parking Brake Sensor 2761
Remove 2761
Install 2762
Service Brake Pressure Sensor 2763
Remove 2763
Install 2765
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2766
Remove 2766
Install 2766
Sensor Microswitch (Foot Directional Control Pedal) 2767
Remove 2767
Install 2770
Low Coolant Level Sensor 2771
Remove 2771
Install 2774
Fuel Level Sensor, Gas and Diesel Engines Only 2775
Remove 2775
Install 2776
Armrest Switch 2776
Remove 2776
Install 2778
Seat Sensor (Operator Presence System) 2778
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) 2778
Remove 2778
Install 2779
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 2779
Remove 2779
Install 2780
Full Suspension Seats; All Lift Truck Models 2780
Remove 2780
Install 2780
Hood Shut Off Switch 2780
Remove 2780
Install 2783
Remote Key Switch 2784
Remove 2784
Install 2784
Hydraulic Filter Pressure Switch 2785
Remove 2785
Install 2787
Transmission Speed Sensor 2787
Remove 2787
Install 2790
Transmission Pressure Sensors 2791
Remove 2791
Install 2793
Transmission Temperature Sensor 2794
Remove 2794
Install 2796
Engine Speed Sensor 2798
Remove 2798
Install 2798
Intermediate Speed Sensor 2799
Remove 2799
Install 2799
Return to Set Tilt (Tilt Angle) Sensor 2799
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) 2799
Remove 2799
Install 2800
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) 2801
Remove 2801
Install 2802
Rear Horn Button Switch 2802
Remove 2802
Install 2803
Impact Sensor 2804
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) 2804
Remove 2804
Install 2807
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) 2807
Remove 2807
Install 2808
Load Weight Sensor 2809
Remove 2809
Install 2810
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 2811
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 2811
Crankshaft Position (CKP) Sensor 2811
Camshaft Position (CMP) Sensor 2811
Oil Pressure Sensor 2811
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 2811
Engine Coolant Temperature (ECT) Sensor 2812
Air Flow Restriction Switch 2812
Remove for GM 2 4L Gas and LPG Trucks 2812
Install for GM 2 4L Gas and LPG Trucks 2812
Oxygen Sensor 2813
Remove 2813
Install 2816
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 2817
Crankshaft Position (CKP) Sensor 2817
Camshaft Position (CMP) Sensor 2817
Oil Pressure Sensor 2817
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 2817
Engine Coolant Temperature (ECT) Sensor 2817
Air Flow Restriction Switch 2817
Oxygen Sensor 2817
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 2817
Low LPG Pressure Switch 2817
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 2818
Air Filter Restriction Switch 2818
Remove 2818
Install 2818
Oil Pressure Sensor 2818
Remove 2818
Install 2818
Engine Speed Sensor 2818
Remove 2818
Install 2818
Engine Coolant Temperature (ECT) Sensor 2818
Remove 2818
Install 2818
Throttle Position Sensor (TPS) 2821
Remove 2821
Install 2822
Fuel/Water Separator Sensor 2822
Remove 2822
Install 2822
Glow Plug Relay 2823
Remove 2823
Install 2825
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 2825
Air Filter Restriction Switch 2825
Remove 2825
Install 2825
Engine Oil Pressure Sensor 2830
Remove 2830
Install 2830
Engine Speed Sensor 2830
Remove 2830
Install 2831
Engine Coolant Temperature (ECT) Sensor 2831
Remove 2831
Install 2832
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 2833
Remove 2833
Install 2833
Fuel/Water Separator Sensor 2834
Remove 2834
Install 2834
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 2835
Intake Air Temperature Sensor 2835
Remove 2835
Install 2836
Intake Air Pressure Sensor 2836
Remove 2836
Install 2836
Air Inlet Heater 2836
Remove 2836
Install 2837
Engine Oil Pressure Sensor 2837
Remove 2837
Install 2837
Engine Coolant Temperature (ECT) Sensor 2837
Remove 2837
Install 2837
Crankshaft Position Sensor 2838
Remove 2838
Install 2838
Adjust Shim Procedure 2839
Camshaft Position Sensor 2840
Remove 2840
Install 2840
Air Flow Restriction Sensor 2841
Remove 2841
Install 2841
Fuel/Water Separator 2841
Remove 2841
Install 2842
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 2842
Intake Air Temperature Sensor 2846
Remove 2846
Install 2847
Boost Sensor 2847
Remove 2847
Install 2848
Throttle Valve Assembly and Air Intake Heater 2848
Remove 2848
Install 2848
Engine Coolant Temperature (ECT) Sensor 2849
Remove 2849
Install 2849
Engine Oil Pressure Sensor 2849
Remove 2849
Install 2850
Crankshaft Position Sensor 2850
Remove 2850
Install 2850
Adjust Shim Procedure 2851
Camshaft Position Sensor 2852
Remove 2852
Install 2853
Differential Pressure Sensor 2853
Remove 2853
Install 2853
Mass Air Flow Sensor 2854
Remove 2854
Install 2855
Fuel/Water Separator 2855
Remove 2855
Install 2856
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 2856
Engine Coolant Temperature (ECT) Sensor 2857
Remove 2857
Install 2857
Throttle Position Sensor 2858
Engine Oil Pressure Sensor 2858
Remove 2858
Install 2858
Engine Speed Sensor 2858
Remove 2858
Install 2858
Fuel Shut Off Solenoid 2858
Remove 2858
Install 2858
Vehicle System Manager (VSM) 2859
General 2859
VSM Replacement 2859
Remove 2859
Install 2861
Programming a New VSM and/or Display Switch Cluster 2861
General 2861
PC Service Tool Software 2862
Data Transferring 2862
New VSM 2862
New (Blank) Display Switch Cluster 2862
Used (Non-Blank) Display Switch Cluster 2862
Power Distribution Module (PDM) and Component Parts 2864
Remove 2864
PDM as a Unit 2864
Install 2868
PDM as a Unit 2868
Remove and Install 2869
PDM Component Parts 2869
Transmission Control Unit 2869
Remove 2869
Install 2873
Battery 2875
Remove 2875
Install 2875
Lights 2876
Work Lights (Front and Rear) 2876
Remove 2876
Install 2876
Strobe Light 2877
Remove 2877
Install 2877
LED Tail, Backup, and Brake Lights 2878
Remove 2878
Install 2879
Front Marker/Turn Signal Lights 2880
Replacing Whole Front Marker/Turn Signal Light Assembly 2880
Remove 2880
Install 2880
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 2881
Remove 2881
Install 2881
Diesel Particulate Filter (DPF) Display 2881
Remove 2881
Clean and Inspect 2882
Install 2882
Electronic-Hydraulic Controls – Generation 1 2883
E-Hydraulic Controls – Test 2883
Mini-Levers 2883
Full Stroke Test 2883
Function Returns to Neutral Test 2883
Push Button Switch 2883
General 2884
Mini-Lever Replacement 2884
Remove 2884
Clean and Inspect 2885
Install 2885
Push Button Switch Replacement 2886
Remove 2886
Install 2888
Mini-Lever Module (MLM) 2888
Remove 2888
Install 2888
Joystick 2889
Remove and Disassemble 2889
Inspect 2889
Assemble and Install 2889
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 2890
General 2890
Mini-levers, Remove and Install 2890
Armrest Assembly 2891
Remove 2891
Install 2894
Horn Button 2894
Remove 2894
Install 2894
Direction Control Switch 2895
Remove 2895
Install 2895
push (override) buttons and Toggle Switch 2895
Remove 2896
Install 2897
Joystick 2898
Remove and Disassemble 2898
Inspect 2898
Assemble and Install 2898
Joystick Armrest Slider Assembly 2899
Remove 2899
Install 2900
Electronic-Hydraulic Controls, After January, 2020 2900
E-Hydraulic Controls – TEST 2900
Mini-Levers 2900
Full Stroke Test 2900
Function Returns to Neutral Test 2900
Push (Override) Button 2901
General 2901
Mini-levers, Remove and Install 2901
Armrest Assembly 2902
Remove 2902
Install 2905
Horn Button 2905
Remove 2905
Install 2905
Direction Control Switch 2905
Remove 2905
Install 2906
Push (Override) buttons and Toggle Switch 2906
Remove 2907
Install 2909
Special Tools 2910
524223780 8000YRM1134 (03 2020) UK EN 2913
Series Code / Model Designation Reference Table 2919
Description 2921
Proc_Cal_001: Service Password Entry 2923
When to Perform 2923
Why Perform 2923
How to Perform 2923
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2924
When to Perform 2924
Calibration Order 2924
Why Perform 2924
How to Perform 2925
Proc_Cal_003: Save and Exit 2926
When to Perform 2926
Why Perform 2926
How to Perform 2926
Proc_Cal_004: Lift Valve Output Threshold 2927
When to Perform 2927
Calibration Order 2927
Why Perform 2927
How to Perform 2928
Proc_Cal_005: Lower Valve Output Threshold 2930
When to Perform 2930
Calibration Order 2930
Why Perform 2930
How to Perform 2930
Proc_Cal_006: Tilt Back Valve Output Threshold 2933
When to Perform 2933
Calibration Order 2933
Why Perform 2933
How to Perform 2933
Proc_Cal_007: Tilt Forward Valve Output Threshold 2936
When to Perform 2936
Calibration Order 2936
Why Perform 2936
How to Perform 2936
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2939
When to Perform 2939
Calibration Order 2939
Why Perform 2939
How to Perform 2939
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2942
When to Perform 2942
Calibration Order 2942
Why Perform 2942
How to Perform 2942
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2945
When to Perform 2945
Calibration Order 2945
Why Perform 2945
How to Perform 2945
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2948
When to Perform 2948
Calibration Order 2948
Why Perform 2948
How to Perform 2948
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2951
When to Perform 2951
Calibration Order 2951
Why Perform 2951
How to Perform 2951
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2954
When to Perform 2954
Calibration Order 2954
Why Perform 2954
How to Perform 2954
Proc_Cal_014: Load Weight Zero Point 2958
When to Perform 2958
Calibration Order 2958
Why Perform 2958
How to Perform 2958
Proc_Cal_015: Loaded Weight Calibration 2960
When to Perform 2960
Calibration Order 2960
Why Perform 2960
How to Perform 2960
Proc_Cal_016: Transmission Valve Calibration 2963
Applicable System/Option 2963
When to Perform 2963
Calibration Order 2963
Why Perform 2963
How to Perform 2963
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2965
Applicable System/Option 2965
When to Perform 2965
Calibration Order 2965
Why Perform 2965
How to Perform 2965
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2967
Applicable System/Option 2967
When to Perform 2967
Calibration Order 2967
Why Perform 2967
How to Perform 2968
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2969
Required Tools 2969
When to Perform 2969
Calibration Order 2969
Why Perform 2970
How to Perform 2970
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2971
When to Perform 2971
Why Perform 2971
How to Perform 2971
Proc_Cal_026: Travel Speed Calibration 2973
When to Perform 2973
Calibration Order 2973
Why Perform 2973
How to Perform 2973
524262279 1800YRM1247 (09 2018) UK EN 2977
General 2981
Dry Brake System 2981
Wet Brake System 2982
Service Brakes Repair (Dry Brake) 2986
Remove and Disassemble 2986
Clean 2988
Inspect 2989
Assemble and Install 2989
Adjust 2993
Parking Brake Repair 2993
Dry Brake System 2994
Remove and Disassembly 2994
Assemble and Install 2996
Wet Brake System 2996
Remove and Install 2997
Assemble and Install 3003
Adjust 3003
Dry Brake System 3003
Wet Brake System 3004
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3004
Master Cylinder Repair 3005
Remove 3005
Disassemble 3010
Clean and Inspect 3011
Assemble 3012
Install and Adjust 3012
Accumulator 3014
Pre-Charge Check 3015
Remove 3016
Install 3018
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3018
Remove 3019
Modulating Brake Valve 3020
Disassemble 3020
Clean and Inspect 3022
Assemble 3022
Accumulator Charge Valve 3023
Disassemble 3023
Clean and Inspect 3025
Assemble 3025
Install 3026
Pressure Checks 3027
Accumulator Charge Valve Check 3027
Accumulator Check 3027
Service Brakes Adjustment (Dry Brake) 3028
Service Brakes Adjustment 3028
Brake System Air Removal 3029
Using Pressure Bleed System 3029
Using Brake Pedal Pressure 3030
Lift Truck Models with Master Cylinder 3030
Lift Truck Models with Modulating Brake Valve 3030
Brake Pedal Adjustment 3031
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) 3031
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3032
Free Pedal Adjustment 3034
Torque Specifications 3035
524288194 1300YRM1317 (03 2020) UK EN 3039
Transmission Repair 3043
Remove 3043
Torque Converter, Remove 3043
Disassemble 3044
Clean and Inspect 3093
Housings 3093
Oil Seals and Gaskets 3093
Bearings 3093
Gears and Shafts 3094
Assemble 3094
Torque Converter, Install 3135
Install 3136
Control Valve Repair 3137
Remove 3137
Disassemble 3137
Clean 3139
Inspect 3139
Assemble 3139
Install 3140
Torque Specification 3141
524288879 0100YRM1321 (11 2016) UK EN 3143
General 3147
Description 3148
Side Covers, Seat, Dash, and Hood Replacement 3149
Side Covers 3149
Remove 3149
Install 3149
Seat and Seat Plate 3150
Remove Seat 3150
Remove Seat Plate 3150
Install Seat Plate 3150
Install Seat 3150
Operator Restraint System 3154
Emergency Locking Retractor (ELR) 3154
Seat Plate and Seat Rail Check 3154
Steering Column, Dash, Kick Panel, and Seal Plate 3154
Remove 3154
Install 3157
Hood Support and Door Assembly 3159
Remove 3159
Install 3159
Hood Door Assembly 3164
Remove 3164
Install 3164
Steering Column 3165
Description 3165
Steering Column Repair 3165
Remove 3165
Disassemble 3166
Clean 3169
Inspect 3169
Assemble 3169
Install 3169
LPG Tank and Bracket Assembly 3169
Counterweight Replacement 3170
Remove 3170
Install 3171
Tow Pin, Remove and Install 3173
Overhead Guard Replacement 3173
Remove 3173
Install 3175
Engine Replacement 3175
Remove Engine 3175
Remove Transmission 3200
Remove Engine and Transmission 3203
Install Engine 3206
Install Transmission 3210
Install Engine and Transmission 3211
Electronic Throttle Replacement 3214
Cummins 4 5L Diesel Engine With Electronic Throttle 3215
Remove 3215
Install 3215
Pull Actuator Linkage Adjustment 3220
Low Idle Adjustment 3220
Throttle Pedal and Cable Adjustment 3220
Cummins 4 5L Diesel Engine 3221
Exhaust System Repair 3222
GM 4 3L Engine for Lift Truck Models GLP60VX, GLP70VX (GP/GLP135VX, GP/GLP155VX) (C878, D878) 3223
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909) 3223
Cummins QSB 3 3L Engine for Lift Truck Models GDP60VX, GDP70VX (GDP135VX, GDP155VX) (C878, D878), GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 3223
Remove 3223
Inspect 3225
Install 3225
Cummins 4 5L Diesel Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3225
Remove 3225
Inspect 3227
Install 3227
Cooling System 3227
Description 3227
Hydraulic Filter Assembly Repair 3227
Remove 3228
Install 3228
Fuel and Hydraulic Tanks Repair 3230
Inspect 3230
Clean 3230
Steam Method of Cleaning 3230
Chemical Solution Method of Cleaning 3231
Additional Preparations for Repair 3231
Small Leaks, Repair 3232
Large Leaks, Repair 3232
Preparations for Use After Repair 3232
Safety Labels 3232
524294878 2100YRM1328 (09 2018) UK EN 3241
General 3245
Safety Procedures When Working Near Mast 3245
Tilt Cylinder Repair 3247
Remove 3247
Disassemble 3252
Clean 3254
Inspect 3254
Assemble 3254
Install 3256
Tilt Cylinders, Adjust 3258
Tilt Cylinder Leak Check 3259
Lift Cylinder Repair 3260
Remove 3260
Disassemble 3270
Clean 3273
Inspect 3273
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) 3273
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3273
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) 3274
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3274
Free-Lift Cylinder Repair 3275
Remove 3275
Disassemble 3281
Clean 3283
Inspect 3283
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) 3284
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3284
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) 3284
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3285
Sideshift Cylinder Repair 3286
Remove 3286
Disassemble 3287
Clean 3290
Inspect 3290
Assemble 3291
Install 3292
Bolzoni Sideshift Cylinder Repair 3293
Remove 3293
Disassemble 3293
Clean 3294
Inspect 3294
Assemble 3295
Install 3295
Fork Positioner Cylinder Repair 3295
Remove 3296
Disassemble 3299
Clean 3303
Inspect 3303
Assemble 3304
Install 3305
Lift Cylinder Leak Check 3306
Seal Kit Installation 3306
External Installation (Seal and Back-Up Ring) 3306
Internal Installation (Piston Rod Assembly) 3307
Special Tools 3308
Torque Specifications 3309
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) 3309
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3309
524296605 1400YRM1344 (03 2020) UK EN 3313
General 3317
Identification Plate 3317
Drive Axle Removal 3317
Planetary Reduction Gear Repair 3329
Clean and Inspect 3339
Brake Repair 3348
Clean and Inspect 3361
Wet Brake Noise Reduction 3371
General 3371
Adding Additive To Transmission 3372
Differential Repair 3373
Clean and Inspect 3384
Bevel Pinion 3396
Clean and Inspect 3400
Drive Axle Installation 3410
Special Tools 3421
Torque Specifications 3422
524306203 0100YRM1290 (04 2014) UK EN 3425
550000873 4000YRM1406 (10 2017) UK EN 3529
Safety Procedures When Working Near Mast 3533
Fork Replacement 3535
Remove 3535
Install 3536
Checks 3536
Carriage Repair 3537
Remove 3537
Clean and Inspect 3540
Install 3540
Integral Sideshift Carriage And Fork Positioners Repair 3540
Integral Sideshift Carriage 3541
Remove 3541
Disassemble 3542
Clean and Inspect 3544
Assemble 3544
Install 3545
Fork Positioners 3545
Remove 3545
Disassemble 3548
Clean and Inspect 3550
Assemble 3550
Install 3550
Two-Stage Mast With Limited Free-Lift Repair 3551
Remove 3551
Disassemble 3554
Clean and Inspect 3557
Assemble 3559
Install 3559
Header Hose Installation 3560
Three-Stage Mast With Full Free-Lift Repair 3563
Remove 3563
Disassemble 3567
Clean and Inspect 3570
Assemble 3572
Install 3572
Header Hose Installation 3574
Mast Operation Check 3576
Tilt Cylinder Adjustment 3576
Main Lift Cylinder Repair 3576
Lift Chain Adjustment 3577
Mast Adjustments 3578
Load Roller Adjustment 3578
Mast Side Kicking Adjustment 3580
Carriage Adjustment 3580
550000875 8000YRM1408 (08 2012) UK EN 3585
toc 3585
Capacities and Specifications 3585
Safety Precautions Maintenance and Repair 3586
Lift Truck Lifting Capacity 3589
Counterweight Weights 3589
Tire Sizes 3589
Capacities 3590
Electrical System 3592
Transmission Oil Pressures 3592
Hydraulic System Relief Pressures 3594
Steering System 3594
Stall Speeds 3594
Mast Speeds 3595
Tilt Angles 3595
Front End Equipment – Mast Creep 3596
Mast Creep 3596
Engine Specifications 3596
Torque Specifications 3597
Frame 3597
Mast, Carriage, and Fork Positioner 3597
Steering System 3597
Transmission 3597
Engine, Cummins QSB 3 3L 3597
Engine, GM 5 7L LPG 3597
550001092 8000YRM1409 (03 2020) UK EN 3601
General Information About Diagrams and Schematics 3605
Symbol Definitions 3605
Diagrams Manual Applications 3606
Diagrams and Schematics 3608
550001097 8000YRM1407 (05 2019) UK EN 3689
General 3695
Serial Number Data 3695
How to Move Disabled Lift Truck 3695
How to Tow Lift Truck 3695
How to Put Lift Truck on Blocks 3696
How to Raise Drive Tires 3696
How to Raise Steering Tires 3697
How to Clean a Lift Truck 3698
Maintenance Schedule 3698
Maintenance Procedures Every 8 Hours or Daily 3709
How to Make Checks With Engine Stopped 3709
Tires and Wheels 3709
Safety Labels 3710
Mast, Carriage, Lift Chains, Header Hoses, and Attachment 3710
Operator Restraint System 3711
Emergency Locking Retractor (ELR) 3711
Adjust Seat – Full Suspension 3712
Adjust Seat – Internal Suspension 3713
Seat Plate and Seat Rails 3713
Engine Compartment 3713
Fuel, Oil, and Coolant Leaks, Check 3713
Hydraulic Hoses 3714
Coolant Hoses 3714
Steering Column Gas Cylinder 3714
Transmission 3714
Hydraulic System Oil 3714
Engine Oil 3715
Forks 3717
Remove 3717
Inspect 3718
Install 3718
Adjust 3719
Integral Sideshift Carriage 3719
How to Make Checks With Engine Running 3720
Indicator Lights, Horn, Fuses, and Relays 3720
Service Brakes 3723
Operation, Check 3723
Accumulator Pressure 3723
Parking Brake Check 3723
Engine Oil Pressure 3723
Cooling System 3724
Steering System 3725
Control Levers and Pedals 3725
Lift System, Operate 3725
Air Filter 3726
First Service After First 100 Hours of Operation 3727
Engine Oil and Oil Filter 3727
Maintenance Procedures Every 500 Hours or 6 Months 3728
Hydraulic System Oil Check 3728
Hydraulic Tank Breather 3729
Inspect 3729
Battery 3731
Engine Oil and Oil Filter 3731
Fuel/Water Separator Filter Replacement, Cummins QSB 3 3L Diesel Engine 3732
Remove 3732
Install 3732
Final Fuel Filter Replacement, Cummins QSB 3 3L Diesel Engine 3734
Priming The Fuel System, Cummins QSB 3 3L Diesel Engine 3734
Controlled Venting 3734
Manual Bleeding 3734
Drive Belt 3736
Fan and Alternator Drive Belt 3736
Fan and Alternator Drive Belt Adjustment, Cummins QSB 3 3L Diesel Engine 3737
Clean Debris From Radiator Core 3737
Transmission and Wet Brake Axle Oil Level Check 3738
Wet Brake Center Body Oil Level Check 3739
Forks 3741
Mast Lubrication 3742
Header Hose Checks 3746
Lift Chain Lubrication 3746
Tilt Cylinder Lubrication 3747
Brake Actuation Valve Rod End Pin 3749
Tie Rod Lubrication 3750
Low Idle Speed Check 3751
Drain Tar From LPG Converter 3751
GM 5 7L LPG Engine 3751
Parking Brake Adjustment 3752
Maintenance Procedures Every 1000 Hours or 6 Months 3752
Lift Chain Lubrication and Wear Check 3753
Integral Sideshift Carriage, Check Sliding Surfaces 3754
Steering Axle Spindle Bearings 3755
Control Levers and Pedals 3756
Inspect Engine Electrical System, Connectors 3756
Spark Plugs 3757
GM 5 7L LPG Engine 3757
PCV Valve 3757
GM 5 7L LPG Engine 3757
LPG Fuel Filter 3757
GM 5 7L LPG Engine 3757
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 3757
Maintenance Procedures Every 2000 Hours or Annually 3762
Hydraulic System 3762
Hydraulic Filter Assembly, Replace 3762
Remove 3762
Install 3763
Hydraulic Tank Breather, Replace 3764
Cooling System Check 3765
Air Filter 3767
Forks 3768
Brake Oil (Master Cylinder), Change 3768
Check Throttle Shaft for Sticking 3769
Inspect Exhaust Manifold and Piping for Leaks 3770
Transmission Automatic Clutch Calibration 3770
Brake System Accumulator 3770
Valve Clearance, Check and Adjust, Cummins QSB 3 3L Diesel Engine 3770
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 3771
GM 5 7L LPG Engine 3771
PCV Valve 3772
GM 5 7L LPG Engine 3772
LPG Electronic Pressure Regulator (EPR)/Fuel Mixer, Inspect 3772
GM 5 7L LPG Engine 3772
LPG Lock-Off Valve 3773
GM 5 7L LPG Engine 3773
Oxygen Sensors 3774
GM 5 7L LPG Engine 3774
Wheel Bearings 3774
Steer Wheels, Lubrication 3774
Maintenance Procedures Every 4000 Hours or 2 Years 3774
Hydraulic Oil, Replace 3774
Safety Procedures When Working Near Mast 3776
Lift Chain Adjustments 3777
Jump-Starting the Lift Truck 3778
Jump-Starting Using a Battery Charger 3779
Jump-Starting a Lift Truck Using Another Lift Truck 3779
Welding Repairs 3779
Overhead Guard Changes 3780
Wheel and Tire Replacement 3780
General 3780
Pneumatic Tire With Tube, Repair 3780
Remove Wheels From Lift Truck 3780
Remove Tire From Wheel 3780
Install Wheel in Tire 3783
Install Tire on Two-Piece Wheel 3785
Add Air to Pneumatic Tires With Tube 3786
Install the Wheels 3787
Dual Drive Wheels, Install 3787
Pneumatic Tubeless Tire, Repair 3787
Remove Wheels From Lift Truck 3787
Add Air to Pneumatic Tubeless Tire 3793
Wheels, Install 3793
Solid Rubber Tires on Pneumatic Wheels, Change 3793
Snap-On-Tire, Change 3797
Adhesives and Sealants 3800
550021072 0600YRM1432 (03 2020) UK EN 3803
General 3809
Engine Removal and Installation 3809
Cylinder Head Repair 3809
Intake Manifold 3809
Remove 3809
Clean and Inspect 3810
Install 3810
Cylinder Head 3811
Remove and Disassemble 3811
Clean and Inspect 3813
Valve Guides and Seats Repairs 3815
Valves Repair 3815
Valve Seats Repair 3816
Valve Springs 3817
Assemble and Install 3817
Engine Block Cleaning and Inspection 3819
Piston Bore Preparation 3821
Lubrication System Repair 3821
Oil Pan Removal 3821
Oil Pump Assembly 3822
Oil Pump, Removal 3822
Oil Pump, Disassemble 3822
Oil Pump, Assemble 3822
Oil Pump, Install 3823
Clean and Inspect 3824
Oil Pan, Install 3824
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 3826
Timing Cover 3826
Remove 3826
Install 3827
Timing Sprockets 3827
Remove 3827
Install 3828
Camshaft 3828
Remove 3828
Inspect 3829
Install 3829
Clean and Inspect 3830
Valve Lifters 3830
Remove 3830
Clean and Inspect 3831
Install 3832
Crankshaft Repair 3833
Crankshaft 3833
Remove 3833
Inspect and Repair 3834
Main Bearings and Journals Clearance Check 3835
Install 3835
Piston and Connecting Rod Assembles 3836
Connecting Rod Bearings, Replace 3836
Piston and Connecting Rod Assemblies, Remove 3837
Disassemble 3838
Piston, Clean and Inspect 3838
Cylinder Bores, Inspect and Repair 3838
Piston Rings 3839
Assemble 3840
Piston and Connecting Rod Assemblies, Install 3841
Flywheel and Flywheel Housing Repair 3842
Flywheel, Remove 3842
Clean 3842
Inspect 3842
Flywheel, Install 3843
Coolant System Repair 3843
Water Pump 3843
Remove 3843
Clean and Inspect 3844
Install 3844
Serpentine Belt 3845
Remove 3845
Inspect 3845
Install 3846
Thermostat 3846
Remove 3846
Thermostat Operation Check 3846
Install 3847
Fan Assembly Replacement 3847
Remove 3847
Inspect 3849
Install 3849
Ignition System 3849
Spark Plug Wire Inspection 3849
Spark Plug Wire Replacement 3849
Remove 3849
Install 3850
Spark Plug Replacement 3851
Remove 3851
Install 3851
Spark Plug Inspection 3852
Usage 3852
Inspect 3852
Visual Inspection 3853
Alternator Repair 3854
Remove 3854
Install 3854
Starter Repair 3854
Remove 3854
Install 3855
Compression Check 3855
Valve Clearance Adjustments 3855
Engine Specifications 3857
Engine Data 3857
Cylinder Head 3857
Camshaft 3857
Cylinder Bore 3857
Piston 3858
Piston Pin 3858
Crankshaft 3858
Connecting Rods 3858
Balance Shaft 3858
Cooling System 3859
Lubrication System 3859
Torque Specifications for Capscrews and Bolts 3859
550021077 0900YRM1433 (03 2020) UK EN 3863
General 3867
LPG Tank and Bracket 3867
LPG Tank 3867
Remove 3867
Install 3870
LPG Tank Bracket 3870
Remove 3870
Install 3870
LPG Tank Bracket Alignment Pin 3871
Remove 3871
Install 3871
Fuel Filter Unit 3872
Fuel Filter Element 3872
Remove 3872
Clean and Inspect 3872
Install 3872
Fuel Filter Housing 3873
Remove 3873
Disassemble 3875
Clean and Inspect 3875
Assemble 3876
Install 3876
Electronic Throttle Body 3877
Remove 3877
Install 3878
Fuel Mixer/Electronic Pressure Regulator (EPR) 3879
Remove 3879
Install 3880
Control System 3881
Engine Control Unit (ECU) 3881
Remove 3881
Install 3882
Low Pressure Switch 3882
Remove 3882
Install 3882
Low Fuel Sensor 3883
Remove 3883
Install 3883
LP Converter 3884
Remove 3884
Disassemble 3885
Assemble 3886
Install 3887
Lock-Off Valve 3888
Remove 3888
Install 3888
Exhaust System 3889
Counterweight Exhaust 3889
Remove and Disassemble 3889
Inspect 3890
Assemble and Install 3891
Exhaust Manifold 3891
Remove 3891
Install 3893
Positive Crankcase Ventilation (PCV) Valve 3893
Remove 3893
Inspect 3894
Install 3895
Oxygen Sensors 3895
Remove 3895
Install 3895
LPG Fuel Testing 3896
General 3896
Available Fuel Tests 3896
Composition Test (ASTM D-2163) 3896
Ammonia Test (ASTM D-4490) 3896
Basic Nitrogen Test (ASTM UOP269-90) 3896
Residues Test (ASTM D-2158) 3896
Vapor Pressure Test (ASTM D-2598) 3896
Sulfur Compounds Test (ASTM D-5623) 3896
Methanol Test (ASTM D-4864) 3897
Copper Corrosion (ASTM D-1838) 3897
Where To Send LPG Fuel Samples For Testing 3897
550073240 1900YRM1620 (03 2020) UK EN 3899
Proper Flushing after Major Hydraulic Repairs 3903
Introduction 3903
The Phases of Wear 3903
Causes of Hydraulic System Failure 3903
Progression of Contaminant Caused Hydraulic System Failure 3904
Hydraulic System Flushing Techniques 3904
Double Oil and Filter Change 3904
Mechanical Cleaning 3905
Cleaning of Components 3905
How to Clean Tubes and Hoses 3905
Filter Caddy 3905
Start-Up Procedure for Cleaned System 3906
Contaminated Oil Coolers 3906
Additional Filter Caddy Functions 3906
How to Handle Different Fluids 3906
Water Removal Filters 3907
Fluid Conditioning and System Flushing Procedures 3907
Operation of the Filter Caddy 3907
Filter Caddy operation 3907
Fluid Conditioning Procedure 3908
Filter Caddy Start-Up 3908
System Flushing Procedure 3909
Component Cleaning Procedure 3909
Reservoir Cleaning Procedure 3909
Cylinder Cleaning Procedure 3909
Hose and Tube Cleaning Procedure 3910
Valve Cleaning Procedure 3910
Front-End Attachment Cleaning Procedure 3911
System Flushing Procedure 3911
Filter Caddy Start-Up 3912
System Start-Up and Flushing 3912
Reservoir Fluid Cleaning Times 3913
Dealing With Different Fluid Types 3913
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 3913
Filter Caddy Maintenance 3914
Servicing the Strainer 3914
DC Motor 3914
Hydraulic Oil Sampling Method and Procedure 3914
Hydraulic Oil Sampling Method 3914
Objective 3914
General Guidelines 3914
Synopsis 3915
Hydraulic Oil Analysis Report Guidelines 3916
Sampling Conditions 3917
Equipment 3917
Sampling Procedure 3917
Hydraulic Oil Sampling 3917
Sample Labeling 3918
Results Documentation 3918