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 : 4132
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 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797 8000YRM0231 (03 2020) UK EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524208014 2200YRM1097 (03 2020) UK EN 43
Series Code / Model Designation Reference Table 47
Description 48
Distributor Ignition (DI) System 48
Crankshaft Position (CKP) Sensor 48
Camshaft Position (CMP) Sensor 48
Ignition Coil and Ignition Control Module (ICM) 48
Secondary Ignition Components 48
Spark Plugs and Wires 49
Spark Plug Wire Inspection 49
Spark Plug Wire Replacement 49
Remove 49
Install 50
Spark Plug Inspection 50
Usage 50
Inspection 50
Visual Inspection 52
Spark Plug Replacement 52
Remove 52
Install 52
Distributor Repair 53
Inspect 53
Overhaul 53
Disassemble 53
Assemble 56
Replace 57
Remove 57
Install Procedure 1 59
Install Procedure 2 60
Ignition Coil Replacement 61
Remove 61
Install 61
Ignition Control Module Replacement 62
Remove 62
Install 62
Starter Replacement 63
Remove 63
Install 66
Sensors and Switches 67
Gas and LPG Trucks 67
Crankshaft Position (CKP) Sensor 67
Remove 67
Install 67
Camshaft Position (CMP) Sensor 68
Remove 68
Install 70
Oil Pressure Sensor 70
Remove 70
Install 71
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 72
Remove 72
Install 72
Engine Coolant Temperature (ECT) Sensor 73
Remove 73
Install 74
Air Flow Restriction Switch 74
Remove 74
Install 75
Specifications and Special Tools 76
524221866 9000YRM1112 (10 2020) UK EN 81
SECTION 9010 Operational Diagnostic Procedures 97
Group 05 – Operational Checkout 99
SECTION 9020 Engine 117
Group 10 – Principles of Operation 127
Group 30 – Observed Symptoms 325
Group 40 – Tests and Adjustments 427
SECTION 9030 Electrical System 459
Group 03 – General Maintenance and Diagnostic Data 483
Group 10 – Principles of Operation 577
Group 20 – Diagnostic Trouble Codes 601
Group 30 – Observed Symptoms 1573
SECTION 9040 Drive Train 1629
Group 10 – Principles of Operation 1633
Group 30 – Observed Symptoms 1689
Group 40 – Tests and Adjustments 1739
SECTION 9050 Hydraulic Systems 1749
Group 10 – Principles of Operation 1753
Group 30 – Observed Symptoms 1811
Group 33 – Observed Symptoms-Gear Pump 1813
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1901
Group 40 – Tests and Adjustments 1945
Group 43 – Tests and Adjustments-Gear Pump 1947
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1971
SECTION 9060 Operators Station 1989
Group 10 – Principles of Operation 1991
SECTION 9070 Front End (Mast) and Chassis 2027
Group 10 – Principles of Operation 2029
Group 30 – Observed Symptoms 2051
SECTION 9080 Supplementary Data 2109
Group 50 – Abbreviations and Acronyms 2111
Group 60 – Special Tools List 2119
Group 70 – Fault Mode Indicator Reference 2129
Group 80 – Supplier Specification Data 2131
524223757 0700YRM1123 (06 2016) UK EN 2135
General 2139
Cooling System Checks 2139
Exhaust Leaks Into Cooling System 2139
Water Flow Restrictions in Radiator 2139
Radiator Hoses 2139
Water Pump 2140
Flushing the Cooling System 2140
Cooling System, Clean 2140
Radiator Replacement 2141
Radiator, Remove GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2142
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2157
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2160
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 2163
Radiator, Install for Lift Truck Models GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2170
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2175
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2177
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2180
Fan Assembly Replacement 2192
Fan Removal 2192
Inspect 2207
Fan Installation 2207
524223764 1600YRM1133 (07 2013) UK EN 2213
toc 2213
Steering Axle 2213
Safety Precautions Maintenance and Repair 2214
General 2217
Steering Axle Assembly Repair 2219
Remove 2219
Disassemble 2220
Clean 2228
Inspect 2228
Assemble 2228
Install 2234
Spindles, Bearings, and Tie Rods Repair 2236
Spindles and Bearings 2236
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2236
Remove 2236
Disassemble 2238
Clean 2239
Inspect 2239
Assemble 2239
Install 2240
Spindles and Bearings 2243
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2243
Remove and Disassemble 2243
Assemble and Install 2244
Tie Rods 2244
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2244
Remove 2244
Install 2245
Tie Rods 2246
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2246
Remove 2246
Install 2252
Steering Cylinder Repair 2252
Remove and Disassemble 2252
Clean and Inspect 2253
Assemble and Install 2253
Torque Specifications 2254
524223766 1900YRM1136 (11 2017) UK EN 2259
General 2263
Hydraulic Gear Pump Assembly 2264
Variable Displacement Pump Assembly 2265
Single Gear Pump Assembly Repair 2265
Remove 2265
Disassemble 2272
Clean 2272
Inspect 2274
Assemble 2274
Install 2274
Tandem Gear Pump Assembly 2278
Remove 2279
Disassemble 2281
Clean 2283
Inspect 2283
Assemble 2283
Install 2284
Gear Pump Specifications 2284
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2290
Remove 2290
Disassemble 2300
Clean 2303
Inspect 2303
Assemble 2303
Install 2304
63 0 cc/rev – Variable Displacement Pump Repair 2307
Remove 2307
Disassemble 2310
Clean 2310
Inspect 2310
Assemble 2312
Install 2312
Variable Displacement Pump Checks and Adjustments (Single Pump) 2314
Margin Pressure Check 2314
Flow Compensator Adjustment 2315
Pressure Compensator Adjustment 2315
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2316
Variable Displacement Pump Specifications 2319
Torque Specifications 2320
Hydraulic Gear Pump 2321
Variable Displacement Pump 2322
Special Tools 2322
524223767 2000YRM1137 (01 2017) UK EN 2327
General 2333
Electro-Hydraulic Main Control Valve 2334
Description 2334
Remove 2342
Electro-Hydraulic Control Valve Sections 2347
General 2347
Outlet Control Valve Section 2347
Remove 2347
Disassemble 2348
Clean 2350
Inspect 2350
Assemble 2350
Install 2351
Auxiliary Control Valve Sections 2351
Remove 2351
Disassemble 2358
Clean 2359
Inspect 2360
Assemble 2360
Install 2362
Tilt Control Valve Section 2363
Remove 2363
Disassemble 2363
Clean 2369
Inspect 2369
Assemble 2369
Install 2370
Lift/Lower Control Valve Section 2371
Remove 2371
Disassemble 2371
Clean 2380
Inspect 2380
Assemble 2380
Install 2381
Mid-Inlet Section 2381
Remove 2381
Clean 2382
Inspect 2382
Install 2382
Install 2382
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2387
Lift Pilot Pin 2387
Lower Pilot Pin 2391
Abnormal/Erroneous EHPV Adjustment 2393
Manual Main Control Valve 2394
Description 2394
Remove 2398
OPS Solenoid Assembly 2406
General 2406
Remove 2407
Clean and Inspect 2410
Install 2410
Manual Control Valve Sections 2411
General 2411
Outlet Control Valve Section 2411
Remove 2411
Disassemble 2411
Clean 2414
Inspect 2414
Assemble 2414
Install 2415
Auxiliary Control Valve Sections 2415
Remove 2415
Disassemble 2415
Clean 2418
Inspect 2418
Assemble 2418
Install 2419
Lift/Tilt Control Valve Section 2419
Remove 2419
Disassemble 2419
Clean 2426
Inspect 2426
Assemble 2427
Install 2428
Mid-Inlet Section 2429
Remove 2429
Clean 2429
Inspect 2429
Install 2429
Install 2430
Pressure Relief Valve Check and Adjustment 2436
Primary Relief Valve 2437
Secondary Relief Valve 2441
Steering Control Unit Repair 2448
Steering Control Unit, Remove 2448
Steering Control Unit, Disassemble 2452
Steering Control Unit, Clean 2454
Steering Control Unit, Inspect 2454
Steering Control Unit, Assemble 2454
Relief Valve, Disassemble 2455
Relief Valve, Clean 2455
Relief Valve, Inspect 2456
Relief Valve, Assemble 2456
Steering Control Unit, Install 2456
524223769 2200YRM1128 (01 2023) US EN 2461
Series Code / Model Designation Reference Table 2469
General 2471
Deutsch Crimping Tool 2472
How to Strip a Wire for Use With Deutsch Crimping Tool 2472
How to Crimp With the Deutsch Crimping Tool 2473
Calibration Test for the Deutsch Crimping Tool 2475
Deutsch Connectors 2477
DT, DTM, and DTP Series Connectors 2477
HD Series Connectors 2520
Metri-Pack Connectors 2542
Remove and Install 2542
Micro-Pack Connectors 2545
Weather-Pack Connectors 2546
AMPSEAL Crimping Tools 2548
AMP Hand Crimping Tool With Certi-Crimp 2548
Description 2548
Stripping Wire for Use with AMP Hand Crimping Tool 2549
Insulation Crimp Adjustment 2550
Maintenance and Inspection for AMP Hand Crimping Tool 2550
AMP Hand Crimping Tool 2550
Crimp Height Inspection 2550
How to use AMP Hand Crimping Tool 2551
AMP Pro-Crimper II Tool 2551
Description 2551
Remove and Install Die Set and Locator Assembly 2552
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2552
Contact Support Adjustment 2553
Crimp Height Adjustment 2554
Maintenance and Inspection Procedures 2554
PRO-CRIMPER II Tool 2554
Crimp Height Inspection 2554
How to Use AMP PRO-CRIMPER II Tool 2555
AMPSEAL Connector Assemblies 2556
Description for Plug Connector Assembly 2556
Seal Plug 2557
Contact Crimping 2557
Description for Plug Connector and Header Assembly 2562
Voltage Reading 2565
Seal Plug 2565
Contact Crimping 2565
AMP Superseal 1 5 Crimping Tools 2572
Mini Mic Receptacle and Tab Contacts 2572
Description 2572
Crimping Conditions and Measurements 2572
Insertion of Rubber Seal on Cable 2574
AMP Hand Application Tool 2579
Description 2579
Maintenance and Inspection 2579
Crimp Height Inspection 2579
Crimp Height Adjustment 2580
How to Use AMP Hand Application Tool 2580
AMP Pro-Crimper II Tool 2581
Description 2581
Remove and Install Die Set and Locator Assembly 2581
Adjustments 2582
Contact Support 2582
Crimp Height 2583
Inspections and Maintenance 2584
Crimp Height Inspection 2584
Visual Inspection 2584
Maintenance 2585
How to Use Pro-Crimper II Tool 2585
AMP Superseal 1 5 Connector Assemblies 2586
Description 2586
Repair and Maintenance 2593
Panel Mount Option 2593
AMP Fastin-Faston Hand Tools 2594
Description – AMP Double Action Hand Tool 2594
Maintenance and Inspection Procedures 2594
Daily Maintenance 2594
Periodic Tool Inspection 2595
Lubrication 2595
Visual Inspection 2595
Crimp Height Inspection 2595
Certi-Crimp Ratchet Inspection 2596
How to Use AMP Double Action Hand Tool 2597
Description – AMP Extraction Tool 2598
Maintenance and Inspection 2599
How to Use AMP Extraction Tool 2599
AMP Fastin-Faston Receptacles and Housings 2601
Description 2601
Wire Repair 2609
Wire Splicing Requirements 2609
Deutsch Jiffy Splice 2610
Twisted/Shielded Cable and Leads Repair 2616
Special Tools 2618
524223769 2200YRM1128 (07 2020) UK EN 2627
Series Code / Model Designation Reference Table 2633
General 2636
Deutsch Crimping Tool 2636
How to Strip a Wire for Use With Deutsch Crimping Tool 2636
How to Crimp With the Deutsch Crimping Tool 2637
Calibration Test for the Deutsch Crimping Tool 2639
Deutsch Connectors 2641
DT, DTM, and DTP Series Connectors 2641
HD Series Connectors 2683
Metri-Pack Connectors 2706
Remove and Install 2706
Micro-Pack Connectors 2708
Weather-Pack Connectors 2709
AMPSEAL Crimping Tools 2711
AMP Hand Crimping Tool With Certi-Crimp 2711
Description 2711
Stripping Wire for Use with AMP Hand Crimping Tool 2711
Insulation Crimp Adjustment 2712
Maintenance and Inspection for AMP Hand Crimping Tool 2712
AMP Hand Crimping Tool 2712
Crimp Height Inspection 2712
How to use AMP Hand Crimping Tool 2713
AMP Pro-Crimper II Tool 2713
Description 2713
Remove and Install Die Set and Locator Assembly 2714
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2715
Contact Support Adjustment 2715
Crimp Height Adjustment 2716
Maintenance and Inspection Procedures 2716
PRO-CRIMPER II Tool 2716
Crimp Height Inspection 2716
How to Use AMP PRO-CRIMPER II Tool 2717
AMPSEAL Connector Assemblies 2718
Description for Plug Connector Assembly 2718
Seal Plug 2719
Contact Crimping 2719
Description for Plug Connector and Header Assembly 2724
Voltage Reading 2726
Seal Plug 2726
Contact Crimping 2726
AMP Superseal 1 5 Crimping Tools 2733
Mini Mic Receptacle and Tab Contacts 2733
Description 2733
Crimping Conditions and Measurements 2733
Insertion of Rubber Seal on Cable 2735
AMP Hand Application Tool 2740
Description 2740
Maintenance and Inspection 2740
Crimp Height Inspection 2740
Crimp Height Adjustment 2741
How to Use AMP Hand Application Tool 2741
AMP Pro-Crimper II Tool 2742
Description 2742
Remove and Install Die Set and Locator Assembly 2743
Adjustments 2743
Contact Support 2743
Crimp Height 2744
Inspections and Maintenance 2745
Crimp Height Inspection 2745
Visual Inspection 2745
Maintenance 2746
How to Use Pro-Crimper II Tool 2746
AMP Superseal 1 5 Connector Assemblies 2747
Description 2747
Repair and Maintenance 2754
Panel Mount Option 2754
AMP Fastin-Faston Hand Tools 2755
Description – AMP Double Action Hand Tool 2755
Maintenance and Inspection Procedures 2755
Daily Maintenance 2755
Periodic Tool Inspection 2756
Lubrication 2756
Visual Inspection 2756
Crimp Height Inspection 2756
Certi-Crimp Ratchet Inspection 2757
How to Use AMP Double Action Hand Tool 2758
Description – AMP Extraction Tool 2759
Maintenance and Inspection 2759
How to Use AMP Extraction Tool 2760
AMP Fastin-Faston Receptacles and Housings 2761
Description 2761
Wire Repair 2768
Wire Splicing Requirements 2768
Deutsch Jiffy Splice 2769
Twisted/Shielded Cable and Leads Repair 2774
Special Tools 2777
524223770 2200YRM1130 (03 2020) UK EN 2785
General 2789
Description 2789
Dash Display Menu Access 2789
Menu Navigation 2790
Standard Display 2790
Main Menu 2790
Passwords Menu 2791
Password Administration 2791
Add Password 2791
Delete Password 2792
Edit Password 2792
Other Password Functions 2793
Operator Passwords – Enable/Disable 2793
Password Time-Out Delay 2793
Passwords – Number Wrong to Disable 2794
Lockout Reset Password 2794
View Password Log 2795
View Versions 2796
VSM Versions 2796
Dash Display Versions 2797
Engine Controller Version 2798
Transmission (Xmsn) Controller Version 2799
Truck Serial Number 2800
Diagnostics 2801
View Fault Log 2801
Set Travel and Braking 2802
Speed Limit 2802
Acceleration Rate 2803
Auto-Deceleration Rate 2803
Set Power Reversal Rate 2804
Set Inching/Brake Overlap 2805
Setup Display Menu 2806
Set Operator Language 2806
Set Units 2807
Set Time Format (12/24 Hour) 2807
Set Daylight Saving Time 2807
Set Time 2810
Set Date Format 2811
Set Date 2811
Setup Hydraulics 2812
Return to Set Tilt Delay/On/Off 2812
Setup General Items 2813
Light Shutdown Time-Out 2813
Impact Sensor – Enable/Disable 2814
Impact Sensor – Soft Impact Settings 2815
Impact Sensor – Hard Impact Settings 2816
Adjust Impact Sensor Settings 2816
Initial Adjustment of Soft and Hard Impact Settings 2818
Readjustment of Soft and Hard Impact Settings 2818
Impact Sensor – Impact Alarm/Shutdown Reset 2819
Impact Sensor – Alarm Time Duration and Deactivation 2820
Impact Sensor – View Impact Event Log 2821
Engine Mode Indicator 2822
Generation 1 (ECO-eLo ONLY) 2822
Generation 2 2823
Operator Checklist 2824
Operator Checklist Off-On Mode 2824
Edit Operator Checklist 2824
Set Operator Checklist Expiration 2825
View Checklist Log 2825
Clear Operator Checklist Log 2826
Clear Operator Checklist Fault 2826
Calibrations 2827
Set Tilt Stop Point 2827
Calibrate Loaded Weight 2827
524223771 2200YRM1131 (03 2020) UK EN 2829
Series Code / Model Designation Reference Table 2835
General 2837
Description 2837
Dash Display Menu Access 2837
Menu Navigation 2838
Main Menu 2838
Passwords 2839
Adding Passwords 2839
Hourmeters 2841
View Versions 2842
VSM Versions 2842
Dash Display Versions 2843
Engine Controller Version 2844
Transmission (Xmsn) Controller Version 2845
Truck Serial Number 2846
Truck Configuration 2847
Diagnostics 2848
Clear Fault Log 2848
View Fault Log 2849
No-Run Data Display 2850
Engine Accelerator and Throttle Data Display 2850
Engine Speeds and Governor Data Display 2851
Engine Fuel and Emissions Data Display 2852
Engine General Data Display 2854
XMSN/Brake Data Display 2855
Hydraulic Data Display 2858
General Truck Data Display 2860
Set Travel and Braking 2861
Speed Limit 2861
Acceleration Rate 2862
Auto-Deceleration Rate 2863
Set Power Reversal Rate 2863
Set Inching/Brake Overlap 2864
Setup Hydraulics 2864
Lift Maximum Speed 2865
Lower Maximum Speed 2865
Tilt Maximum Speed 2866
Auxiliary Function One, Direction A, Maximum Speed 2868
Auxiliary Function One, Direction B, Maximum Speed 2870
Auxiliary Function Two, Direction A, Maximum Speed 2870
Auxiliary Function Two, Direction B, Maximum Speed 2871
Auxiliary Function Three, Direction A, Maximum Speed 2872
Auxiliary Function Three, Direction B, Maximum Speed 2872
Lift/Lower Ramp Rate 2873
Hydraulic Auxiliary Ramp Rate 2873
Return to Set Tilt Delay/On/Off 2874
Hydraulic Input Device 2875
Auxiliary Solenoid 2875
Dual Function 2876
Setup Display 2877
Set Service Language 2877
Setup General Items 2877
Motion Alarm Activation Type 2878
Light Shutdown Time-Out 2879
Restore Default Settings 2879
Restore Engine Controller Default Calibration 2880
Impact Sensor – Enable/Disable 2880
Impact Sensor – Soft Impact Settings 2881
Impact Sensor – Hard Impact Settings 2882
Adjust Impact Sensor Settings 2883
Initial Adjustment of Soft and Hard Impact Settings 2885
Readjustment of Soft and Hard Impact Settings 2885
Impact Sensor – Impact Alarm/Shutdown Reset 2886
Impact Sensor – Alarm Time Duration and Deactivation 2887
Impact Sensor – View Impact Event Log 2888
Engine Mode Indicator 2888
Generation 1 (ECO-eLo ONLY) 2888
Generation 2 2889
Diesel Particulate Filter (DPF) Display 2890
General Description 2890
Passive Regeneration Only 2890
Regeneration Level 0 2890
Auto/Active Regeneration Inhibited 2891
Auto/Active Regeneration 2891
Regeneration Level 1 2891
Parked Regeneration Request 2892
Regeneration Level 2 2892
Warning Level 2892
Regeneration Level 3 2892
Service Level 2893
Regeneration Level 4 2893
Display, Diesel Particulate Filter (DPF), Revised 2893
Operator Interface 2893
Refer to Operator Manual 2893
CAN Communication Lost 2894
Passive Regeneration Only 2894
Regeneration Level 0 2894
Auto/Active Regeneration Inhibited 2894
Auto/Active Regeneration 2895
Regeneration Level 1 2895
Idle-up Auto/Active Regeneration 2895
Parked Regeneration Request 2895
Regeneration Level 2 2895
Warning Level 2897
Regeneration Level 3 2897
Service Level 2897
Regeneration Level 4 2897
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2897
Display, Diesel Particulate Filter (DPF), Stage V Engine 2897
Operator Interface 2898
Refer to Operator Manual 2898
CAN Communication Lost 2898
Passive Regeneration Only 2898
Regeneration Level 0 2898
Auto/Active Regeneration Inhibited 2899
Auto/Active Regeneration 2899
Regeneration Level 1 2899
Idle-up Auto/Active Regeneration 2900
Parked Regeneration Request 2900
Regeneration Level 2 2900
Warning Level 2901
Regeneration Level 3 2901
Service Level 2902
Regeneration Level 4 2902
Stage V Content 2902
Emissions System Malfunction 2902
Ash Load 2902
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2903
Operator Interface 2903
Refer to Operator Manual 2903
CAN Communication Lost 2904
Passive Regeneration Only 2904
Regeneration Level 0 2904
Auto/Active Regeneration Inhibited 2904
Auto/Active Regeneration 2905
Regeneration Level 1 2905
Idle-up Auto/Active Regeneration 2905
Parked Regeneration Request 2905
Regeneration Level 2 2905
Warning Level 2907
Regeneration Level 3 2907
Service Level 2907
Regeneration Level 4 2907
Calibrations 2908
Calibrate Transmission Valve 2910
Set Tilt Stop Point 2910
Calibrate Loaded Weight 2910
Calibrate Travel Speed Sensor 2911
Calibrate Mazda LP and Gas Accelerator Pedal 2911
524223772 2200YRM1142 (01 2020) UK EN 2913
General 2923
Display Switch Cluster 2926
Remove 2926
Install 2929
Direction Control and Turn Signal Levers 2929
Remove 2929
Install 2931
Key Switch 2931
Remove 2931
Install 2932
Display Switch Cluster Panel Bezel and Overlay 2932
Remove 2932
Install 2932
Steering Column Repair 2932
Remove 2932
Disassemble 2935
Assemble 2935
Install 2935
Sensors and Switches 2936
General 2936
Dash and Kick Panel, Remove and Install 2936
Remove 2936
Install 2937
Accelerator Pedal Position Sensor 2938
Remove 2938
Install 2941
Brake Fluid Level Switch 2942
Remove 2942
Install 2944
Service Brake Pedal Position Sensor 2945
Remove 2945
Install 2948
Parking Brake Sensor 2949
Remove 2949
Install 2950
Service Brake Pressure Sensor 2951
Remove 2951
Install 2953
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2954
Remove 2954
Install 2954
Sensor Microswitch (Foot Directional Control Pedal) 2955
Remove 2955
Install 2958
Low Coolant Level Sensor 2959
Remove 2959
Install 2962
Fuel Level Sensor, Gas and Diesel Engines Only 2963
Remove 2963
Install 2964
Armrest Switch 2964
Remove 2964
Install 2966
Seat Sensor (Operator Presence System) 2966
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) 2966
Remove 2966
Install 2967
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 2967
Remove 2967
Install 2968
Full Suspension Seats; All Lift Truck Models 2968
Remove 2968
Install 2968
Hood Shut Off Switch 2968
Remove 2968
Install 2971
Remote Key Switch 2972
Remove 2972
Install 2972
Hydraulic Filter Pressure Switch 2973
Remove 2973
Install 2975
Transmission Speed Sensor 2975
Remove 2975
Install 2978
Transmission Pressure Sensors 2979
Remove 2979
Install 2981
Transmission Temperature Sensor 2982
Remove 2982
Install 2984
Engine Speed Sensor 2986
Remove 2986
Install 2986
Intermediate Speed Sensor 2987
Remove 2987
Install 2987
Return to Set Tilt (Tilt Angle) Sensor 2987
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) 2987
Remove 2987
Install 2988
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) 2989
Remove 2989
Install 2990
Rear Horn Button Switch 2990
Remove 2990
Install 2991
Impact Sensor 2992
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) 2992
Remove 2992
Install 2995
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) 2995
Remove 2995
Install 2996
Load Weight Sensor 2997
Remove 2997
Install 2998
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 2999
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 2999
Crankshaft Position (CKP) Sensor 2999
Camshaft Position (CMP) Sensor 2999
Oil Pressure Sensor 2999
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 2999
Engine Coolant Temperature (ECT) Sensor 3000
Air Flow Restriction Switch 3000
Remove for GM 2 4L Gas and LPG Trucks 3000
Install for GM 2 4L Gas and LPG Trucks 3000
Oxygen Sensor 3001
Remove 3001
Install 3004
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3005
Crankshaft Position (CKP) Sensor 3005
Camshaft Position (CMP) Sensor 3005
Oil Pressure Sensor 3005
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3005
Engine Coolant Temperature (ECT) Sensor 3005
Air Flow Restriction Switch 3005
Oxygen Sensor 3005
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3005
Low LPG Pressure Switch 3005
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3006
Air Filter Restriction Switch 3006
Remove 3006
Install 3006
Oil Pressure Sensor 3006
Remove 3006
Install 3006
Engine Speed Sensor 3006
Remove 3006
Install 3006
Engine Coolant Temperature (ECT) Sensor 3006
Remove 3006
Install 3006
Throttle Position Sensor (TPS) 3009
Remove 3009
Install 3010
Fuel/Water Separator Sensor 3010
Remove 3010
Install 3010
Glow Plug Relay 3011
Remove 3011
Install 3013
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3013
Air Filter Restriction Switch 3013
Remove 3013
Install 3013
Engine Oil Pressure Sensor 3018
Remove 3018
Install 3018
Engine Speed Sensor 3018
Remove 3018
Install 3019
Engine Coolant Temperature (ECT) Sensor 3019
Remove 3019
Install 3020
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3021
Remove 3021
Install 3021
Fuel/Water Separator Sensor 3022
Remove 3022
Install 3022
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3023
Intake Air Temperature Sensor 3023
Remove 3023
Install 3024
Intake Air Pressure Sensor 3024
Remove 3024
Install 3024
Air Inlet Heater 3024
Remove 3024
Install 3025
Engine Oil Pressure Sensor 3025
Remove 3025
Install 3025
Engine Coolant Temperature (ECT) Sensor 3025
Remove 3025
Install 3025
Crankshaft Position Sensor 3026
Remove 3026
Install 3026
Adjust Shim Procedure 3027
Camshaft Position Sensor 3028
Remove 3028
Install 3028
Air Flow Restriction Sensor 3029
Remove 3029
Install 3029
Fuel/Water Separator 3029
Remove 3029
Install 3030
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3030
Intake Air Temperature Sensor 3034
Remove 3034
Install 3035
Boost Sensor 3035
Remove 3035
Install 3036
Throttle Valve Assembly and Air Intake Heater 3036
Remove 3036
Install 3036
Engine Coolant Temperature (ECT) Sensor 3037
Remove 3037
Install 3037
Engine Oil Pressure Sensor 3037
Remove 3037
Install 3038
Crankshaft Position Sensor 3038
Remove 3038
Install 3038
Adjust Shim Procedure 3039
Camshaft Position Sensor 3040
Remove 3040
Install 3041
Differential Pressure Sensor 3041
Remove 3041
Install 3041
Mass Air Flow Sensor 3042
Remove 3042
Install 3043
Fuel/Water Separator 3043
Remove 3043
Install 3044
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3044
Engine Coolant Temperature (ECT) Sensor 3045
Remove 3045
Install 3045
Throttle Position Sensor 3046
Engine Oil Pressure Sensor 3046
Remove 3046
Install 3046
Engine Speed Sensor 3046
Remove 3046
Install 3046
Fuel Shut Off Solenoid 3046
Remove 3046
Install 3046
Vehicle System Manager (VSM) 3047
General 3047
VSM Replacement 3047
Remove 3047
Install 3049
Programming a New VSM and/or Display Switch Cluster 3049
General 3049
PC Service Tool Software 3050
Data Transferring 3050
New VSM 3050
New (Blank) Display Switch Cluster 3050
Used (Non-Blank) Display Switch Cluster 3050
Power Distribution Module (PDM) and Component Parts 3052
Remove 3052
PDM as a Unit 3052
Install 3056
PDM as a Unit 3056
Remove and Install 3057
PDM Component Parts 3057
Transmission Control Unit 3057
Remove 3057
Install 3061
Battery 3063
Remove 3063
Install 3063
Lights 3064
Work Lights (Front and Rear) 3064
Remove 3064
Install 3064
Strobe Light 3065
Remove 3065
Install 3065
LED Tail, Backup, and Brake Lights 3066
Remove 3066
Install 3067
Front Marker/Turn Signal Lights 3068
Replacing Whole Front Marker/Turn Signal Light Assembly 3068
Remove 3068
Install 3068
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3069
Remove 3069
Install 3069
Diesel Particulate Filter (DPF) Display 3069
Remove 3069
Clean and Inspect 3070
Install 3070
Electronic-Hydraulic Controls – Generation 1 3071
E-Hydraulic Controls – Test 3071
Mini-Levers 3071
Full Stroke Test 3071
Function Returns to Neutral Test 3071
Push Button Switch 3071
General 3072
Mini-Lever Replacement 3072
Remove 3072
Clean and Inspect 3073
Install 3073
Push Button Switch Replacement 3074
Remove 3074
Install 3076
Mini-Lever Module (MLM) 3076
Remove 3076
Install 3076
Joystick 3077
Remove and Disassemble 3077
Inspect 3077
Assemble and Install 3077
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3078
General 3078
Mini-levers, Remove and Install 3078
Armrest Assembly 3079
Remove 3079
Install 3082
Horn Button 3082
Remove 3082
Install 3082
Direction Control Switch 3083
Remove 3083
Install 3083
push (override) buttons and Toggle Switch 3083
Remove 3084
Install 3085
Joystick 3086
Remove and Disassemble 3086
Inspect 3086
Assemble and Install 3086
Joystick Armrest Slider Assembly 3087
Remove 3087
Install 3088
Electronic-Hydraulic Controls, After January, 2020 3088
E-Hydraulic Controls – TEST 3088
Mini-Levers 3088
Full Stroke Test 3088
Function Returns to Neutral Test 3088
Push (Override) Button 3089
General 3089
Mini-levers, Remove and Install 3089
Armrest Assembly 3090
Remove 3090
Install 3093
Horn Button 3093
Remove 3093
Install 3093
Direction Control Switch 3093
Remove 3093
Install 3094
Push (Override) buttons and Toggle Switch 3094
Remove 3095
Install 3097
Special Tools 3098
524223780 8000YRM1134 (03 2020) UK EN 3101
Series Code / Model Designation Reference Table 3107
Description 3109
Proc_Cal_001: Service Password Entry 3111
When to Perform 3111
Why Perform 3111
How to Perform 3111
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3112
When to Perform 3112
Calibration Order 3112
Why Perform 3112
How to Perform 3113
Proc_Cal_003: Save and Exit 3114
When to Perform 3114
Why Perform 3114
How to Perform 3114
Proc_Cal_004: Lift Valve Output Threshold 3115
When to Perform 3115
Calibration Order 3115
Why Perform 3115
How to Perform 3116
Proc_Cal_005: Lower Valve Output Threshold 3118
When to Perform 3118
Calibration Order 3118
Why Perform 3118
How to Perform 3118
Proc_Cal_006: Tilt Back Valve Output Threshold 3121
When to Perform 3121
Calibration Order 3121
Why Perform 3121
How to Perform 3121
Proc_Cal_007: Tilt Forward Valve Output Threshold 3124
When to Perform 3124
Calibration Order 3124
Why Perform 3124
How to Perform 3124
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3127
When to Perform 3127
Calibration Order 3127
Why Perform 3127
How to Perform 3127
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3130
When to Perform 3130
Calibration Order 3130
Why Perform 3130
How to Perform 3130
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3133
When to Perform 3133
Calibration Order 3133
Why Perform 3133
How to Perform 3133
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3136
When to Perform 3136
Calibration Order 3136
Why Perform 3136
How to Perform 3136
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3139
When to Perform 3139
Calibration Order 3139
Why Perform 3139
How to Perform 3139
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3142
When to Perform 3142
Calibration Order 3142
Why Perform 3142
How to Perform 3142
Proc_Cal_014: Load Weight Zero Point 3146
When to Perform 3146
Calibration Order 3146
Why Perform 3146
How to Perform 3146
Proc_Cal_015: Loaded Weight Calibration 3148
When to Perform 3148
Calibration Order 3148
Why Perform 3148
How to Perform 3148
Proc_Cal_016: Transmission Valve Calibration 3151
Applicable System/Option 3151
When to Perform 3151
Calibration Order 3151
Why Perform 3151
How to Perform 3151
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3153
Applicable System/Option 3153
When to Perform 3153
Calibration Order 3153
Why Perform 3153
How to Perform 3153
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3155
Applicable System/Option 3155
When to Perform 3155
Calibration Order 3155
Why Perform 3155
How to Perform 3156
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3157
Required Tools 3157
When to Perform 3157
Calibration Order 3157
Why Perform 3158
How to Perform 3158
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3159
When to Perform 3159
Why Perform 3159
How to Perform 3159
Proc_Cal_026: Travel Speed Calibration 3161
When to Perform 3161
Calibration Order 3161
Why Perform 3161
How to Perform 3161
524262279 1800YRM1247 (09 2018) UK EN 3165
General 3169
Dry Brake System 3169
Wet Brake System 3170
Service Brakes Repair (Dry Brake) 3174
Remove and Disassemble 3174
Clean 3176
Inspect 3177
Assemble and Install 3177
Adjust 3181
Parking Brake Repair 3181
Dry Brake System 3182
Remove and Disassembly 3182
Assemble and Install 3184
Wet Brake System 3184
Remove and Install 3185
Assemble and Install 3191
Adjust 3191
Dry Brake System 3191
Wet Brake System 3192
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3192
Master Cylinder Repair 3193
Remove 3193
Disassemble 3198
Clean and Inspect 3199
Assemble 3200
Install and Adjust 3200
Accumulator 3202
Pre-Charge Check 3203
Remove 3204
Install 3206
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3206
Remove 3207
Modulating Brake Valve 3208
Disassemble 3208
Clean and Inspect 3210
Assemble 3210
Accumulator Charge Valve 3211
Disassemble 3211
Clean and Inspect 3213
Assemble 3213
Install 3214
Pressure Checks 3215
Accumulator Charge Valve Check 3215
Accumulator Check 3215
Service Brakes Adjustment (Dry Brake) 3216
Service Brakes Adjustment 3216
Brake System Air Removal 3217
Using Pressure Bleed System 3217
Using Brake Pedal Pressure 3218
Lift Truck Models with Master Cylinder 3218
Lift Truck Models with Modulating Brake Valve 3218
Brake Pedal Adjustment 3219
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) 3219
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3220
Free Pedal Adjustment 3222
Torque Specifications 3223
524288194 1300YRM1317 (03 2020) UK EN 3227
Transmission Repair 3231
Remove 3231
Torque Converter, Remove 3231
Disassemble 3232
Clean and Inspect 3281
Housings 3281
Oil Seals and Gaskets 3281
Bearings 3281
Gears and Shafts 3282
Assemble 3282
Torque Converter, Install 3323
Install 3324
Control Valve Repair 3325
Remove 3325
Disassemble 3325
Clean 3327
Inspect 3327
Assemble 3327
Install 3328
Torque Specification 3329
524288879 0100YRM1321 (11 2016) UK EN 3331
General 3335
Description 3336
Side Covers, Seat, Dash, and Hood Replacement 3337
Side Covers 3337
Remove 3337
Install 3337
Seat and Seat Plate 3338
Remove Seat 3338
Remove Seat Plate 3338
Install Seat Plate 3338
Install Seat 3338
Operator Restraint System 3342
Emergency Locking Retractor (ELR) 3342
Seat Plate and Seat Rail Check 3342
Steering Column, Dash, Kick Panel, and Seal Plate 3342
Remove 3342
Install 3345
Hood Support and Door Assembly 3347
Remove 3347
Install 3347
Hood Door Assembly 3352
Remove 3352
Install 3352
Steering Column 3353
Description 3353
Steering Column Repair 3353
Remove 3353
Disassemble 3354
Clean 3357
Inspect 3357
Assemble 3357
Install 3357
LPG Tank and Bracket Assembly 3357
Counterweight Replacement 3358
Remove 3358
Install 3359
Tow Pin, Remove and Install 3361
Overhead Guard Replacement 3361
Remove 3361
Install 3363
Engine Replacement 3363
Remove Engine 3363
Remove Transmission 3388
Remove Engine and Transmission 3391
Install Engine 3394
Install Transmission 3398
Install Engine and Transmission 3399
Electronic Throttle Replacement 3402
Cummins 4 5L Diesel Engine With Electronic Throttle 3403
Remove 3403
Install 3403
Pull Actuator Linkage Adjustment 3408
Low Idle Adjustment 3408
Throttle Pedal and Cable Adjustment 3408
Cummins 4 5L Diesel Engine 3409
Exhaust System Repair 3410
GM 4 3L Engine for Lift Truck Models GLP60VX, GLP70VX (GP/GLP135VX, GP/GLP155VX) (C878, D878) 3411
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909) 3411
Cummins QSB 3 3L Engine for Lift Truck Models GDP60VX, GDP70VX (GDP135VX, GDP155VX) (C878, D878), GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 3411
Remove 3411
Inspect 3413
Install 3413
Cummins 4 5L Diesel Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3413
Remove 3413
Inspect 3415
Install 3415
Cooling System 3415
Description 3415
Hydraulic Filter Assembly Repair 3415
Remove 3416
Install 3416
Fuel and Hydraulic Tanks Repair 3418
Inspect 3418
Clean 3418
Steam Method of Cleaning 3418
Chemical Solution Method of Cleaning 3419
Additional Preparations for Repair 3419
Small Leaks, Repair 3420
Large Leaks, Repair 3420
Preparations for Use After Repair 3420
Safety Labels 3420
524294878 2100YRM1328 (09 2018) UK EN 3429
General 3433
Safety Procedures When Working Near Mast 3433
Tilt Cylinder Repair 3435
Remove 3435
Disassemble 3440
Clean 3442
Inspect 3442
Assemble 3442
Install 3444
Tilt Cylinders, Adjust 3446
Tilt Cylinder Leak Check 3447
Lift Cylinder Repair 3448
Remove 3448
Disassemble 3458
Clean 3461
Inspect 3461
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) 3461
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3461
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) 3462
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3462
Free-Lift Cylinder Repair 3463
Remove 3463
Disassemble 3469
Clean 3471
Inspect 3471
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) 3472
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3472
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) 3472
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3473
Sideshift Cylinder Repair 3474
Remove 3474
Disassemble 3475
Clean 3478
Inspect 3478
Assemble 3479
Install 3480
Bolzoni Sideshift Cylinder Repair 3481
Remove 3481
Disassemble 3481
Clean 3482
Inspect 3482
Assemble 3483
Install 3483
Fork Positioner Cylinder Repair 3483
Remove 3484
Disassemble 3487
Clean 3491
Inspect 3491
Assemble 3492
Install 3493
Lift Cylinder Leak Check 3494
Seal Kit Installation 3494
External Installation (Seal and Back-Up Ring) 3494
Internal Installation (Piston Rod Assembly) 3495
Special Tools 3496
Torque Specifications 3497
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) 3497
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3497
524296605 1400YRM1344 (03 2020) UK EN 3501
General 3505
Identification Plate 3505
Drive Axle Removal 3505
Planetary Reduction Gear Repair 3517
Clean and Inspect 3527
Brake Repair 3536
Clean and Inspect 3549
Wet Brake Noise Reduction 3559
General 3559
Adding Additive To Transmission 3560
Differential Repair 3561
Clean and Inspect 3572
Bevel Pinion 3584
Clean and Inspect 3588
Drive Axle Installation 3598
Special Tools 3609
Torque Specifications 3610
524306203 0100YRM1290 (04 2014) UK EN 3613
550000873 4000YRM1406 (10 2017) UK EN 3717
Safety Procedures When Working Near Mast 3721
Fork Replacement 3723
Remove 3723
Install 3724
Checks 3724
Carriage Repair 3725
Remove 3725
Clean and Inspect 3728
Install 3728
Integral Sideshift Carriage And Fork Positioners Repair 3728
Integral Sideshift Carriage 3729
Remove 3729
Disassemble 3730
Clean and Inspect 3732
Assemble 3732
Install 3733
Fork Positioners 3733
Remove 3733
Disassemble 3736
Clean and Inspect 3738
Assemble 3738
Install 3738
Two-Stage Mast With Limited Free-Lift Repair 3739
Remove 3739
Disassemble 3742
Clean and Inspect 3745
Assemble 3747
Install 3747
Header Hose Installation 3748
Three-Stage Mast With Full Free-Lift Repair 3751
Remove 3751
Disassemble 3755
Clean and Inspect 3758
Assemble 3760
Install 3760
Header Hose Installation 3762
Mast Operation Check 3764
Tilt Cylinder Adjustment 3764
Main Lift Cylinder Repair 3764
Lift Chain Adjustment 3765
Mast Adjustments 3766
Load Roller Adjustment 3766
Mast Side Kicking Adjustment 3768
Carriage Adjustment 3768
550000875 8000YRM1408 (08 2012) UK EN 3773
toc 3773
Capacities and Specifications 3773
Safety Precautions Maintenance and Repair 3774
Lift Truck Lifting Capacity 3777
Counterweight Weights 3777
Tire Sizes 3777
Capacities 3778
Electrical System 3780
Transmission Oil Pressures 3780
Hydraulic System Relief Pressures 3782
Steering System 3782
Stall Speeds 3782
Mast Speeds 3783
Tilt Angles 3783
Front End Equipment – Mast Creep 3784
Mast Creep 3784
Engine Specifications 3784
Torque Specifications 3785
Frame 3785
Mast, Carriage, and Fork Positioner 3785
Steering System 3785
Transmission 3785
Engine, Cummins QSB 3 3L 3785
Engine, GM 5 7L LPG 3785
550001092 8000YRM1409 (03 2020) UK EN 3789
General Information About Diagrams and Schematics 3793
Symbol Definitions 3793
Diagrams Manual Applications 3794
Diagrams and Schematics 3796
550001097 8000YRM1407 (05 2019) UK EN 3877
General 3883
Serial Number Data 3883
How to Move Disabled Lift Truck 3883
How to Tow Lift Truck 3883
How to Put Lift Truck on Blocks 3884
How to Raise Drive Tires 3884
How to Raise Steering Tires 3885
How to Clean a Lift Truck 3886
Maintenance Schedule 3886
Maintenance Procedures Every 8 Hours or Daily 3897
How to Make Checks With Engine Stopped 3897
Tires and Wheels 3897
Safety Labels 3898
Mast, Carriage, Lift Chains, Header Hoses, and Attachment 3898
Operator Restraint System 3899
Emergency Locking Retractor (ELR) 3899
Adjust Seat – Full Suspension 3900
Adjust Seat – Internal Suspension 3901
Seat Plate and Seat Rails 3901
Engine Compartment 3901
Fuel, Oil, and Coolant Leaks, Check 3901
Hydraulic Hoses 3902
Coolant Hoses 3902
Steering Column Gas Cylinder 3902
Transmission 3902
Hydraulic System Oil 3902
Engine Oil 3903
Forks 3905
Remove 3905
Inspect 3906
Install 3906
Adjust 3907
Integral Sideshift Carriage 3907
How to Make Checks With Engine Running 3908
Indicator Lights, Horn, Fuses, and Relays 3908
Service Brakes 3911
Operation, Check 3911
Accumulator Pressure 3911
Parking Brake Check 3911
Engine Oil Pressure 3911
Cooling System 3912
Steering System 3913
Control Levers and Pedals 3913
Lift System, Operate 3913
Air Filter 3914
First Service After First 100 Hours of Operation 3915
Engine Oil and Oil Filter 3915
Maintenance Procedures Every 500 Hours or 6 Months 3916
Hydraulic System Oil Check 3916
Hydraulic Tank Breather 3917
Inspect 3917
Battery 3919
Engine Oil and Oil Filter 3919
Fuel/Water Separator Filter Replacement, Cummins QSB 3 3L Diesel Engine 3920
Remove 3920
Install 3920
Final Fuel Filter Replacement, Cummins QSB 3 3L Diesel Engine 3922
Priming The Fuel System, Cummins QSB 3 3L Diesel Engine 3922
Controlled Venting 3922
Manual Bleeding 3922
Drive Belt 3924
Fan and Alternator Drive Belt 3924
Fan and Alternator Drive Belt Adjustment, Cummins QSB 3 3L Diesel Engine 3925
Clean Debris From Radiator Core 3925
Transmission and Wet Brake Axle Oil Level Check 3926
Wet Brake Center Body Oil Level Check 3927
Forks 3929
Mast Lubrication 3930
Header Hose Checks 3934
Lift Chain Lubrication 3934
Tilt Cylinder Lubrication 3935
Brake Actuation Valve Rod End Pin 3937
Tie Rod Lubrication 3938
Low Idle Speed Check 3939
Drain Tar From LPG Converter 3939
GM 5 7L LPG Engine 3939
Parking Brake Adjustment 3940
Maintenance Procedures Every 1000 Hours or 6 Months 3940
Lift Chain Lubrication and Wear Check 3941
Integral Sideshift Carriage, Check Sliding Surfaces 3942
Steering Axle Spindle Bearings 3943
Control Levers and Pedals 3944
Inspect Engine Electrical System, Connectors 3944
Spark Plugs 3945
GM 5 7L LPG Engine 3945
PCV Valve 3945
GM 5 7L LPG Engine 3945
LPG Fuel Filter 3945
GM 5 7L LPG Engine 3945
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 3945
Maintenance Procedures Every 2000 Hours or Annually 3950
Hydraulic System 3950
Hydraulic Filter Assembly, Replace 3950
Remove 3950
Install 3951
Hydraulic Tank Breather, Replace 3952
Cooling System Check 3953
Air Filter 3955
Forks 3956
Brake Oil (Master Cylinder), Change 3956
Check Throttle Shaft for Sticking 3957
Inspect Exhaust Manifold and Piping for Leaks 3958
Transmission Automatic Clutch Calibration 3958
Brake System Accumulator 3958
Valve Clearance, Check and Adjust, Cummins QSB 3 3L Diesel Engine 3958
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 3959
GM 5 7L LPG Engine 3959
PCV Valve 3960
GM 5 7L LPG Engine 3960
LPG Electronic Pressure Regulator (EPR)/Fuel Mixer, Inspect 3960
GM 5 7L LPG Engine 3960
LPG Lock-Off Valve 3961
GM 5 7L LPG Engine 3961
Oxygen Sensors 3962
GM 5 7L LPG Engine 3962
Wheel Bearings 3962
Steer Wheels, Lubrication 3962
Maintenance Procedures Every 4000 Hours or 2 Years 3962
Hydraulic Oil, Replace 3962
Safety Procedures When Working Near Mast 3964
Lift Chain Adjustments 3965
Jump-Starting the Lift Truck 3966
Jump-Starting Using a Battery Charger 3967
Jump-Starting a Lift Truck Using Another Lift Truck 3967
Welding Repairs 3967
Overhead Guard Changes 3968
Wheel and Tire Replacement 3968
General 3968
Pneumatic Tire With Tube, Repair 3968
Remove Wheels From Lift Truck 3968
Remove Tire From Wheel 3968
Install Wheel in Tire 3971
Install Tire on Two-Piece Wheel 3973
Add Air to Pneumatic Tires With Tube 3974
Install the Wheels 3975
Dual Drive Wheels, Install 3975
Pneumatic Tubeless Tire, Repair 3975
Remove Wheels From Lift Truck 3975
Add Air to Pneumatic Tubeless Tire 3981
Wheels, Install 3981
Solid Rubber Tires on Pneumatic Wheels, Change 3981
Snap-On-Tire, Change 3985
Adhesives and Sealants 3988
550021072 0600YRM1432 (03 2020) UK EN 3991
General 3997
Engine Removal and Installation 3997
Cylinder Head Repair 3997
Intake Manifold 3997
Remove 3997
Clean and Inspect 3998
Install 3998
Cylinder Head 3999
Remove and Disassemble 3999
Clean and Inspect 4001
Valve Guides and Seats Repairs 4003
Valves Repair 4003
Valve Seats Repair 4004
Valve Springs 4005
Assemble and Install 4005
Engine Block Cleaning and Inspection 4007
Piston Bore Preparation 4009
Lubrication System Repair 4009
Oil Pan Removal 4009
Oil Pump Assembly 4010
Oil Pump, Removal 4010
Oil Pump, Disassemble 4010
Oil Pump, Assemble 4010
Oil Pump, Install 4011
Clean and Inspect 4012
Oil Pan, Install 4012
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4014
Timing Cover 4014
Remove 4014
Install 4015
Timing Sprockets 4015
Remove 4015
Install 4016
Camshaft 4016
Remove 4016
Inspect 4017
Install 4017
Clean and Inspect 4018
Valve Lifters 4018
Remove 4018
Clean and Inspect 4019
Install 4020
Crankshaft Repair 4021
Crankshaft 4021
Remove 4021
Inspect and Repair 4022
Main Bearings and Journals Clearance Check 4023
Install 4023
Piston and Connecting Rod Assembles 4024
Connecting Rod Bearings, Replace 4024
Piston and Connecting Rod Assemblies, Remove 4025
Disassemble 4026
Piston, Clean and Inspect 4026
Cylinder Bores, Inspect and Repair 4026
Piston Rings 4027
Assemble 4028
Piston and Connecting Rod Assemblies, Install 4029
Flywheel and Flywheel Housing Repair 4030
Flywheel, Remove 4030
Clean 4030
Inspect 4030
Flywheel, Install 4031
Coolant System Repair 4031
Water Pump 4031
Remove 4031
Clean and Inspect 4032
Install 4032
Serpentine Belt 4033
Remove 4033
Inspect 4033
Install 4034
Thermostat 4034
Remove 4034
Thermostat Operation Check 4034
Install 4035
Fan Assembly Replacement 4035
Remove 4035
Inspect 4037
Install 4037
Ignition System 4037
Spark Plug Wire Inspection 4037
Spark Plug Wire Replacement 4037
Remove 4037
Install 4038
Spark Plug Replacement 4039
Remove 4039
Install 4039
Spark Plug Inspection 4040
Usage 4040
Inspect 4040
Visual Inspection 4041
Alternator Repair 4042
Remove 4042
Install 4042
Starter Repair 4042
Remove 4042
Install 4043
Compression Check 4043
Valve Clearance Adjustments 4043
Engine Specifications 4045
Engine Data 4045
Cylinder Head 4045
Camshaft 4045
Cylinder Bore 4045
Piston 4046
Piston Pin 4046
Crankshaft 4046
Connecting Rods 4046
Balance Shaft 4046
Cooling System 4047
Lubrication System 4047
Torque Specifications for Capscrews and Bolts 4047
550021077 0900YRM1433 (03 2020) UK EN 4051
General 4055
LPG Tank and Bracket 4055
LPG Tank 4055
Remove 4055
Install 4058
LPG Tank Bracket 4058
Remove 4058
Install 4058
LPG Tank Bracket Alignment Pin 4059
Remove 4059
Install 4059
Fuel Filter Unit 4060
Fuel Filter Element 4060
Remove 4060
Clean and Inspect 4060
Install 4060
Fuel Filter Housing 4061
Remove 4061
Disassemble 4063
Clean and Inspect 4063
Assemble 4064
Install 4064
Electronic Throttle Body 4065
Remove 4065
Install 4066
Fuel Mixer/Electronic Pressure Regulator (EPR) 4067
Remove 4067
Install 4068
Control System 4069
Engine Control Unit (ECU) 4069
Remove 4069
Install 4070
Low Pressure Switch 4070
Remove 4070
Install 4070
Low Fuel Sensor 4071
Remove 4071
Install 4071
LP Converter 4072
Remove 4072
Disassemble 4073
Assemble 4074
Install 4075
Lock-Off Valve 4076
Remove 4076
Install 4076
Exhaust System 4077
Counterweight Exhaust 4077
Remove and Disassemble 4077
Inspect 4078
Assemble and Install 4079
Exhaust Manifold 4079
Remove 4079
Install 4081
Positive Crankcase Ventilation (PCV) Valve 4081
Remove 4081
Inspect 4082
Install 4083
Oxygen Sensors 4083
Remove 4083
Install 4083
LPG Fuel Testing 4084
General 4084
Available Fuel Tests 4084
Composition Test (ASTM D-2163) 4084
Ammonia Test (ASTM D-4490) 4084
Basic Nitrogen Test (ASTM UOP269-90) 4084
Residues Test (ASTM D-2158) 4084
Vapor Pressure Test (ASTM D-2598) 4084
Sulfur Compounds Test (ASTM D-5623) 4084
Methanol Test (ASTM D-4864) 4085
Copper Corrosion (ASTM D-1838) 4085
Where To Send LPG Fuel Samples For Testing 4085
550073240 1900YRM1620 (01 2023) US EN 4087
Proper Flushing after Major Hydraulic Repairs 4093
Introduction 4093
The Phases of Wear 4093
Causes of Hydraulic System Failure 4093
Progression of Contaminant Caused Hydraulic System Failure 4094
Hydraulic System Flushing Techniques 4094
Double Oil and Filter Change 4094
Mechanical Cleaning 4095
Cleaning of Components 4095
How to Clean Tubes and Hoses 4095
Filter Caddy 4095
Start-Up Procedure for Cleaned System 4096
Contaminated Oil Coolers 4096
Additional Filter Caddy Functions 4097
How to Handle Different Fluids 4097
Water Removal Filters 4097
Fluid Conditioning and System Flushing Procedures 4098
Operation of the Filter Caddy 4098
Filter Caddy operation 4098
Fluid Conditioning Procedure 4098
Filter Caddy Start-Up 4099
System Flushing Procedure 4099
Component Cleaning Procedure 4100
Reservoir Cleaning Procedure 4100
Cylinder Cleaning Procedure 4100
Hose and Tube Cleaning Procedure 4100
Valve Cleaning Procedure 4101
Front-End Attachment Cleaning Procedure 4102
System Flushing Procedure 4102
Filter Caddy Start-Up 4103
System Start-Up and Flushing 4103
Reservoir Fluid Cleaning Times 4104
Dealing With Different Fluid Types 4105
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4105
Filter Caddy Maintenance 4105
Servicing the Strainer 4105
DC Motor 4105
Hydraulic Oil Sampling Method and Procedure 4106
Hydraulic Oil Sampling Method 4106
Objective 4106
General Guidelines 4106
Synopsis 4107
Hydraulic Oil Analysis Report Guidelines 4108
Sampling Conditions 4108
Equipment 4108
Sampling Procedure 4109
Hydraulic Oil Sampling 4109
Sample Labeling 4109
Results Documentation 4109
550073240 1900YRM1620 (03 2020) UK EN 4111
Proper Flushing after Major Hydraulic Repairs 4115
Introduction 4115
The Phases of Wear 4115
Causes of Hydraulic System Failure 4115
Progression of Contaminant Caused Hydraulic System Failure 4116
Hydraulic System Flushing Techniques 4116
Double Oil and Filter Change 4116
Mechanical Cleaning 4117
Cleaning of Components 4117
How to Clean Tubes and Hoses 4117
Filter Caddy 4117
Start-Up Procedure for Cleaned System 4118
Contaminated Oil Coolers 4118
Additional Filter Caddy Functions 4118
How to Handle Different Fluids 4118
Water Removal Filters 4119
Fluid Conditioning and System Flushing Procedures 4119
Operation of the Filter Caddy 4119
Filter Caddy operation 4119
Fluid Conditioning Procedure 4120
Filter Caddy Start-Up 4120
System Flushing Procedure 4121
Component Cleaning Procedure 4121
Reservoir Cleaning Procedure 4121
Cylinder Cleaning Procedure 4121
Hose and Tube Cleaning Procedure 4122
Valve Cleaning Procedure 4122
Front-End Attachment Cleaning Procedure 4123
System Flushing Procedure 4123
Filter Caddy Start-Up 4124
System Start-Up and Flushing 4124
Reservoir Fluid Cleaning Times 4125
Dealing With Different Fluid Types 4125
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4125
Filter Caddy Maintenance 4126
Servicing the Strainer 4126
DC Motor 4126
Hydraulic Oil Sampling Method and Procedure 4126
Hydraulic Oil Sampling Method 4126
Objective 4126
General Guidelines 4126
Synopsis 4127
Hydraulic Oil Analysis Report Guidelines 4128
Sampling Conditions 4129
Equipment 4129
Sampling Procedure 4129
Hydraulic Oil Sampling 4129
Sample Labeling 4130
Results Documentation 4130