Yale Forklift B875 (GPGLPGDP040VX-GPGLPGDP070VX) Service Manual - PDF

Yale Forklift B875 (GPGLPGDP040VX-GPGLPGDP070VX) Service Manual – PDF DOWNLOAD

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Yale Forklift B875 (GPGLPGDP040VX-GPGLPGDP070VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5660
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift B875 (GPGLPGDP040VX-GPGLPGDP070VX) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797 8000YRM0231 (03 2020) US EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524221866 9000YRM1112 (10 2020) US EN 43
SECTION 9010 Operational Diagnostic Procedures 59
Group 05 – Operational Checkout 61
SECTION 9020 Engine 79
Group 10 – Principles of Operation 89
Group 30 – Observed Symptoms 287
Group 40 – Tests and Adjustments 389
SECTION 9030 Electrical System 421
Group 03 – General Maintenance and Diagnostic Data 445
Group 10 – Principles of Operation 539
Group 20 – Diagnostic Trouble Codes 563
Group 30 – Observed Symptoms 1535
SECTION 9040 Drive Train 1591
Group 10 – Principles of Operation 1595
Group 30 – Observed Symptoms 1651
Group 40 – Tests and Adjustments 1701
SECTION 9050 Hydraulic Systems 1711
Group 10 – Principles of Operation 1715
Group 30 – Observed Symptoms 1773
Group 33 – Observed Symptoms-Gear Pump 1775
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1863
Group 40 – Tests and Adjustments 1907
Group 43 – Tests and Adjustments-Gear Pump 1909
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1933
SECTION 9060 Operators Station 1951
Group 10 – Principles of Operation 1953
SECTION 9070 Front End (Mast) and Chassis 1989
Group 10 – Principles of Operation 1991
Group 30 – Observed Symptoms 2013
SECTION 9080 Supplementary Data 2071
Group 50 – Abbreviations and Acronyms 2073
Group 60 – Special Tools List 2081
Group 70 – Fault Mode Indicator Reference 2091
Group 80 – Supplier Specification Data 2093
524223754 0100YRM1120 (12 2012) US EN 2097
toc 2097
Frame 2097
Safety Precautions Maintenance and Repair 2098
General 2101
Description 2101
Hood, Seat, and Side Covers Replacement 2102
Remove 2102
Install 2108
Steering Column 2113
Description 2113
Steering Column Repair 2113
Remove 2113
Disassemble 2115
Clean 2115
Inspect 2115
Assemble 2115
Install 2118
LPG Tank and Bracket Assembly 2118
Counterweight Replacement 2119
Remove 2119
Install 2122
Tow Pin, Remove and Install 2123
Overhead Guard Replacement 2123
Remove and Install 2123
LED Tail, Backup, and Brake Lights, Replace 2124
Operator Restraint System Replacement 2125
Description 2125
Automatic Locking Retractor (ALR) 2125
Emergency Locking Retractor (ELR) 2125
Engine Replacement 2127
Remove 2127
Install 2132
Transmission Replacement 2134
Remove Transmission with Iron Housing 2134
Install Transmission with Iron Housing 2136
Remove Transmission with Aluminum Housing 2136
Install Transmission with Aluminum Housing 2141
Throttle Pedal and Cable Adjustment 2144
Mazda Gas/LPG Engines With Basic Power Shift Transmission and El 2144
Mazda Gasoline Engine With Electronic Transmission 2146
Throttle Pedal Stop Adjustment 2147
Yanmar Diesel Engine With Basic Power Shift Transmission 2148
Yanmar Diesel Engine With Electronic Throttle 2148
Exhaust System Repair 2149
Lift Trucks With Counterweight Exhaust System 2149
Mazda Gas and LPG Engines 2149
Remove and Disassemble 2149
Inspect 2149
Assemble and Install 2149
Yanmar Diesel Engine 2151
Remove and Disassemble 2151
Inspect 2151
Assemble and Install 2151
Lift Trucks With Overhead Exhaust System 2153
Yanmar Diesel Engine 2153
Remove and Disassemble 2153
Inspect 2153
Assemble and Install 2154
Mazda Gas and LPG Engines 2156
Remove and Disassemble 2156
Inspect 2156
Assemble and Install 2156
Cooling System 2158
Description 2158
Hydraulic Filter Assembly Repair 2158
Remove 2158
Clean and Inspect 2159
Install 2159
Fuel and Hydraulic Tanks Repair 2160
Inspect 2160
Clean 2160
Steam Method of Cleaning 2160
Chemical Solution Method of Cleaning 2161
Additional Preparations for Repair 2161
Small Leaks, Repair 2161
Large Leaks, Repair 2161
Preparations for Use After Repair 2162
Safety Labels 2162
tables 2097
Table 1 Gas Spring Installation, Lift Truck Models GLP/GDP16VX, 2109
Table 2 Gas Spring Installation, Lift Truck Models GLP/GDP20-35 2111
Table 3 Weight of Counterweights, Lift Truck Models GLC20-35VX 2121
Table 4 Weight of Counterweights, Lift Truck Models GC/GLC030VX 2121
Table 5 Weight of Counterweights, Lift Truck Models GLP/GDP16-1 2121
Table 6 Weight of Counterweights, Lift Truck Models GLP/GDP20-3 2121
524223755 0600YRM1121 (12 2012) US EN 2169
toc 2169
GM Engine Repair 2169
Safety Precautions Maintenance and Repair 2170
General 2175
Engine Serial Number 2175
Engine Removal and Installation 2177
Intake Manifold 2177
Remove 2177
Clean and Inspect 2178
Install 2178
Exhaust Manifold 2179
Remove 2179
Clean and Inspect 2179
Install 2179
Camshaft and Cylinder Head Repair 2180
Rocker Arm Cover 2180
Remove 2180
Install 2180
Camshaft Timing Pulley and/or Front Seal 2180
Remove 2180
Install 2181
Camshaft Carrier and Cylinder Head 2182
Remove 2182
Disassemble 2183
Camshaft Carrier 2183
Cylinder Head 2184
Clean and Inspect 2185
Camshaft Carrier 2185
Cylinder Head 2185
Valve and Valve Seat 2187
Assemble 2188
Cylinder Head 2188
Camshaft Carrier 2188
Install 2188
Timing Belt 2190
Timing Belt Front Cover 2190
Remove 2190
Install 2191
Timing Belt and Timing Belt Tensioner 2191
Remove 2191
Install 2192
Timing Belt Rear Cover 2193
Remove 2193
Install 2193
Lubrication System Repair 2194
Oil Pan 2194
Remove 2194
Install 2194
Oil Pump 2196
Remove 2196
Clean and Inspect 2197
Install 2198
Piston and Piston Rod Assemblies Repair 2198
Piston Rod Bearings, Replace 2198
Piston and Piston Rod Assemblies 2200
Remove 2200
Disassemble 2201
Pistons, Clean and Inspect 2202
Cylinder Bores, Inspect and Repair 2202
Piston Rings, Inspect 2203
Assemble 2204
Install 2204
Crankshaft and Main Bearings 2205
Crankshaft Timing Pulley and/or Front Seal 2205
Remove 2205
Install 2206
Crankshaft Rear Main Oil Seal 2207
Remove 2207
Install 2207
Crankshaft/RPM Sensor 2207
Remove 2207
Install 2208
Crankshaft Reluctor Wheel 2208
Remove and Install 2208
Crankshaft and Main Bearings 2208
Remove 2208
Inspect and Repair 2209
Bearing Selection 2210
Main Bearings and Journal Clearance, Check 2211
Install 2212
Flywheel and Flywheel Housing 2213
Remove 2213
Install 2213
Cooling System Repair 2214
Serpentine Belt 2214
Remove 2214
Inspect 2214
Install 2214
Water Pump 2215
Remove 2215
Inspect 2215
Install 2217
Thermostat 2218
Remove 2218
Check 2218
Install 2219
Thermostat Housing 2220
Remove 2220
Clean and Inspect 2220
Install 2220
Sensors and Switches 2222
Crankshaft Position (CKP) Sensor 2222
Remove 2222
Install 2222
Camshaft Position (CMP) Sensor 2222
Remove for Lift Trucks Built Before January, 2010 2222
Assembly 2222
Sensor Only 2222
Install for Lift Trucks Built Before January, 2010 2223
Assembly 2223
Sensor Only 2223
Remove for Lift Trucks Built After January, 2010 2224
Install for Lift Trucks Built After January, 2010 2224
Oil Pressure Sensor 2224
Remove 2224
Install 2224
Ignition System 2225
Spark Plug Wire Inspection 2225
Spark Plug Wire Replacement 2225
Remove 2225
Install 2226
Spark Plug Replacement 2226
Remove 2226
Install 2227
Spark Plug Inspection 2227
Usage 2227
Inspect 2227
Visual Inspection 2229
Coil Pack 2229
Remove 2229
Install 2229
Alternator Repair 2230
Alternator 2230
Remove 2230
Install 2230
Alternator Fuse, Replace 2230
Starter Repair 2231
Remove 2231
Install 2231
Engine Specifications 2232
Engine Data 2232
Cylinder Bore 2232
Piston 2232
Piston Rings 2233
Wrist Pin 2233
Crankshaft 2233
Piston Rod 2234
Camshaft and Camshaft Carrier 2234
Valve System 2234
Cylinder Head Warpage 2235
Lubrication System 2235
Cooling System 2235
Torque Specifications 2236
Special Tools 2237
524223756 0600YRM1122 (03 2020) US EN 2243
General 2247
Serial Number 2248
Engine Removal and Installation 2248
Cylinder Head, Camshaft, and Valve Mechanism Repair 2248
Remove 2248
Clean 2251
Inspect and Repair 2251
Cylinder Head 2251
Rocker Shaft Assembly 2251
Camshaft 2252
Valve Guides 2253
Valve Seats 2253
Valves 2254
Valve Springs 2254
Install 2255
Crankshaft and Main Bearings Repair 2259
Remove 2259
Inspect and Repair 2260
Crankshaft 2260
Main Bearings 2260
Install 2261
Pistons and Connecting Rods Repair 2262
Remove and Disassemble 2262
Clean 2262
Inspect and Repair 2262
Pistons 2262
Piston Rings 2262
Connecting Rods and Bearings 2263
Assemble and Install 2263
Cylinder Block Repair 2265
Oil Pump Repair 2266
Remove 2266
Disassemble 2267
Clean 2267
Inspect 2267
Assemble 2268
Install 2268
Cooling System Repair 2270
Thermostat 2270
Replace 2270
Fan Assembly 2270
Remove and Disassemble 2270
Assemble and Install 2271
Water Pump 2271
Remove 2271
Install 2272
Flywheel and Ring Gear Repair 2273
Remove 2273
Install 2273
Valve Adjustment 2273
Compression Pressure Check 2275
Engine Timing Adjustment 2276
Engine Specifications 2276
Engine Data 2276
Engine Speeds 2276
2007, and Later, Emission Compliant Engines 2276
All Engines Except 2007, and Later, Emission Compliant Engines 2277
Thermostat 2277
Cylinder Head 2277
Valve Mechanism 2277
Camshaft 2278
Crankshaft 2278
Connecting Rods 2278
Cylinder Block 2279
Pistons 2279
Oil Pump 2279
Torque Specifications 2280
524223757 0700YRM1123 (06 2016) US EN 2283
General 2287
Cooling System Checks 2287
Exhaust Leaks Into Cooling System 2287
Water Flow Restrictions in Radiator 2287
Radiator Hoses 2287
Water Pump 2288
Flushing the Cooling System 2288
Cooling System, Clean 2288
Radiator Replacement 2289
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) 2290
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 2305
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2308
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) 2311
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) 2318
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 2323
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2325
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) 2328
Fan Assembly Replacement 2340
Fan Removal 2340
Inspect 2355
Fan Installation 2355
524223758 0900YRM1124 (04 2018) US EN 2361
General 2365
Hoses Replacement 2365
LPG Tank and Bracket Replacement 2365
Remove LPG Tank 2365
Install LPG Tank 2367
Remove LPG Bracket 2368
Install LPG Bracket 2370
Remove LPG Tank Bracket Alignment Pin 2370
Install LPG Tank Bracket Alignment Pin 2372
Fuel Filter Unit Repair 2372
Fuel Filter Element 2372
Remove 2372
Clean/Inspect 2373
Install 2373
Fuel Filter Housing 2373
Remove 2373
Disassemble 2374
Assemble 2374
Install 2375
Electronic Throttle Body Repair 2375
Electronic Throttle Body 2375
Remove 2375
Install 2376
Electronic Throttle Body Adapter Plate 2376
Remove 2376
Install 2376
Fuel Injector Repair 2376
Fuel Rail 2377
Remove for Lift Trucks Built Before January, 2010 2377
Install for Lift Trucks Built Before January, 2010 2378
Remove for Lift Trucks Built After January, 2010 2378
Install for Lift Trucks Built After January, 2010 2379
Fuel Injector for Lift Trucks Built Before January, 2010 2380
Remove 2380
Clean 2380
Install 2380
Fuel Injector Adapters for Lift Trucks Built Before January, 2010 2381
Remove 2381
Install 2383
Fuel Injectors and Adapters for Lift Trucks Built After January, 2010 2383
Remove 2383
Clean 2383
Install 2384
LPG Regulator Repair 2384
LPG Regulator 2384
Remove 2384
Install 2385
LPG Regulator Fuel Filter 2385
Remove 2385
Install 2386
Lock-Off Solenoid and Cartridge 2386
Remove 2386
Install 2387
Control System 2387
Electronic Control Unit (ECU) 2387
Remove 2387
Install 2389
Fuel Pump Relay 2389
Remove 2389
Install 2390
Injector Driver Module 2390
Remove 2390
Install 2391
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 2391
Remove 2391
Install 2391
Engine Coolant Temperature (ECT) Sensor 2392
Remove 2392
Install 2392
Oxygen Sensor 2392
Remove 2392
Install 2393
Low LPG Pressure Switch 2393
Remove 2393
Install 2394
Exhaust System Repair 2395
Remove and Disassemble 2395
Inspect 2396
Assemble and Install 2396
LPG Fuel Testing 2397
General 2397
Available Fuel Tests 2397
Composition Test (ASTM D-2163) 2397
Ammonia Test (ASTM D-4490) 2397
Basic Nitrogen Test (ASTM UOP269-90) 2397
Residues Test (ASTM D-2158) 2397
Vapor Pressure Test (ASTM D-2598) 2398
Sulfur Compounds Test (ASTM D-5623) 2398
Methanol Test (ASTM D-4864) 2398
Copper Corrosion (ASTM D-1838) 2398
Where To Send LPG Fuel Samples For Testing 2398
524223759 0900YRM1125 (05 2005) US EN 2401
toc 2401
LPG Fuel System 2401
Safety Precautions Maintenance and Repair 2402
General 2405
Hoses Replacement 2405
LPG Tank Replacement 2405
Remove 2405
Install 2407
Fuel Filter 2408
Remove 2408
Clean and Inspect 2408
Install 2409
Relief Valve Replacement 2410
Remove and Install 2410
Carburetor Repair 2410
Remove 2410
Disassemble 2410
Clean 2412
Assemble 2412
Install 2412
Fuel Injector Repair 2413
Remove 2413
Clean and Inspect 2413
Install 2413
Governor Repair 2413
Remove 2413
Install 2413
Regulator Repair 2414
Remove 2414
Install 2414
Control System 2415
Engine Control Unit (ECU) 2415
Remove 2415
Install 2416
Engine Coolant Temperature (ECT) Sensor 2416
Remove 2416
Install 2416
Camshaft Position (CMP) Sensor 2416
Voltage Check 2416
Intake Air Temperature (IAT) Sensor 2417
Remove 2417
Install 2417
Manifold Absolute Pressure (MAP) Sensor 2418
Remove 2418
Install 2418
Oxygen Sensor 2418
Remove 2418
Install 2418
Throttle Position (TP) Sensor 2419
Remove 2419
Install 2419
524223760 0900YRM1126 (02 2010) US EN 2423
toc 2423
Gasoline Fuel System 2423
Safety Precautions Maintenance and Repair 2424
General 2427
Electronic Throttle Body Repair 2427
Electronic Throttle Body 2427
Remove 2427
Install 2427
Fuel System Repair 2428
Before Repair Procedure 2428
After Repair Procedure 2428
Fuel Leakage Check for Lift Trucks Built Before January, 2010 2428
Fuel Leakage Check for Lift Trucks Built After January, 2010 2429
Fuel Line Pressure Check 2430
Fuel Injectors 2431
Remove 2431
Install 2433
Pressure Regulator 2434
Remove 2434
Install 2434
Control System 2434
Electronic Control Unit (ECU) 2434
Remove 2434
Install 2436
Power Latch Relay 2436
Remove 2436
Install 2436
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) 2437
Remove 2437
Install 2437
Engine Coolant Temperature (ECT) Sensor 2437
Remove 2437
Install 2438
Oxygen Sensor 2438
Remove 2438
Install 2438
Exhaust System Repair 2439
Remove and Disassemble 2439
Inspect 2439
Assemble and Install 2439
524223761 0900YRM1127 (05 2005) US EN 2443
toc 2443
Gasoline Fuel System 2443
Safety Precautions Maintenance and Repair 2444
General 2447
Abbreviations 2447
Engine Tune-up 2447
Engine Tune-Up Preparation 2447
Idle Speed Adjustment 2447
Idle-Up Speed Check 2447
Intake-Air System 2449
Intake-Air System Manifold Vacuum Check 2449
Throttle Body 2450
Remove 2450
Install 2450
Electronic Governor 2450
Remove 2450
Install 2450
Intake-Air Control (IAC) Valve 2450
Remove 2450
Install 2450
Intake Manifold 2452
Remove 2452
Install 2452
Fuel System 2453
Before Repair Procedure 2453
Fuel Line Safety Procedure 2453
After Repair Procedure 2453
Fuel Hose, Install 2453
Fuel Leakage Check 2454
Fuel Line Pressure Check 2454
Fuel Injector 2455
Remove 2455
Install 2456
Pressure Regulator 2456
Remove 2456
Install 2457
Exhaust System 2457
Exhaust System, Inspect 2457
Three-Way Catalytic (TWC) Converter 2457
Remove and Install 2457
Exhaust Manifold 2457
Remove 2457
Install 2457
Positive Crankcase Ventilation (PCV) Valve 2459
Remove 2459
Inspect 2459
Install 2459
Control System 2459
Engine Control Unit (ECU) 2459
Remove 2459
Install 2461
Intake Air Temperature (IAT) Sensor 2462
Remove 2462
Install 2462
Mass Air Flow (MAF) Sensor 2462
Remove 2462
Install 2462
Throttle Position (TP) Sensor 2463
TP Sensor, Adjust 2463
Remove 2464
Install 2464
Engine Coolant Temperature (ECT) Sensor 2464
Remove 2464
Install 2464
Camshaft Position (CMP) Sensor 2465
Voltage Check 2465
Oxygen Sensor 2466
Remove 2466
Install 2466
Manifold Absolute Pressure (MAP)/Boost Sensor 2466
Remove 2466
Install 2466
Technical Data 2467
tables 2443
Table 1 PCV Valve Specifications 2459
Table 2 Closed Throttle Position Specifications 2464
Table 3 Gasoline Fuel Systems Technical Data 2467
524223762 1300YRM1129 (11 2018) US EN 2471
General 2475
Serial Number 2475
Charge Pump Repair 2475
Remove 2475
Inspect 2476
Install 2476
Torque Converter Replace 2476
Remove 2476
Install 2484
Front Cover Housing and Chain Drive Repair 2490
Remove 2490
Clean 2499
Inspect 2499
Install 2499
Clutch Packs Repair 2508
Remove and Disassemble 2508
Transmission, Remove and Disassemble 2508
Clean 2527
Inspect 2527
Assemble and Install 2528
Transmission, Assemble and Install 2536
Control Valve Repair 2542
Remove and Disassemble 2542
Clean 2546
Inspect 2546
Assemble and Install 2546
Foot Directional Control Pedal Repair 2547
Remove and Disassemble 2547
Assemble and Install 2551
Direction Control Lever 2552
Remove 2552
Install 2552
524223764 1600YRM1133 (07 2013) US EN 2557
toc 2557
Steering Axle 2557
Safety Precautions Maintenance and Repair 2558
General 2561
Steering Axle Assembly Repair 2563
Remove 2563
Disassemble 2564
Clean 2572
Inspect 2572
Assemble 2572
Install 2578
Spindles, Bearings, and Tie Rods Repair 2580
Spindles and Bearings 2580
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2580
Remove 2580
Disassemble 2582
Clean 2583
Inspect 2583
Assemble 2583
Install 2584
Spindles and Bearings 2587
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2587
Remove and Disassemble 2587
Assemble and Install 2588
Tie Rods 2588
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2588
Remove 2588
Install 2589
Tie Rods 2590
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2590
Remove 2590
Install 2596
Steering Cylinder Repair 2596
Remove and Disassemble 2596
Clean and Inspect 2597
Assemble and Install 2597
Torque Specifications 2598
524223765 1800YRM1135 (09 2018) US EN 2603
General 2607
Dry Brake System 2607
Wet Brake System 2607
Service Brakes Repair (Dry Brake) 2607
Remove and Disassemble 2608
Clean 2616
Inspect 2616
Assemble and Install 2617
Adjust 2624
Inching Overlap Adjustment 2624
Parking Brake Repair 2625
Remove and Disassemble 2625
Assemble and Install 2628
Adjust 2628
Master Cylinder Repair 2629
Remove (Dry Brake) 2629
Disassemble (Dry Brake) 2630
Clean and Inspect (Dry Brake) 2632
Assemble (Dry Brake) 2632
Bench Bleed Master Cylinder (Dry Brake) 2632
Install and Adjust (Dry Brake) 2632
Remove (Wet Brake) 2633
Disassemble (Wet Brake) 2635
Clean and Inspect (Wet Brake) 2636
Assemble (Wet Brake) 2637
Install and Adjust (Wet Brake) 2637
Service Brakes Adjustment (Dry Brake) 2638
Brake System Air Removal 2638
Using Pressure Bleed System 2638
Using Brake Pedal Pressure 2639
Brake Pedal Adjustment 2639
Free Pedal Adjustment 2640
Torque Specifications 2642
524223766 1900YRM1136 (11 2017) US EN 2645
General 2649
Hydraulic Gear Pump Assembly 2650
Variable Displacement Pump Assembly 2651
Single Gear Pump Assembly Repair 2651
Remove 2651
Disassemble 2658
Clean 2658
Inspect 2660
Assemble 2660
Install 2660
Tandem Gear Pump Assembly 2664
Remove 2665
Disassemble 2667
Clean 2669
Inspect 2669
Assemble 2669
Install 2670
Gear Pump Specifications 2670
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2676
Remove 2676
Disassemble 2686
Clean 2689
Inspect 2689
Assemble 2689
Install 2690
63 0 cc/rev – Variable Displacement Pump Repair 2693
Remove 2693
Disassemble 2696
Clean 2696
Inspect 2696
Assemble 2698
Install 2698
Variable Displacement Pump Checks and Adjustments (Single Pump) 2700
Margin Pressure Check 2700
Flow Compensator Adjustment 2701
Pressure Compensator Adjustment 2701
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2702
Variable Displacement Pump Specifications 2705
Torque Specifications 2706
Hydraulic Gear Pump 2707
Variable Displacement Pump 2708
Special Tools 2708
524223767 2000YRM1137 (01 2017) US EN 2713
General 2719
Electro-Hydraulic Main Control Valve 2720
Description 2720
Remove 2728
Electro-Hydraulic Control Valve Sections 2733
General 2733
Outlet Control Valve Section 2733
Remove 2733
Disassemble 2734
Clean 2736
Inspect 2736
Assemble 2736
Install 2737
Auxiliary Control Valve Sections 2737
Remove 2737
Disassemble 2744
Clean 2745
Inspect 2746
Assemble 2746
Install 2748
Tilt Control Valve Section 2749
Remove 2749
Disassemble 2749
Clean 2755
Inspect 2755
Assemble 2755
Install 2756
Lift/Lower Control Valve Section 2757
Remove 2757
Disassemble 2757
Clean 2766
Inspect 2766
Assemble 2766
Install 2767
Mid-Inlet Section 2767
Remove 2767
Clean 2768
Inspect 2768
Install 2768
Install 2768
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2773
Lift Pilot Pin 2773
Lower Pilot Pin 2777
Abnormal/Erroneous EHPV Adjustment 2779
Manual Main Control Valve 2780
Description 2780
Remove 2784
OPS Solenoid Assembly 2792
General 2792
Remove 2793
Clean and Inspect 2796
Install 2796
Manual Control Valve Sections 2797
General 2797
Outlet Control Valve Section 2797
Remove 2797
Disassemble 2797
Clean 2800
Inspect 2800
Assemble 2800
Install 2801
Auxiliary Control Valve Sections 2801
Remove 2801
Disassemble 2801
Clean 2804
Inspect 2804
Assemble 2804
Install 2805
Lift/Tilt Control Valve Section 2805
Remove 2805
Disassemble 2805
Clean 2812
Inspect 2812
Assemble 2813
Install 2814
Mid-Inlet Section 2815
Remove 2815
Clean 2815
Inspect 2815
Install 2815
Install 2816
Pressure Relief Valve Check and Adjustment 2822
Primary Relief Valve 2823
Secondary Relief Valve 2827
Steering Control Unit Repair 2834
Steering Control Unit, Remove 2834
Steering Control Unit, Disassemble 2838
Steering Control Unit, Clean 2840
Steering Control Unit, Inspect 2840
Steering Control Unit, Assemble 2840
Relief Valve, Disassemble 2841
Relief Valve, Clean 2841
Relief Valve, Inspect 2842
Relief Valve, Assemble 2842
Steering Control Unit, Install 2842
524223768 2100YRM1139 (02 2014) US EN 2847
524223769 2200YRM1128 (01 2023) US EN 2895
Series Code / Model Designation Reference Table 2903
General 2905
Deutsch Crimping Tool 2906
How to Strip a Wire for Use With Deutsch Crimping Tool 2906
How to Crimp With the Deutsch Crimping Tool 2907
Calibration Test for the Deutsch Crimping Tool 2909
Deutsch Connectors 2911
DT, DTM, and DTP Series Connectors 2911
HD Series Connectors 2954
Metri-Pack Connectors 2976
Remove and Install 2976
Micro-Pack Connectors 2979
Weather-Pack Connectors 2980
AMPSEAL Crimping Tools 2982
AMP Hand Crimping Tool With Certi-Crimp 2982
Description 2982
Stripping Wire for Use with AMP Hand Crimping Tool 2983
Insulation Crimp Adjustment 2984
Maintenance and Inspection for AMP Hand Crimping Tool 2984
AMP Hand Crimping Tool 2984
Crimp Height Inspection 2984
How to use AMP Hand Crimping Tool 2985
AMP Pro-Crimper II Tool 2985
Description 2985
Remove and Install Die Set and Locator Assembly 2986
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2986
Contact Support Adjustment 2987
Crimp Height Adjustment 2988
Maintenance and Inspection Procedures 2988
PRO-CRIMPER II Tool 2988
Crimp Height Inspection 2988
How to Use AMP PRO-CRIMPER II Tool 2989
AMPSEAL Connector Assemblies 2990
Description for Plug Connector Assembly 2990
Seal Plug 2991
Contact Crimping 2991
Description for Plug Connector and Header Assembly 2996
Voltage Reading 2999
Seal Plug 2999
Contact Crimping 2999
AMP Superseal 1 5 Crimping Tools 3006
Mini Mic Receptacle and Tab Contacts 3006
Description 3006
Crimping Conditions and Measurements 3006
Insertion of Rubber Seal on Cable 3008
AMP Hand Application Tool 3013
Description 3013
Maintenance and Inspection 3013
Crimp Height Inspection 3013
Crimp Height Adjustment 3014
How to Use AMP Hand Application Tool 3014
AMP Pro-Crimper II Tool 3015
Description 3015
Remove and Install Die Set and Locator Assembly 3015
Adjustments 3016
Contact Support 3016
Crimp Height 3017
Inspections and Maintenance 3018
Crimp Height Inspection 3018
Visual Inspection 3018
Maintenance 3019
How to Use Pro-Crimper II Tool 3019
AMP Superseal 1 5 Connector Assemblies 3020
Description 3020
Repair and Maintenance 3027
Panel Mount Option 3027
AMP Fastin-Faston Hand Tools 3028
Description – AMP Double Action Hand Tool 3028
Maintenance and Inspection Procedures 3028
Daily Maintenance 3028
Periodic Tool Inspection 3029
Lubrication 3029
Visual Inspection 3029
Crimp Height Inspection 3029
Certi-Crimp Ratchet Inspection 3030
How to Use AMP Double Action Hand Tool 3031
Description – AMP Extraction Tool 3032
Maintenance and Inspection 3033
How to Use AMP Extraction Tool 3033
AMP Fastin-Faston Receptacles and Housings 3035
Description 3035
Wire Repair 3043
Wire Splicing Requirements 3043
Deutsch Jiffy Splice 3044
Twisted/Shielded Cable and Leads Repair 3050
Special Tools 3052
524223769 2200YRM1128 (07 2020) US EN 3061
Series Code / Model Designation Reference Table 3067
General 3070
Deutsch Crimping Tool 3070
How to Strip a Wire for Use With Deutsch Crimping Tool 3070
How to Crimp With the Deutsch Crimping Tool 3071
Calibration Test for the Deutsch Crimping Tool 3073
Deutsch Connectors 3075
DT, DTM, and DTP Series Connectors 3075
HD Series Connectors 3117
Metri-Pack Connectors 3140
Remove and Install 3140
Micro-Pack Connectors 3142
Weather-Pack Connectors 3143
AMPSEAL Crimping Tools 3145
AMP Hand Crimping Tool With Certi-Crimp 3145
Description 3145
Stripping Wire for Use with AMP Hand Crimping Tool 3145
Insulation Crimp Adjustment 3146
Maintenance and Inspection for AMP Hand Crimping Tool 3146
AMP Hand Crimping Tool 3146
Crimp Height Inspection 3146
How to use AMP Hand Crimping Tool 3147
AMP Pro-Crimper II Tool 3147
Description 3147
Remove and Install Die Set and Locator Assembly 3148
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3149
Contact Support Adjustment 3149
Crimp Height Adjustment 3150
Maintenance and Inspection Procedures 3150
PRO-CRIMPER II Tool 3150
Crimp Height Inspection 3150
How to Use AMP PRO-CRIMPER II Tool 3151
AMPSEAL Connector Assemblies 3152
Description for Plug Connector Assembly 3152
Seal Plug 3153
Contact Crimping 3153
Description for Plug Connector and Header Assembly 3158
Voltage Reading 3160
Seal Plug 3160
Contact Crimping 3160
AMP Superseal 1 5 Crimping Tools 3167
Mini Mic Receptacle and Tab Contacts 3167
Description 3167
Crimping Conditions and Measurements 3167
Insertion of Rubber Seal on Cable 3169
AMP Hand Application Tool 3174
Description 3174
Maintenance and Inspection 3174
Crimp Height Inspection 3174
Crimp Height Adjustment 3175
How to Use AMP Hand Application Tool 3175
AMP Pro-Crimper II Tool 3176
Description 3176
Remove and Install Die Set and Locator Assembly 3177
Adjustments 3177
Contact Support 3177
Crimp Height 3178
Inspections and Maintenance 3179
Crimp Height Inspection 3179
Visual Inspection 3179
Maintenance 3180
How to Use Pro-Crimper II Tool 3180
AMP Superseal 1 5 Connector Assemblies 3181
Description 3181
Repair and Maintenance 3188
Panel Mount Option 3188
AMP Fastin-Faston Hand Tools 3189
Description – AMP Double Action Hand Tool 3189
Maintenance and Inspection Procedures 3189
Daily Maintenance 3189
Periodic Tool Inspection 3190
Lubrication 3190
Visual Inspection 3190
Crimp Height Inspection 3190
Certi-Crimp Ratchet Inspection 3191
How to Use AMP Double Action Hand Tool 3192
Description – AMP Extraction Tool 3193
Maintenance and Inspection 3193
How to Use AMP Extraction Tool 3194
AMP Fastin-Faston Receptacles and Housings 3195
Description 3195
Wire Repair 3202
Wire Splicing Requirements 3202
Deutsch Jiffy Splice 3203
Twisted/Shielded Cable and Leads Repair 3208
Special Tools 3211
524223770 2200YRM1130 (03 2020) US EN 3219
General 3223
Description 3223
Dash Display Menu Access 3223
Menu Navigation 3224
Standard Display 3224
Main Menu 3224
Passwords Menu 3225
Password Administration 3225
Add Password 3225
Delete Password 3226
Edit Password 3226
Other Password Functions 3227
Operator Passwords – Enable/Disable 3227
Password Time-Out Delay 3227
Passwords – Number Wrong to Disable 3228
Lockout Reset Password 3228
View Password Log 3229
View Versions 3230
VSM Versions 3230
Dash Display Versions 3231
Engine Controller Version 3232
Transmission (Xmsn) Controller Version 3233
Truck Serial Number 3234
Diagnostics 3235
View Fault Log 3235
Set Travel and Braking 3236
Speed Limit 3236
Acceleration Rate 3237
Auto-Deceleration Rate 3237
Set Power Reversal Rate 3238
Set Inching/Brake Overlap 3239
Setup Display Menu 3240
Set Operator Language 3240
Set Units 3241
Set Time Format (12/24 Hour) 3241
Set Daylight Saving Time 3241
Set Time 3244
Set Date Format 3245
Set Date 3245
Setup Hydraulics 3246
Return to Set Tilt Delay/On/Off 3246
Setup General Items 3247
Light Shutdown Time-Out 3247
Impact Sensor – Enable/Disable 3248
Impact Sensor – Soft Impact Settings 3249
Impact Sensor – Hard Impact Settings 3250
Adjust Impact Sensor Settings 3250
Initial Adjustment of Soft and Hard Impact Settings 3252
Readjustment of Soft and Hard Impact Settings 3252
Impact Sensor – Impact Alarm/Shutdown Reset 3253
Impact Sensor – Alarm Time Duration and Deactivation 3254
Impact Sensor – View Impact Event Log 3255
Engine Mode Indicator 3256
Generation 1 (ECO-eLo ONLY) 3256
Generation 2 3257
Operator Checklist 3258
Operator Checklist Off-On Mode 3258
Edit Operator Checklist 3258
Set Operator Checklist Expiration 3259
View Checklist Log 3259
Clear Operator Checklist Log 3260
Clear Operator Checklist Fault 3260
Calibrations 3261
Set Tilt Stop Point 3261
Calibrate Loaded Weight 3261
524223771 2200YRM1131 (03 2020) US EN 3263
Series Code / Model Designation Reference Table 3269
General 3271
Description 3271
Dash Display Menu Access 3271
Menu Navigation 3272
Main Menu 3272
Passwords 3273
Adding Passwords 3273
Hourmeters 3275
View Versions 3276
VSM Versions 3276
Dash Display Versions 3277
Engine Controller Version 3278
Transmission (Xmsn) Controller Version 3279
Truck Serial Number 3280
Truck Configuration 3281
Diagnostics 3282
Clear Fault Log 3282
View Fault Log 3283
No-Run Data Display 3284
Engine Accelerator and Throttle Data Display 3284
Engine Speeds and Governor Data Display 3285
Engine Fuel and Emissions Data Display 3286
Engine General Data Display 3288
XMSN/Brake Data Display 3289
Hydraulic Data Display 3292
General Truck Data Display 3294
Set Travel and Braking 3295
Speed Limit 3295
Acceleration Rate 3296
Auto-Deceleration Rate 3297
Set Power Reversal Rate 3297
Set Inching/Brake Overlap 3298
Setup Hydraulics 3298
Lift Maximum Speed 3299
Lower Maximum Speed 3299
Tilt Maximum Speed 3300
Auxiliary Function One, Direction A, Maximum Speed 3302
Auxiliary Function One, Direction B, Maximum Speed 3304
Auxiliary Function Two, Direction A, Maximum Speed 3304
Auxiliary Function Two, Direction B, Maximum Speed 3305
Auxiliary Function Three, Direction A, Maximum Speed 3306
Auxiliary Function Three, Direction B, Maximum Speed 3306
Lift/Lower Ramp Rate 3307
Hydraulic Auxiliary Ramp Rate 3307
Return to Set Tilt Delay/On/Off 3308
Hydraulic Input Device 3309
Auxiliary Solenoid 3309
Dual Function 3310
Setup Display 3311
Set Service Language 3311
Setup General Items 3311
Motion Alarm Activation Type 3312
Light Shutdown Time-Out 3313
Restore Default Settings 3313
Restore Engine Controller Default Calibration 3314
Impact Sensor – Enable/Disable 3314
Impact Sensor – Soft Impact Settings 3315
Impact Sensor – Hard Impact Settings 3316
Adjust Impact Sensor Settings 3317
Initial Adjustment of Soft and Hard Impact Settings 3319
Readjustment of Soft and Hard Impact Settings 3319
Impact Sensor – Impact Alarm/Shutdown Reset 3320
Impact Sensor – Alarm Time Duration and Deactivation 3321
Impact Sensor – View Impact Event Log 3322
Engine Mode Indicator 3322
Generation 1 (ECO-eLo ONLY) 3322
Generation 2 3323
Diesel Particulate Filter (DPF) Display 3324
General Description 3324
Passive Regeneration Only 3324
Regeneration Level 0 3324
Auto/Active Regeneration Inhibited 3325
Auto/Active Regeneration 3325
Regeneration Level 1 3325
Parked Regeneration Request 3326
Regeneration Level 2 3326
Warning Level 3326
Regeneration Level 3 3326
Service Level 3327
Regeneration Level 4 3327
Display, Diesel Particulate Filter (DPF), Revised 3327
Operator Interface 3327
Refer to Operator Manual 3327
CAN Communication Lost 3328
Passive Regeneration Only 3328
Regeneration Level 0 3328
Auto/Active Regeneration Inhibited 3328
Auto/Active Regeneration 3329
Regeneration Level 1 3329
Idle-up Auto/Active Regeneration 3329
Parked Regeneration Request 3329
Regeneration Level 2 3329
Warning Level 3331
Regeneration Level 3 3331
Service Level 3331
Regeneration Level 4 3331
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3331
Display, Diesel Particulate Filter (DPF), Stage V Engine 3331
Operator Interface 3332
Refer to Operator Manual 3332
CAN Communication Lost 3332
Passive Regeneration Only 3332
Regeneration Level 0 3332
Auto/Active Regeneration Inhibited 3333
Auto/Active Regeneration 3333
Regeneration Level 1 3333
Idle-up Auto/Active Regeneration 3334
Parked Regeneration Request 3334
Regeneration Level 2 3334
Warning Level 3335
Regeneration Level 3 3335
Service Level 3336
Regeneration Level 4 3336
Stage V Content 3336
Emissions System Malfunction 3336
Ash Load 3336
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3337
Operator Interface 3337
Refer to Operator Manual 3337
CAN Communication Lost 3338
Passive Regeneration Only 3338
Regeneration Level 0 3338
Auto/Active Regeneration Inhibited 3338
Auto/Active Regeneration 3339
Regeneration Level 1 3339
Idle-up Auto/Active Regeneration 3339
Parked Regeneration Request 3339
Regeneration Level 2 3339
Warning Level 3341
Regeneration Level 3 3341
Service Level 3341
Regeneration Level 4 3341
Calibrations 3342
Calibrate Transmission Valve 3344
Set Tilt Stop Point 3344
Calibrate Loaded Weight 3344
Calibrate Travel Speed Sensor 3345
Calibrate Mazda LP and Gas Accelerator Pedal 3345
524223772 2200YRM1142 (01 2020) US EN 3347
General 3357
Display Switch Cluster 3360
Remove 3360
Install 3363
Direction Control and Turn Signal Levers 3363
Remove 3363
Install 3365
Key Switch 3365
Remove 3365
Install 3366
Display Switch Cluster Panel Bezel and Overlay 3366
Remove 3366
Install 3366
Steering Column Repair 3366
Remove 3366
Disassemble 3369
Assemble 3369
Install 3369
Sensors and Switches 3370
General 3370
Dash and Kick Panel, Remove and Install 3370
Remove 3370
Install 3371
Accelerator Pedal Position Sensor 3372
Remove 3372
Install 3375
Brake Fluid Level Switch 3376
Remove 3376
Install 3378
Service Brake Pedal Position Sensor 3379
Remove 3379
Install 3382
Parking Brake Sensor 3383
Remove 3383
Install 3384
Service Brake Pressure Sensor 3385
Remove 3385
Install 3387
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3388
Remove 3388
Install 3388
Sensor Microswitch (Foot Directional Control Pedal) 3389
Remove 3389
Install 3392
Low Coolant Level Sensor 3393
Remove 3393
Install 3396
Fuel Level Sensor, Gas and Diesel Engines Only 3397
Remove 3397
Install 3398
Armrest Switch 3398
Remove 3398
Install 3400
Seat Sensor (Operator Presence System) 3400
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) 3400
Remove 3400
Install 3401
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3401
Remove 3401
Install 3402
Full Suspension Seats; All Lift Truck Models 3402
Remove 3402
Install 3402
Hood Shut Off Switch 3402
Remove 3402
Install 3405
Remote Key Switch 3406
Remove 3406
Install 3406
Hydraulic Filter Pressure Switch 3407
Remove 3407
Install 3409
Transmission Speed Sensor 3409
Remove 3409
Install 3412
Transmission Pressure Sensors 3413
Remove 3413
Install 3415
Transmission Temperature Sensor 3416
Remove 3416
Install 3418
Engine Speed Sensor 3420
Remove 3420
Install 3420
Intermediate Speed Sensor 3421
Remove 3421
Install 3421
Return to Set Tilt (Tilt Angle) Sensor 3421
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) 3421
Remove 3421
Install 3422
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) 3423
Remove 3423
Install 3424
Rear Horn Button Switch 3424
Remove 3424
Install 3425
Impact Sensor 3426
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) 3426
Remove 3426
Install 3429
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) 3429
Remove 3429
Install 3430
Load Weight Sensor 3431
Remove 3431
Install 3432
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3433
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3433
Crankshaft Position (CKP) Sensor 3433
Camshaft Position (CMP) Sensor 3433
Oil Pressure Sensor 3433
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3433
Engine Coolant Temperature (ECT) Sensor 3434
Air Flow Restriction Switch 3434
Remove for GM 2 4L Gas and LPG Trucks 3434
Install for GM 2 4L Gas and LPG Trucks 3434
Oxygen Sensor 3435
Remove 3435
Install 3438
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3439
Crankshaft Position (CKP) Sensor 3439
Camshaft Position (CMP) Sensor 3439
Oil Pressure Sensor 3439
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3439
Engine Coolant Temperature (ECT) Sensor 3439
Air Flow Restriction Switch 3439
Oxygen Sensor 3439
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3439
Low LPG Pressure Switch 3439
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3440
Air Filter Restriction Switch 3440
Remove 3440
Install 3440
Oil Pressure Sensor 3440
Remove 3440
Install 3440
Engine Speed Sensor 3440
Remove 3440
Install 3440
Engine Coolant Temperature (ECT) Sensor 3440
Remove 3440
Install 3440
Throttle Position Sensor (TPS) 3443
Remove 3443
Install 3444
Fuel/Water Separator Sensor 3444
Remove 3444
Install 3444
Glow Plug Relay 3445
Remove 3445
Install 3447
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3447
Air Filter Restriction Switch 3447
Remove 3447
Install 3447
Engine Oil Pressure Sensor 3452
Remove 3452
Install 3452
Engine Speed Sensor 3452
Remove 3452
Install 3453
Engine Coolant Temperature (ECT) Sensor 3453
Remove 3453
Install 3454
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3455
Remove 3455
Install 3455
Fuel/Water Separator Sensor 3456
Remove 3456
Install 3456
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3457
Intake Air Temperature Sensor 3457
Remove 3457
Install 3458
Intake Air Pressure Sensor 3458
Remove 3458
Install 3458
Air Inlet Heater 3458
Remove 3458
Install 3459
Engine Oil Pressure Sensor 3459
Remove 3459
Install 3459
Engine Coolant Temperature (ECT) Sensor 3459
Remove 3459
Install 3459
Crankshaft Position Sensor 3460
Remove 3460
Install 3460
Adjust Shim Procedure 3461
Camshaft Position Sensor 3462
Remove 3462
Install 3462
Air Flow Restriction Sensor 3463
Remove 3463
Install 3463
Fuel/Water Separator 3463
Remove 3463
Install 3464
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3464
Intake Air Temperature Sensor 3468
Remove 3468
Install 3469
Boost Sensor 3469
Remove 3469
Install 3470
Throttle Valve Assembly and Air Intake Heater 3470
Remove 3470
Install 3470
Engine Coolant Temperature (ECT) Sensor 3471
Remove 3471
Install 3471
Engine Oil Pressure Sensor 3471
Remove 3471
Install 3472
Crankshaft Position Sensor 3472
Remove 3472
Install 3472
Adjust Shim Procedure 3473
Camshaft Position Sensor 3474
Remove 3474
Install 3475
Differential Pressure Sensor 3475
Remove 3475
Install 3475
Mass Air Flow Sensor 3476
Remove 3476
Install 3477
Fuel/Water Separator 3477
Remove 3477
Install 3478
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3478
Engine Coolant Temperature (ECT) Sensor 3479
Remove 3479
Install 3479
Throttle Position Sensor 3480
Engine Oil Pressure Sensor 3480
Remove 3480
Install 3480
Engine Speed Sensor 3480
Remove 3480
Install 3480
Fuel Shut Off Solenoid 3480
Remove 3480
Install 3480
Vehicle System Manager (VSM) 3481
General 3481
VSM Replacement 3481
Remove 3481
Install 3483
Programming a New VSM and/or Display Switch Cluster 3483
General 3483
PC Service Tool Software 3484
Data Transferring 3484
New VSM 3484
New (Blank) Display Switch Cluster 3484
Used (Non-Blank) Display Switch Cluster 3484
Power Distribution Module (PDM) and Component Parts 3486
Remove 3486
PDM as a Unit 3486
Install 3490
PDM as a Unit 3490
Remove and Install 3491
PDM Component Parts 3491
Transmission Control Unit 3491
Remove 3491
Install 3495
Battery 3497
Remove 3497
Install 3497
Lights 3498
Work Lights (Front and Rear) 3498
Remove 3498
Install 3498
Strobe Light 3499
Remove 3499
Install 3499
LED Tail, Backup, and Brake Lights 3500
Remove 3500
Install 3501
Front Marker/Turn Signal Lights 3502
Replacing Whole Front Marker/Turn Signal Light Assembly 3502
Remove 3502
Install 3502
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3503
Remove 3503
Install 3503
Diesel Particulate Filter (DPF) Display 3503
Remove 3503
Clean and Inspect 3504
Install 3504
Electronic-Hydraulic Controls – Generation 1 3505
E-Hydraulic Controls – Test 3505
Mini-Levers 3505
Full Stroke Test 3505
Function Returns to Neutral Test 3505
Push Button Switch 3505
General 3506
Mini-Lever Replacement 3506
Remove 3506
Clean and Inspect 3507
Install 3507
Push Button Switch Replacement 3508
Remove 3508
Install 3510
Mini-Lever Module (MLM) 3510
Remove 3510
Install 3510
Joystick 3511
Remove and Disassemble 3511
Inspect 3511
Assemble and Install 3511
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3512
General 3512
Mini-levers, Remove and Install 3512
Armrest Assembly 3513
Remove 3513
Install 3516
Horn Button 3516
Remove 3516
Install 3516
Direction Control Switch 3517
Remove 3517
Install 3517
push (override) buttons and Toggle Switch 3517
Remove 3518
Install 3519
Joystick 3520
Remove and Disassemble 3520
Inspect 3520
Assemble and Install 3520
Joystick Armrest Slider Assembly 3521
Remove 3521
Install 3522
Electronic-Hydraulic Controls, After January, 2020 3522
E-Hydraulic Controls – TEST 3522
Mini-Levers 3522
Full Stroke Test 3522
Function Returns to Neutral Test 3522
Push (Override) Button 3523
General 3523
Mini-levers, Remove and Install 3523
Armrest Assembly 3524
Remove 3524
Install 3527
Horn Button 3527
Remove 3527
Install 3527
Direction Control Switch 3527
Remove 3527
Install 3528
Push (Override) buttons and Toggle Switch 3528
Remove 3529
Install 3531
Special Tools 3532
524223773 2200YRM1143 (05 2005) US EN 3535
toc 3535
Electrical System 3535
Safety Precautions Maintenance and Repair 3536
Ignition System 3539
General 3539
Ignition Timing Adjustment, Gasoline and LPG 3539
Spark Plugs Check 3539
Spark Plug Wires Check 3539
Distributor Repair 3542
Remove 3542
Disassemble 3543
Inspect 3543
Assemble 3544
Install 3544
Igniter 3545
Remove 3545
Test 3545
Install 3545
Camshaft Position (CMP) Sensor 3546
Voltage Check 3546
Ignition Coil Check 3547
Primary Coil Winding 3547
Secondary Coil Winding 3547
Starter Repair 3548
General 3548
Remove 3548
No-Load Test 3549
Magnetic Switch Test 3549
Pull-Out Test 3549
Holding Coil Test 3550
Return Test 3550
Pinion Movement Inspection 3550
Install 3550
Alternator Repair 3551
General 3551
Charging System Inspection 3551
Output Current Check 3552
No-Load Adjusted Voltage Check 3552
Remove 3553
Inspect 3553
Rectifier Check 3553
Install 3554
tables 3535
Table 1 Spark Plug Wire 3539
Table 2 Starter Specifications 3548
Table 3 Problem Diagnosis Chart 3549
Table 4 Specifications 3552
Table 5 Rectifier Check Table 3553
524223776 4000YRM1148 (09 2015) US EN 3557
General 3561
Safety Procedures When Working Near Mast 3562
Fork Replacement 3564
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3564
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3566
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3567
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3567
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3568
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3569
Carriages Repair 3570
Standard Carriage 3570
Remove 3570
Repair 3571
Install 3571
Standard Carriage, Remove 3572
Hang-On Sideshift Carriage, Remove 3573
Standard Carriage and Hang-On Sideshift Carriage, Repair 3574
Standard Carriage, Install 3575
Hang-On Sideshift Carriage, Install 3575
Integral Sideshift Carriage 3576
Remove 3576
Clean and Inspect 3579
Repair 3580
Install 3580
Fork Positioner 3581
Remove 3581
Clean and Inspect 3586
Disassemble and Assemble 3586
Install 3586
Fork Positioner Hydraulic Hose Adjustment 3587
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3589
Connecting Attachment Hydraulic Quick Disconnect Hoses 3589
Mast Repair 3590
Mast, Remove 3590
Two-Stage LFL and Two-Stage FFL Masts 3593
Disassemble 3593
Clean and Inspect 3603
Three-Stage FFL Mast 3604
Disassemble 3604
Clean and Inspect 3612
Two-Stage LFL and Two-Stage FFL Mast 3614
Assemble 3614
Three-Stage FFL Mast 3617
Assemble 3617
Four-Stage FFL Mast – Manufactured Before July, 2009 3619
Disassemble 3619
Clean and Inspect 3624
Assemble 3626
Four-Stage FFL Mast – Manufactured After July, 2009 3627
Disassemble 3627
Clean and Inspect 3634
Assemble 3637
Mast, Install 3638
Header Hose Arrangement 3641
Two-Stage LFL 3641
Two-Stage FFL 3649
Three-Stage FFL 3664
Standard 3664
Optional Equipment Lift Truck GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 3681
Four-Stage FFL Mast – Manufactured Before July, 2009 3689
Four-Stage FFL Mast – Manufactured After July, 2009 3698
Adjustment 3705
Lift Chains Adjustment 3705
Carriage Adjustments 3708
Mast Adjustments 3708
Load Roller Adjustment 3708
Mast Side Kicking Adjustment 3711
524223777 8000YRM1150 (12 2017) US EN 3715
General 3721
Serial Number Data 3721
How to Move Disabled Lift Truck 3721
How to Tow Lift Truck 3721
How to Put Lift Truck on Blocks 3722
How to Raise Drive Tires 3722
How to Raise Steering Tires 3723
How to Clean a Lift Truck 3724
Maintenance Schedule 3724
Maintenance Procedures Every 8 Hours or Daily 3749
How to Make Checks With Engine Stopped 3750
Tires and Wheels 3750
Safety Labels 3751
Mast, Carriage, Lift Chains, Header Hoses, Attachment 3751
Operator Restraint System 3752
Automatic Locking Retractor (ALR) 3752
Emergency Locking Retractor (ELR) 3752
Adjust Seat – Full Suspension 3752
Adjust Seat – Internal Suspension 3754
Hood and Seat Latches 3755
Engine Compartment 3755
Paper Application 3755
Fuel, Oil, and Coolant Leaks, Check 3756
Hydraulic Hoses 3756
Coolant Hoses 3756
Steering Column Gas Cylinder 3756
Transmission 3756
Hydraulic System Oil 3756
Engine Oil 3757
Air Filter 3763
Forks 3763
Remove 3763
Inspect 3765
Install 3766
Adjust 3766
How to Make Checks With Engine Running 3767
Indicator Lights, Horn, Fuses, and Relays 3767
Service Brakes 3770
Brake Fluid Level 3770
Operation, Check 3770
Parking Brake 3770
Engine Oil Pressure 3771
Cooling System 3771
Steering System 3772
Control Levers and Pedals 3772
Lift System, Operate 3772
First Service After First 100 Hours of Operation 3773
Mazda and GM Engine Oil and Oil Filter 3773
Yanmar Engine Oil and Oil Filter 3774
Maintenance Procedures Every 250 Hours or 6 Months 3774
Mazda and GM Engine Oil and Oil Filter 3774
Drive Belt 3775
Mazda 2 0L and 2 2L Engines 3775
Fan and Alternator Drive Belt 3775
GM 2 4L Engine 3775
Fan and Alternator Drive Belt 3775
Drain Tar From LPG Regulator (Except 2007 Mazda Emission Compliant Engines) 3776
Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engines Only) 3777
Maintenance Procedures Every 500 Hours or 6 Months 3777
Hydraulic System Oil 3778
Hydraulic Tank Breather 3778
Inspect 3778
Battery 3779
Yanmar Engine Oil and Oil Filter 3779
Drive Belt 3780
Yanmar Diesel Engine 3780
Fan and Alternator Drive Belt 3780
Timing Belt, Checks and Inspection 3781
PCV Valve 3783
Clean Debris From Radiator Core 3783
Transmission Oil Level 3783
Wet Brake Planetary Housing Oil Level Check 3785
Forks 3786
Mast Lubrication 3786
Header Hose Checks 3790
Lift Chain Lubrication 3790
Tilt Cylinder Lubrication 3791
Master Brake Cylinder Rod End Pin Lubrication 3792
Manual Hydraulic Levers Lubrication 3792
Brake Fluid 3793
Tie Rod Lubrication (GP/GLP/GDP040-070VX) 3794
Differential and Drive Axle Oil (Dry Brake) 3794
Maintenance Procedures Every 1000 Hours or 6 Months 3794
Valve Clearance, Check and Adjust 3794
Ignition System 3795
GM 2 4L Engine 3795
Mazda Engines 2 0L and 2 2LFE and F2 3795
LPG Fuel Filter Element Replace, GM 2 4L Engine 3795
Remove 3795
Install 3795
LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 3796
LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines Only 3796
Remove 3796
Clean/Inspect 3797
Install 3797
Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant Engines Only 3797
Remove and Replace 3797
Fuel Filter Replacement, Yanmar Engine 3798
Priming the Fuel System (Yanmar) 3800
Lift Chains Wear Check 3800
Lift Chain Lubrication 3801
Integral Sideshift Carriage, Check Bearings 3801
Integral Sideshift Carriage, Check Lower Mounting Hooks 3802
Steering Axle 3802
Control Levers and Pedals 3802
Maintenance Procedures Every 2000 Hours or Annually 3802
Hydraulic System 3803
Hydraulic Filter, Replace 3803
Hydraulic Tank Breather, Replace 3804
Air Filter 3805
PCV Valve 3806
Oxygen Sensor 3807
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 3809
Remove and Replace 3809
LPG Regulator Fuel Filter, GM Engines 3809
Remove 3809
Install 3810
Gasoline Fuel Filter 3810
Remove and Replace for Lift Trucks Equipped with GFI 3810
Timing Belt 3811
Mazda Engines 3811
GM 2 4L Engine 3811
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 3811
Gasoline Fuel Injector, Mazda Engines 3811
LPG Fuel Injector, GM Engines 3811
Gasoline Fuel Injector, GM Engines 3811
Fuel Injector, Yanmar Engines 3811
Forks 3811
Integral Sideshift Carriage 3811
Bearings, Replace 3811
Transmission Oil and Filter (Dry Brake), Replace 3811
Iron Transmission Housing 3811
Aluminum Transmission Housing 3812
Remove 3812
Clean and Inspect 3816
Install 3816
Transmission Oil Change, Wet Brake Drive Axle 3817
Iron Transmission Housing 3817
Aluminum Transmission Housing 3818
Wet Brake Axle Center Section and Planetary Housing, Oil Change 3821
Brake Fluid (Master Cylinder), Change 3821
Brake Fluid (Dry Brake), Remove 3826
Steer Axle, Wheel Bearing Lubrication 3826
Service Brakes (Dry Brake) 3826
Differential (Dry Brake) 3827
Maintenance Procedures Every 4000 Hours or 2 Years 3827
Hydraulic Oil, Replace 3828
Cooling System 3828
Safety Procedures When Working Near Mast 3829
Hood Latch Check 3832
Lift Chain Adjustments 3833
Jump-Starting the Lift Truck 3835
Jump-Starting Using a Battery Charger 3835
Jump-Starting a Lift Truck Using Another Lift Truck 3835
Welding Repairs 3835
Overhead Guard Changes 3836
Wheel and Tire Replacement 3836
General 3836
Solid Rubber Tire, Change (GC/GLC Series) 3836
Remove and Install Tire on Wheel 3837
Pneumatic Tire With Tube, Repair 3838
Remove Wheels From Lift Truck 3838
Remove Tire From Wheel 3838
Install Wheel in Tire 3841
Install Tire on Two-Piece Wheel 3843
Add Air to Pneumatic Tires With Tube 3844
Install the Wheels 3845
Dual Drive Wheels, Install 3845
Pneumatic Tubeless Tire, Repair 3846
Remove Wheels From Lift Truck 3846
Add Air to Pneumatic Tubeless Tire 3851
Wheels, Install 3851
Solid Rubber Tires on Pneumatic Wheels, Change 3851
Adhesives and Sealants 3855
524223778 8000YRM1151 (10 2016) US EN 3859
Lift Truck Lifting Capacity 3863
Counterweight Weights 3863
Tire Sizes 3863
Capacities 3864
Electrical System 3869
Transmission Oil Pressures 3870
Hydraulic System Relief Pressures 3874
Steering System 3875
Stall Speeds (in RPM ±100 rpm) 3876
Mazda FE (Except 2007 Emission Compliant Engines) 3876
Mazda FE (2007 Emission Compliant Engines Only) 3876
Mazda F2 (Except 2007 Emission Compliant Engines) 3876
Mazda F2 (2007 Emission Compliant Engines Only) 3876
GM 2 4L 3877
Yanmar 2 6L 3877
Yanmar 3 3L 3877
Mast Speeds 3877
Tilt Angles 3880
Front End Equipment – Mast Creep 3881
Mast Creep 3881
Engine Specifications 3881
Torque Specifications 3883
Frame 3883
Mast 3883
Steering System, Cushioned Tire Trucks 3883
Steering System, Pneumatic Tire Trucks 3884
Drive Axle (Dry Brake) 3884
Drive Axle (Wet Brake) 3884
Transmission – Iron Housing 3885
Transmission – Aluminum Housing 3885
Engine – Mazda FE and F2 3886
Engine – GM 2 4L 3887
Engine – Yanmar 2 6L and 3 3L Diesel 3888
524223779 8000YRM1152 (03 2020) US EN 3893
General Information About Diagrams and Schematics 3897
Symbol Definitions 3897
Diagrams Manual Applications 3898
Diagrams and Schematics 3900
524223780 8000YRM1134 (03 2020) US EN 3963
Series Code / Model Designation Reference Table 3969
Description 3971
Proc_Cal_001: Service Password Entry 3973
When to Perform 3973
Why Perform 3973
How to Perform 3973
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3974
When to Perform 3974
Calibration Order 3974
Why Perform 3974
How to Perform 3975
Proc_Cal_003: Save and Exit 3976
When to Perform 3976
Why Perform 3976
How to Perform 3976
Proc_Cal_004: Lift Valve Output Threshold 3977
When to Perform 3977
Calibration Order 3977
Why Perform 3977
How to Perform 3978
Proc_Cal_005: Lower Valve Output Threshold 3980
When to Perform 3980
Calibration Order 3980
Why Perform 3980
How to Perform 3980
Proc_Cal_006: Tilt Back Valve Output Threshold 3983
When to Perform 3983
Calibration Order 3983
Why Perform 3983
How to Perform 3983
Proc_Cal_007: Tilt Forward Valve Output Threshold 3986
When to Perform 3986
Calibration Order 3986
Why Perform 3986
How to Perform 3986
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3989
When to Perform 3989
Calibration Order 3989
Why Perform 3989
How to Perform 3989
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3992
When to Perform 3992
Calibration Order 3992
Why Perform 3992
How to Perform 3992
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3995
When to Perform 3995
Calibration Order 3995
Why Perform 3995
How to Perform 3995
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3998
When to Perform 3998
Calibration Order 3998
Why Perform 3998
How to Perform 3998
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 4001
When to Perform 4001
Calibration Order 4001
Why Perform 4001
How to Perform 4001
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 4004
When to Perform 4004
Calibration Order 4004
Why Perform 4004
How to Perform 4004
Proc_Cal_014: Load Weight Zero Point 4008
When to Perform 4008
Calibration Order 4008
Why Perform 4008
How to Perform 4008
Proc_Cal_015: Loaded Weight Calibration 4010
When to Perform 4010
Calibration Order 4010
Why Perform 4010
How to Perform 4010
Proc_Cal_016: Transmission Valve Calibration 4013
Applicable System/Option 4013
When to Perform 4013
Calibration Order 4013
Why Perform 4013
How to Perform 4013
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 4015
Applicable System/Option 4015
When to Perform 4015
Calibration Order 4015
Why Perform 4015
How to Perform 4015
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 4017
Applicable System/Option 4017
When to Perform 4017
Calibration Order 4017
Why Perform 4017
How to Perform 4018
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 4019
Required Tools 4019
When to Perform 4019
Calibration Order 4019
Why Perform 4020
How to Perform 4020
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 4021
When to Perform 4021
Why Perform 4021
How to Perform 4021
Proc_Cal_026: Travel Speed Calibration 4023
When to Perform 4023
Calibration Order 4023
Why Perform 4023
How to Perform 4023
524223780 8000YRM1134 (05 2022) US EN 4027
Series Code / Model Designation Reference Table 4033
Description 4036
Proc_Cal_001: Service Password Entry 4038
When to Perform 4038
Why Perform 4038
How to Perform 4038
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 4039
When to Perform 4039
Calibration Order 4039
Why Perform 4039
How to Perform 4039
Proc_Cal_003: Save and Exit 4041
When to Perform 4041
Why Perform 4041
How to Perform 4041
Proc_Cal_004: Lift Valve Output Threshold 4042
When to Perform 4042
Calibration Order 4042
Why Perform 4042
How to Perform 4042
Proc_Cal_005: Lower Valve Output Threshold 4045
When to Perform 4045
Calibration Order 4045
Why Perform 4045
How to Perform 4045
Proc_Cal_006: Tilt Back Valve Output Threshold 4048
When to Perform 4048
Calibration Order 4048
Why Perform 4048
How to Perform 4048
Proc_Cal_007: Tilt Forward Valve Output Threshold 4051
When to Perform 4051
Calibration Order 4051
Why Perform 4051
How to Perform 4051
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 4054
When to Perform 4054
Calibration Order 4054
Why Perform 4054
How to Perform 4054
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 4057
When to Perform 4057
Calibration Order 4057
Why Perform 4057
How to Perform 4057
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 4060
When to Perform 4060
Calibration Order 4060
Why Perform 4060
How to Perform 4060
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 4063
When to Perform 4063
Calibration Order 4063
Why Perform 4063
How to Perform 4063
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 4066
When to Perform 4066
Calibration Order 4066
Why Perform 4066
How to Perform 4066
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 4069
When to Perform 4069
Calibration Order 4069
Why Perform 4069
How to Perform 4069
Proc_Cal_014: Load Weight Zero Point 4072
When to Perform 4072
Calibration Order 4072
Why Perform 4072
How to Perform 4072
Proc_Cal_015: Loaded Weight Calibration 4074
When to Perform 4074
Calibration Order 4074
Why Perform 4074
How to Perform 4074
Proc_Cal_016: Transmission Valve Calibration 4077
Applicable System/Option 4077
When to Perform 4077
Calibration Order 4077
Why Perform 4077
How to Perform 4077
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 4079
Applicable System/Option 4079
When to Perform 4079
Calibration Order 4079
Why Perform 4079
How to Perform 4079
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 4082
Applicable System/Option 4082
When to Perform 4082
Calibration Order 4082
Why Perform 4082
How to Perform 4082
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 4085
Required Tools 4085
When to Perform 4085
Calibration Order 4085
Why Perform 4085
How to Perform 4085
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 4087
When to Perform 4087
Why Perform 4087
How to Perform 4087
Proc_Cal_026: Travel Speed Calibration 4089
When to Perform 4089
Calibration Order 4089
Why Perform 4089
How to Perform 4089
524240453 0600YRM1205 (01 2017) US EN 4093
General 4099
Engine Identification 4099
Major Engine Component Identification 4099
Location of Labels 4100
Engine Removal and Installation 4101
Cylinder Head Assembly Repair 4101
Glow Plugs 4104
Remove 4104
Install 4104
Valve Cover 4104
Remove 4104
Clean and Inspect 4105
Install 4105
Rocker Arm Assembly 4105
Remove 4105
Disassemble 4106
Clean and Inspect 4107
Push Rods 4107
Rocker Arm Assembly 4107
Assemble 4107
Install 4108
Valve Clearance Adjustments 4108
Cylinder Head Assembly 4109
Remove 4109
Disassemble 4114
Valves and Valve Springs, Remove 4114
Valve Guides, Remove 4114
Clean and Inspect 4115
Cylinder Head 4115
Valve Guides 4116
Valves 4116
Valve Sink 4116
Valve Seat 4117
Valve Springs 4117
Assemble 4118
Valve Guides, Install 4118
Valves and Valve Springs, Install 4118
Install 4119
Timing Gear Case and Timing Gears Repair 4120
Timing Gear Case Cover 4121
Remove 4121
Clean and Inspect 4121
Install 4122
Timing Gears 4122
Crankshaft Gear 4123
Remove 4123
Install 4123
Idler Gear 4123
Remove 4123
Inspect 4124
Install 4124
Camshaft Gear 4124
Remove 4124
Install 4125
Timing Gear Case 4125
Remove 4125
Clean and Inspect 4126
Install 4126
Drive Train, Camshaft, and Cylinder Block Repair 4127
Remove 4127
Disassemble 4128
Pistons and Connecting Rods 4128
Crankshaft 4128
Camshaft 4131
Clean and Inspect 4132
Cylinder Block 4132
Honing and Boring 4135
Pistons 4136
Piston Pin 4136
Connecting Rod 4137
Tappets 4137
Crankshaft 4138
Camshaft 4139
Camshaft Bushing 4140
Assemble 4140
Camshaft 4140
Crankshaft 4140
Pistons and Connecting Rods 4141
Install 4142
Lubrication System Repair 4143
Engine Oil and Oil Filter Change 4143
Oil Pan 4143
Remove 4143
Install 4144
Oil Suction Tube 4144
Remove 4144
Clean 4145
Install 4145
Oil Pump 4145
Remove 4145
Clean and Inspect 4146
Outer Rotor Outside Clearance 4146
Outer Rotor to Inner Rotor Tip Clearance 4147
Outer Rotor Side Clearance 4147
Rotor Shaft Clearance 4147
Install 4148
Fuel System Repair 4148
Fuel Injectors 4149
Remove 4149
Inspect 4150
Clean 4150
Test 4150
Install 4153
Electronic Throttle System 4153
Remove 4153
Install 4156
Inspect 4157
Adjust 4158
Manual Throttle System 4159
Fuel Injection Pump 4159
Remove 4159
Clean and Inspect 4163
Install 4163
Check/Adjust Fuel Injection Timing 4164
Cooling System Repair 4166
V-Belt 4166
Remove 4166
Inspect 4166
Install 4166
Adjust 4166
Water Pump 4168
4TNE92-NMHA, 4TNE92-NMHA/580090035, 4TNE92-SNMU, and 4TNE98-SNMU Engines 4168
Remove 4168
Install 4169
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/580090036, and 4TNE98-BNMH Engines 4170
Remove 4170
Install 4171
Thermostat 4173
Remove 4173
Inspect 4174
Install 4174
Flywheel and Flywheel Housing 4174
Flywheel 4175
Remove 4175
Install 4176
Flywheel Housing 4176
Remove 4176
Install 4176
Electrical Equipment Repair 4178
Alternator 4178
Remove 4178
Bench Test 4180
Regulate Voltage Check 4180
No Load Test 4182
Output Test 4182
Install 4182
Starter 4183
Remove 4184
No Load Test 4184
Install 4185
Engine Specifications 4186
Engine Data 4186
Engine Tuning 4194
Cylinder Head 4194
Intake/Exhaust Valve and Guide 4195
Valve Spring 4195
Rocker Arm and Shaft 4195
Push Rod 4196
Gear Train and Camshaft 4196
Camshaft 4196
Idle Gear Shaft and Bushing 4196
Backlash of Each Gear 4197
Cylinder Block 4197
Crankshaft 4197
Thrust Bearing 4198
Piston 4198
Piston Ring 4198
Connecting Rod 4199
Rod Small End 4199
Tappet 4199
Oil Pump 4200
Engine Oil Pressure 4200
Outer Rotor Outside Clearance 4200
Outer Rotor Side Clearance 4200
Outer Rotor to Inner Rotor Tip Clearance 4200
Rotor Shaft Clearance 4200
Standard Torque Specifications 4201
Standard Torque Chart 4201
Special Torque Specifications 4202
Special Tools 4203
524240908 1400YRM1215 (02 2018) US EN 4211
General 4215
Identification Plate 4215
Drive Axle Removal 4215
Reduction Gear Assembly 4221
Reduction Gear Assembly Repair 4221
Clean and Inspect 4231
Brake Repair 4245
Wet Disc Brake 4245
Clean and Inspect 4255
Wet Brake Noise Reduction 4269
General 4269
Adding Additive To Transmission 4269
Parking Brake Control Lever 4269
General 4269
Clean and Inspect 4272
Differential Repair 4276
Remove 4276
Clean and Inspect 4293
Gear Set, Tooth Contact Pattern Check 4313
Drive Axle Installation 4318
Special Tools 4323
Torque Specifications 4326
524240909 1400YRM1214 (11 2012) US EN 4331
toc 4331
Drive Axle and Differential Assembly Repair 4331
Safety Precautions Maintenance and Repair 4332
General 4335
Drive Axle Repair 4335
Remove and Disassemble 4335
Clean and Inspect 4337
Assemble and Install 4337
Differential Repair 4340
Remove 4340
Differential Assembly From Center Section 4340
Drive Pinion, Pinion Gear, and Bearings From Center Section 4345
Disassemble 4350
Differential Assembly 4350
Drop Box Housing 4353
Center Section 4354
Clean and Inspect 4356
Assemble 4356
Center Section 4356
Drop Box Housing 4360
Differential Assembly 4361
Install 4365
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 4365
Drive Pinion, Pinion Gear, and Bearings Into Center Section 4367
Differential Assembly Into Center Section 4372
Ring Gear Backlash, Adjust 4378
Ring Gear, Runout Check 4379
Gear Set, Tooth Contact Pattern Check 4379
Torque Specifications 4382
tables 4331
Table 1 Pinion Variation Numbers Examples 4366
Table 2 Ring and Pinion Tooth Contact Adjustment 4379
Table 3 Correct Tooth Contact 4380
Table 4 Incorrect Tooth Contact 4381
524289373 0900YRM1325 (12 2009) US EN 4385
toc 4385
Gasoline Fuel System 4385
Safety Precautions Maintenance and Repair 4386
General 4389
Abbreviations 4389
Intake-Air System 4389
Intake-Air System Manifold Vacuum Check 4389
Throttle Body 4390
Remove 4390
Install 4391
Intake Manifold 4391
Remove 4391
Install 4391
Fuel System 4392
Before Repair Procedure 4392
Fuel Line Safety Procedure 4392
After Repair Procedure 4395
Fuel Hose, Install 4395
Fuel Leakage Check 4395
Fuel Line Pressure Check 4396
Fuel Injectors 4397
Remove 4397
Install 4397
Pressure Regulator 4399
Remove 4399
Install 4399
Exhaust System 4400
Counterweight Exhaust System 4400
Remove and Disassemble 4400
Inspect 4400
Assemble and Install 4400
Overhead Exhaust System 4402
Remove and Disassemble 4402
Inspect 4402
Assemble and Install 4402
Exhaust Manifold 4404
Remove 4404
Install 4404
Positive Crankcase Ventilation (PCV) Valve 4406
Remove 4406
Inspect 4406
Install 4406
Oxygen Sensor 4407
Remove 4407
Install 4407
Control System 4409
Engine Control Unit (ECU) 4409
Remove 4409
Install 4410
Fuel Level Sensor 4411
Remove 4411
Install 4411
Technical Data 4412
tables 4385
Table 1 PCV Valve Specifications 4406
Table 2 Gasoline Fuel Systems Technical Data 4412
524289374 0900YRM1326 (04 2018) US EN 4415
General 4421
LPG Tank and Bracket Replacement 4421
Remove LPG Tank for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4421
Install LPG Tank for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4423
Remove LPG Tank for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4424
LPG Tank Install for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4426
Remove LPG Bracket for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4427
Install LPG Bracket for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4429
Remove LPG Tank Bracket Alignment Pin, Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4430
Install LPG Tank Bracket Alignment Pin, Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4432
Remove LPG Bracket for Lift Truck Models and GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4433
Install LPG Bracket for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4433
Fuel Filter Unit Repair 4433
Fuel Filter Element 4433
Remove 4433
Clean/Inspect 4434
Install 4434
Fuel Filter Housing 4434
Remove 4434
Disassemble 4437
Assemble 4439
Install 4440
Electronic Throttle Body Repair 4440
Remove 4440
Install 4442
Electronic Pressure Regulator (EPR) Repair 4442
Remove 4443
Disassemble 4447
Assemble 4449
Install 4450
LPG Shutoff Valve Assembly 4450
Remove 4450
Install 4454
Fuel Mixer Repair 4456
Remove 4456
Install 4459
Control System 4459
Engine Control Unit (ECU) 4459
Remove 4459
Install 4461
Low LPG Pressure Switch 4461
Remove 4461
Install 4462
LPG Low Level Sensor 4462
Remove 4463
Install 4466
Exhaust System 4467
Counterweight Exhaust System 4467
Remove and Disassemble 4467
Inspect 4469
Assemble and Install 4469
Overhead Exhaust System 4469
Remove and Disassemble 4470
Inspect 4472
Assemble and Install 4472
Exhaust Manifold 4473
Remove 4473
Install 4474
Positive Crankcase Ventilation (PCV) Valve 4475
Remove 4475
Inspect 4475
Install 4475
Oxygen Sensor 4475
Remove 4475
Install 4477
LPG Fuel Testing 4478
General 4478
Available Fuel Tests 4478
Composition Test (ASTM D-2163) 4478
Ammonia Test (ASTM D-4490) 4478
Basic Nitrogen Test (ASTM UOP269-90) 4478
Residues Test (ASTM D-2158) 4478
Vapor Pressure Test (ASTM D-2598) 4478
Sulfur Compounds Test (ASTM D-5623) 4479
Methanol Test (ASTM D-4864) 4479
Copper Corrosion (ASTM D-1838) 4479
Where To Send LPG Fuel Samples For Testing 4479
524289375 2200YRM1327 (09 2012) US EN 4483
General 4487
Ignition System 4487
General 4487
Ignition Timing Adjustment, Gasoline and LPG 4487
Spark Plugs Check 4492
Spark Plug Wires Check 4492
Coil Replacement 4493
Remove 4493
Inspect 4494
Install 4494
Starter Repair 4495
General 4495
Remove 4495
No-Load Test 4496
Magnetic Switch Test 4497
Pull-Out Test 4497
Holding Coil Test 4497
Return Test 4497
Pinion Movement Inspection 4498
Install 4498
Alternator Repair 4498
General 4498
Charging System Inspection 4500
Output Current Check 4500
No-Load Adjusted Voltage Check 4501
Remove 4502
Inspect 4502
Rectifier Check 4502
Install 4503
Engine Sensors and Switches 4504
Oil Pressure Sensor, Gas and LPG Engines 4504
Remove 4504
Install 4504
Air Filter Restriction Switch, Gas and LPG Engines 4504
Remove 4504
Install 4504
Cam Angle Sensor, Gas and LPG Engines 4505
Remove 4505
Install 4506
Voltage Check 4506
Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Engines 4507
Remove 4507
Install 4508
Intake Air Temperature (IAT) Sensor, LPG Engines 4509
Remove 4509
Install 4509
Intake Air Temperature (IAT) Sensor, Gas Engines 4509
Remove 4509
Install 4509
Fuel Temperature Sensor, LPG Engines 4512
Remove 4512
Install 4512
Engine Coolant Temperature (ECT) Sensor 4513
2007 Emissions Compliant Gas Engines 4513
Remove 4513
Install 4513
2007 and 2010 Emissions Compliant LPG Engines 4514
Remove 4514
Install 4514
2010 Emissions Compliant Gas and LPG Engines 4516
Remove 4516
Install 4516
524306203 0100YRM1290 (04 2014) US EN 4521
524329117 8000YRM1387 (03 2020) US EN 4625
General Information About Diagrams and Schematics 4629
Symbol Definitions 4629
Diagrams Manual Applications 4630
Diagrams and Schematics 4632
550001092 8000YRM1409 (03 2020) US EN 4697
General Information About Diagrams and Schematics 4701
Symbol Definitions 4701
Diagrams Manual Applications 4702
Diagrams and Schematics 4704
550010194 1300YRM1421 (08 2013) US EN 4785
toc 4785
Single Speed PowerShift 4785
Safety Precautions Maintenance and Repair 4786
General 4789
Serial Number 4789
Hydraulic Gear Pump 4790
Remove 4790
Install 4790
Charge Pump Repair 4791
Original Charge Pump 4791
Remove 4791
Disassemble 4792
Clean 4792
Inspect 4792
Assemble 4792
Install 4792
New Charge Pump, Manufactured After July, 2013 4793
Remove 4793
Clean 4794
Inspect 4794
Install 4795
Torque Converter Replacement 4797
Remove 4797
Clean and Inspect 4797
Install 4797
Stator Support Assembly Repair 4798
Remove 4798
Disassemble 4803
Clean 4804
Inspect 4804
Assemble 4805
Install 4805
Clutch Packs Repair 4807
Remove 4807
Engine, Torque Converter, and Transmission Assembly 4807
Transmission Components 4808
Disassemble 4810
Transmission 4810
Housings 4810
Forward Clutch Pack 4813
Reverse Clutch Pack 4818
Clean 4824
Inspect 4824
Assemble 4825
Transmission 4825
Reverse Clutch Pack 4825
Forward Clutch Pack 4832
Housings 4838
Install 4840
Transmission Components 4840
Engine, Torque Converter, and Transmission Assembly 4843
Inching Overlap Adjustment 4843
Proportional and Enable Solenoid Valves 4844
Proportional Valves 4844
Remove 4844
Disassemble 4846
Clean and Inspect 4846
Assemble 4846
Install 4846
Enable Solenoid Valve 4846
Remove 4846
Disassemble 4846
Clean and Inspect 4846
Assemble 4847
Install 4847
Foot Directional Control Pedal Repair 4847
Remove and Disassembly 4847
Clean and Inspect 4851
Assemble and Install 4851
550030170 1300YRM1447 (08 2013) US EN 4855
toc 4855
Single Speed Powershift 4855
Safety Precautions Maintenance and Repair 4856
General 4859
Serial Number 4859
Hydraulic Gear Pump 4860
Remove 4860
Install 4860
Housing Fittings Replacement 4860
Remove 4860
Disassemble 4861
Assemble 4861
Install 4861
Charge Pump Repair 4861
Lift Trucks Manufactured Before July, 2013 4861
Remove 4861
Disassemble 4863
Clean 4863
Inspect 4863
Assemble 4863
Install 4863
Lift Trucks Manufactured After July, 2013 4865
Remove 4865
Clean 4865
Inspect 4865
Install 4866
Torque Converter Replacement 4869
Remove 4869
Clean and Inspect 4869
Install 4869
Stator Support Assembly Repair 4871
Remove 4871
Disassemble 4876
Clean 4880
Inspect 4880
Assemble 4881
Install 4881
Clutch Packs Repair 4884
Remove 4884
Disassemble 4885
Housings 4885
Clutch Packs 4890
Forward Clutch Pack 4890
Reverse Clutch Pack 4895
Clean 4901
Inspect 4901
Assemble 4902
Clutch Packs 4902
Reverse Clutch Pack 4902
Forward Clutch Pack 4909
Housings 4916
Install 4916
Drive Chains and Sprockets 4922
Remove 4922
Clean 4924
Inspect 4924
Install 4924
Proportional and Enable Solenoid Valves 4925
Proportional Valves 4925
Remove 4925
Disassemble 4925
Clean and Inspect 4925
Assemble 4928
Install 4928
Enable Solenoid Valve 4928
Remove 4928
Disassemble 4929
Clean and Inspect 4929
Assemble 4929
Install 4929
Foot Directional Control Pedal Repair 4931
Remove and Disassemble 4931
Clean and Inspect 4935
Assemble and Install 4935
550043436 1300YRM1529 (11 2018) US EN 4941
General 4945
Serial Number 4945
Charge Pump Repair 4945
Lift Trucks Manufactured Before July, 2013 4945
Remove 4945
Inspect 4945
Install 4945
Lift Trucks Manufactured After July, 2013 4946
Remove 4946
Inspect 4946
Install 4946
Torque Converter Replace 4947
Remove 4947
Install 4956
Housings and Chain Drive Repair 4962
Remove 4962
Clean 4973
Inspect 4973
Install 4973
Clutch Packs Repair 4980
Remove and Disassemble 4980
Transmission, Remove and Disassemble 4980
Clean 4999
Inspect 4999
Assemble and Install 5000
Transmission, Assemble and Install 5008
Control Valve Repair 5012
Remove and Disassemble 5012
Clean 5016
Inspect 5016
Assemble and Install 5016
Foot Directional Control Pedal Repair 5017
Remove and Disassemble 5017
Assemble and Install 5021
Direction Control Lever 5022
Remove 5022
Install 5022
550055283 8000YRM1585 (07 2020) US EN 5027
General Information About Diagrams and Schematics 5031
Symbol Definitions 5031
Diagrams Manual Applications 5032
Diagrams and Schematics 5034
550073240 1900YRM1620 (01 2023) US EN 5123
Proper Flushing after Major Hydraulic Repairs 5129
Introduction 5129
The Phases of Wear 5129
Causes of Hydraulic System Failure 5129
Progression of Contaminant Caused Hydraulic System Failure 5130
Hydraulic System Flushing Techniques 5130
Double Oil and Filter Change 5130
Mechanical Cleaning 5131
Cleaning of Components 5131
How to Clean Tubes and Hoses 5131
Filter Caddy 5131
Start-Up Procedure for Cleaned System 5132
Contaminated Oil Coolers 5132
Additional Filter Caddy Functions 5133
How to Handle Different Fluids 5133
Water Removal Filters 5133
Fluid Conditioning and System Flushing Procedures 5134
Operation of the Filter Caddy 5134
Filter Caddy operation 5134
Fluid Conditioning Procedure 5134
Filter Caddy Start-Up 5135
System Flushing Procedure 5135
Component Cleaning Procedure 5136
Reservoir Cleaning Procedure 5136
Cylinder Cleaning Procedure 5136
Hose and Tube Cleaning Procedure 5136
Valve Cleaning Procedure 5137
Front-End Attachment Cleaning Procedure 5138
System Flushing Procedure 5138
Filter Caddy Start-Up 5139
System Start-Up and Flushing 5139
Reservoir Fluid Cleaning Times 5140
Dealing With Different Fluid Types 5141
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5141
Filter Caddy Maintenance 5141
Servicing the Strainer 5141
DC Motor 5141
Hydraulic Oil Sampling Method and Procedure 5142
Hydraulic Oil Sampling Method 5142
Objective 5142
General Guidelines 5142
Synopsis 5143
Hydraulic Oil Analysis Report Guidelines 5144
Sampling Conditions 5144
Equipment 5144
Sampling Procedure 5145
Hydraulic Oil Sampling 5145
Sample Labeling 5145
Results Documentation 5145
550073240 1900YRM1620 (03 2020) US EN 5147
Proper Flushing after Major Hydraulic Repairs 5151
Introduction 5151
The Phases of Wear 5151
Causes of Hydraulic System Failure 5151
Progression of Contaminant Caused Hydraulic System Failure 5152
Hydraulic System Flushing Techniques 5152
Double Oil and Filter Change 5152
Mechanical Cleaning 5153
Cleaning of Components 5153
How to Clean Tubes and Hoses 5153
Filter Caddy 5153
Start-Up Procedure for Cleaned System 5154
Contaminated Oil Coolers 5154
Additional Filter Caddy Functions 5154
How to Handle Different Fluids 5154
Water Removal Filters 5155
Fluid Conditioning and System Flushing Procedures 5155
Operation of the Filter Caddy 5155
Filter Caddy operation 5155
Fluid Conditioning Procedure 5156
Filter Caddy Start-Up 5156
System Flushing Procedure 5157
Component Cleaning Procedure 5157
Reservoir Cleaning Procedure 5157
Cylinder Cleaning Procedure 5157
Hose and Tube Cleaning Procedure 5158
Valve Cleaning Procedure 5158
Front-End Attachment Cleaning Procedure 5159
System Flushing Procedure 5159
Filter Caddy Start-Up 5160
System Start-Up and Flushing 5160
Reservoir Fluid Cleaning Times 5161
Dealing With Different Fluid Types 5161
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5161
Filter Caddy Maintenance 5162
Servicing the Strainer 5162
DC Motor 5162
Hydraulic Oil Sampling Method and Procedure 5162
Hydraulic Oil Sampling Method 5162
Objective 5162
General Guidelines 5162
Synopsis 5163
Hydraulic Oil Analysis Report Guidelines 5164
Sampling Conditions 5165
Equipment 5165
Sampling Procedure 5165
Hydraulic Oil Sampling 5165
Sample Labeling 5166
Results Documentation 5166
550093750 2100YRM1668 (02 2018) US EN 5169
General 5173
Safety Procedures When Working Near Mast 5174
Main Lift Cylinder Repair 5176
Remove 5176
Disassemble 5178
Clean 5180
Inspect 5180
Assemble 5180
Install 5181
Main Lift Cylinder Leak Check 5181
Free-Lift Cylinder 5182
Remove 5182
Disassemble 5183
Clean 5185
Inspect 5185
Assemble 5185
Install 5185
Tilt Cylinder Repair 5186
Remove 5186
Disassemble 5188
Clean 5190
Inspect 5190
Assemble 5190
Install 5191
Tilt Cylinder Adjustment 5192
Tilt Cylinder Leak Check 5193
Integral Sideshift Cylinder Repair Prior to December 2016 5195
Remove 5195
Disassemble 5196
Clean 5197
Inspect 5197
Assemble 5197
Install 5197
Integral Sideshift Cylinder Repair After December 2016 5198
General 5198
Remove 5198
Disassemble 5200
Clean 5200
Inspect 5200
Assemble 5200
Install 5201
Integral Side-Shift Cylinder Gland Leak Checks 5202
Fork Positioner Cylinder Repair Prior to December 2016 5203
Remove 5203
Disassemble 5203
Clean 5205
Inspect 5206
Assemble 5206
Install 5206
Fork Positioner Cylinder Adjustment 5206
Fork Positioner Cylinder Repair After December 2016 5207
General 5207
Remove 5207
Disassemble 5207
Clean 5210
Inspect 5211
Assemble 5211
Install 5211
Fork Positioner Cylinder Adjustment 5211
Seal Kit Installation 5212
External Installation (Seal and Backup Ring) 5212
Internal Installation (Piston Rod Assembly) 5212
Torque Specifications 5213
Main Lift Cylinders 5213
Free-Lift Cylinder 5213
Tilt Cylinders 5213
Integral Sideshift Cylinder 5213
Fork Positioner Cylinder 5213
550093750 2100YRM1668 (04 2023) US EN 5217
General 5223
Safety Procedures When Working Near Mast 5226
Main Lift Cylinder Repair 5228
Remove 5228
Disassemble 5230
Clean 5232
Inspect 5232
Assemble 5232
Install 5233
Main Lift Cylinder Leak Check 5233
Free-Lift Cylinder 5234
Remove 5234
Disassemble 5235
Clean 5237
Inspect 5237
Assemble 5237
Install 5237
Tilt Cylinder Repair 5239
Remove 5239
Disassemble 5241
Clean 5242
Inspect 5243
Assemble 5243
Install 5244
Tilt Cylinder Adjustment 5244
Tilt Cylinder Leak Check 5246
Integral Sideshift Cylinder Repair Prior to December 2016 5248
Remove 5248
Disassemble 5248
Clean 5249
Inspect 5249
Assemble 5249
Install 5250
Integral Sideshift Cylinder Repair After December 2016 5251
General 5251
Remove 5251
Disassemble 5252
Clean 5253
Inspect 5253
Assemble 5253
Install 5253
Integral Side-Shift Cylinder Gland Leak Checks 5254
Fork Positioner Cylinder Repair Prior to December 2016 5255
Remove 5255
Disassemble 5255
Clean 5258
Inspect 5258
Assemble 5259
Install 5259
Fork Positioner Cylinder Adjustment 5259
Fork Positioner Cylinder Repair After December 2016 5261
General 5261
Remove 5261
Disassemble 5261
Clean 5264
Inspect 5264
Assemble 5265
Install 5265
Fork Positioner Cylinder Adjustment 5265
Seal Kit Installation 5267
External Installation (Seal and Backup Ring) 5267
Internal Installation (Piston Rod Assembly) 5267
Torque Specifications 5268
Main Lift Cylinders 5268
Free-Lift Cylinder 5268
Tilt Cylinders 5268
Integral Sideshift Cylinder 5268
Fork Positioner Cylinder 5268
550093755 4000YRM1669 (04 2023) US EN 5271
General 5279
Safety Procedures When Working Near Mast 5281
Fork Replacement 5283
Standard Carriage and Integral Sideshift Carriage 5283
Remove 5283
Install 5284
Checks 5284
Fork Positioner Carriage 5286
Remove 5287
Install 5287
Checks 5289
Carriages Repair, Two-Stage LFL Mast 5292
Standard Carriage 5292
Remove 5292
Clean and Inspect 5293
Install 5293
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5293
Remove 5293
Disassemble 5295
Clean and Inspect 5296
Assemble 5297
Install 5297
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 5298
Remove 5298
Disassemble 5301
Clean and Inspect 5301
Assemble 5302
Install 5303
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5303
Remove 5303
Disassemble 5306
Clean and Inspect 5306
Assemble 5307
Install 5308
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5308
Remove 5308
Install 5310
Fork Positioner Hydraulic Hose Adjustment 5312
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5313
Remove 5313
Disassemble and Assemble 5317
Clean and Inspect 5317
Install 5317
Fork Positioner Hydraulic Hose Adjustment 5318
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 5319
Remove 5319
Disassemble and Assemble 5323
Clean and Inspect 5323
Install 5323
Fork Positioner Hydraulic Hose Adjustment 5324
Two-Stage LFL Mast Repair 5326
Mast With Serial Number F507 5326
Remove 5326
Disassemble 5330
Clean and Inspect 5337
Assemble 5339
Install 5340
Header Hoses 5342
Remove 5342
Installation 5342
Adjustment 5346
Mast With Serial Number F562 5347
Remove 5347
Disassemble 5351
Clean and Inspect 5358
Assemble 5360
Install 5361
Header Hose Installation and Adjustment 5362
Remove 5362
Installation 5363
Adjustment 5367
Carriages Repair, Three-Stage FFL Mast 5369
Standard Carriage 5369
Remove 5369
Clean and Inspect 5370
Install 5371
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5371
Remove 5371
Disassemble 5372
Clean and Inspect 5373
Assemble 5374
Install 5374
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5375
Remove 5375
Disassemble 5377
Clean and Inspect 5378
Assemble 5379
Install 5379
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5380
Remove 5380
Disassemble 5382
Clean and Inspect 5383
Assemble 5384
Install 5384
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5385
Remove 5385
Install 5387
Fork Positioner Hydraulic Hose Adjustment 5389
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5390
Remove 5390
Disassemble and Assemble 5392
Clean and Inspect 5392
Install 5392
Fork Positioner Hydraulic Hose Adjustment 5393
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 5394
Remove 5394
Disassemble and Assemble 5397
Clean and Inspect 5397
Install 5397
Fork Positioner Hydraulic Hose Adjustment 5398
Three-Stage FFL Mast Repair 5400
Mast With Serial Number F508 5400
Remove 5400
Disassemble 5403
Clean and Inspect 5413
Assemble 5416
Install 5417
Header Hose Installation and Adjustment 5419
Remove 5419
Installation 5419
Adjustment 5428
Mast With Serial Number F563 5428
Remove 5428
Disassemble 5432
Clean and Inspect 5442
Assemble 5445
Install 5446
Header Hose Installation and Adjustment 5448
Remove 5448
Installation 5448
Adjustment 5456
Mast Adjustments 5458
Load Roller, Adjust 5458
Mast Side Kicking, Adjust 5460
Carriage Adjustments 5461
Lift Chains Adjustment 5463
Hydraulic Quick Disconnect Hoses 5465
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5465
Lift Trucks Equipped With E-Hydraulic Controls 5465
Lift Trucks Equipped With Manual Hydraulic Controls 5465
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5466
Lift Trucks Equipped With E-Hydraulic Controls 5466
Lift Trucks Equipped With Manual Hydraulic Controls 5466
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5466
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5466
550093755 4000YRM1669 (06 2019) US EN 5469
General 5475
Safety Procedures When Working Near Mast 5476
Fork Replacement 5478
Standard Carriage and Integral Sideshift Carriage 5478
Remove 5478
Install 5480
Checks 5480
Fork Positioner Carriage 5482
Remove 5483
Install 5483
Checks 5485
Carriages Repair, Two-Stage LFL Mast 5487
Standard Carriage 5487
Remove 5487
Clean and Inspect 5488
Install 5489
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5489
Remove 5489
Disassemble 5490
Clean and Inspect 5491
Assemble 5492
Install 5492
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 5493
Remove 5493
Disassemble 5496
Clean and Inspect 5496
Assemble 5497
Install 5497
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5498
Remove 5498
Disassemble 5501
Clean and Inspect 5501
Assemble 5502
Install 5502
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5503
Remove 5503
Install 5505
Fork Positioner Hydraulic Hose Adjustment 5507
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5508
Remove 5508
Disassemble and Assemble 5512
Clean and Inspect 5512
Install 5512
Fork Positioner Hydraulic Hose Adjustment 5513
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 5514
Remove 5514
Disassemble and Assemble 5518
Clean and Inspect 5518
Install 5518
Fork Positioner Hydraulic Hose Adjustment 5519
Two-Stage LFL Mast Repair 5520
Mast With Serial Number F507 5520
Remove 5520
Disassemble 5524
Clean and Inspect 5531
Assemble 5533
Install 5534
Header Hoses 5536
Remove 5536
Installation 5536
Adjustment 5540
Mast With Serial Number F562 5541
Remove 5541
Disassemble 5545
Clean and Inspect 5552
Assemble 5554
Install 5555
Header Hose Installation and Adjustment 5556
Remove 5556
Installation 5557
Adjustment 5561
Carriages Repair, Three-Stage FFL Mast 5562
Standard Carriage 5562
Remove 5562
Clean and Inspect 5564
Install 5564
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5564
Remove 5564
Disassemble 5566
Clean and Inspect 5567
Assemble 5568
Install 5568
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5569
Remove 5569
Disassemble 5571
Clean and Inspect 5572
Assemble 5573
Install 5573
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5574
Remove 5574
Disassemble 5576
Clean and Inspect 5577
Assemble 5578
Install 5578
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5579
Remove 5579
Install 5581
Fork Positioner Hydraulic Hose Adjustment 5583
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5584
Remove 5584
Disassemble and Assemble 5586
Clean and Inspect 5586
Install 5586
Fork Positioner Hydraulic Hose Adjustment 5587
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 5588
Remove 5588
Disassemble and Assemble 5591
Clean and Inspect 5591
Install 5591
Fork Positioner Hydraulic Hose Adjustment 5592
Three-Stage FFL Mast Repair 5593
Mast With Serial Number F508 5593
Remove 5593
Disassemble 5597
Clean and Inspect 5607
Assemble 5610
Install 5611
Header Hose Installation and Adjustment 5613
Remove 5613
Installation 5613
Adjustment 5621
Mast With Serial Number F563 5622
Remove 5622
Disassemble 5625
Clean and Inspect 5635
Assemble 5638
Install 5639
Header Hose Installation and Adjustment 5641
Remove 5641
Installation 5641
Adjustment 5649
Mast Adjustments 5650
Load Roller, Adjust 5650
Mast Side Kicking, Adjust 5652
Carriage Adjustments 5652
Lift Chains Adjustment 5654
Hydraulic Quick Disconnect Hoses 5656
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5656
Lift Trucks Equipped With E-Hydraulic Controls 5656
Lift Trucks Equipped With Manual Hydraulic Controls 5657
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5657
Lift Trucks Equipped With E-Hydraulic Controls 5657
Lift Trucks Equipped With Manual Hydraulic Controls 5658
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5658
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5658