Yale Forklift C810 (GPGDPGLP030-040VXSVX) Service Manual PDF

Yale Forklift C810 (GPGDPGLP030-040VXSVX) Service Manual – PDF DOWNLOAD

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Yale Forklift C810 (GPGDPGLP030-040VXSVX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4796
Downloadable : Yes
File Type : PDF

PART NO. 524150797

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TABLE OF CONTENTS:

Yale Forklift C810 (GPGDPGLP030-040VXSVX) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (03 2020) US EN 1
General 5
Threaded Fasteners 5
Nomenclature, Threads 5
Strength Identification 6
Cotter (Split) Pins 7
Fastener Torque Tables 12
Conversion Table 14
524221866 9000YRM1112 (10 2020) US EN 21
SECTION 9010 Operational Diagnostic Procedures 37
Group 05 – Operational Checkout 39
SECTION 9020 Engine 57
Group 10 – Principles of Operation 67
Group 30 – Observed Symptoms 265
Group 40 – Tests and Adjustments 367
SECTION 9030 Electrical System 399
Group 03 – General Maintenance and Diagnostic Data 423
Group 10 – Principles of Operation 517
Group 20 – Diagnostic Trouble Codes 541
Group 30 – Observed Symptoms 1513
SECTION 9040 Drive Train 1569
Group 10 – Principles of Operation 1573
Group 30 – Observed Symptoms 1629
Group 40 – Tests and Adjustments 1679
SECTION 9050 Hydraulic Systems 1689
Group 10 – Principles of Operation 1693
Group 30 – Observed Symptoms 1751
Group 33 – Observed Symptoms-Gear Pump 1753
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1841
Group 40 – Tests and Adjustments 1885
Group 43 – Tests and Adjustments-Gear Pump 1887
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1911
SECTION 9060 Operators Station 1929
Group 10 – Principles of Operation 1931
SECTION 9070 Front End (Mast) and Chassis 1967
Group 10 – Principles of Operation 1969
Group 30 – Observed Symptoms 1991
SECTION 9080 Supplementary Data 2049
Group 50 – Abbreviations and Acronyms 2051
Group 60 – Special Tools List 2059
Group 70 – Fault Mode Indicator Reference 2069
Group 80 – Supplier Specification Data 2071
524223754 0100YRM1120 (12 2012) US EN 2075
toc 2075
Frame 2075
Safety Precautions Maintenance and Repair 2076
General 2079
Description 2079
Hood, Seat, and Side Covers Replacement 2080
Remove 2080
Install 2086
Steering Column 2091
Description 2091
Steering Column Repair 2091
Remove 2091
Disassemble 2093
Clean 2093
Inspect 2093
Assemble 2093
Install 2096
LPG Tank and Bracket Assembly 2096
Counterweight Replacement 2097
Remove 2097
Install 2100
Tow Pin, Remove and Install 2101
Overhead Guard Replacement 2101
Remove and Install 2101
LED Tail, Backup, and Brake Lights, Replace 2102
Operator Restraint System Replacement 2103
Description 2103
Automatic Locking Retractor (ALR) 2103
Emergency Locking Retractor (ELR) 2103
Engine Replacement 2105
Remove 2105
Install 2110
Transmission Replacement 2112
Remove Transmission with Iron Housing 2112
Install Transmission with Iron Housing 2114
Remove Transmission with Aluminum Housing 2114
Install Transmission with Aluminum Housing 2119
Throttle Pedal and Cable Adjustment 2122
Mazda Gas/LPG Engines With Basic Power Shift Transmission and El 2122
Mazda Gasoline Engine With Electronic Transmission 2124
Throttle Pedal Stop Adjustment 2125
Yanmar Diesel Engine With Basic Power Shift Transmission 2126
Yanmar Diesel Engine With Electronic Throttle 2126
Exhaust System Repair 2127
Lift Trucks With Counterweight Exhaust System 2127
Mazda Gas and LPG Engines 2127
Remove and Disassemble 2127
Inspect 2127
Assemble and Install 2127
Yanmar Diesel Engine 2129
Remove and Disassemble 2129
Inspect 2129
Assemble and Install 2129
Lift Trucks With Overhead Exhaust System 2131
Yanmar Diesel Engine 2131
Remove and Disassemble 2131
Inspect 2131
Assemble and Install 2132
Mazda Gas and LPG Engines 2134
Remove and Disassemble 2134
Inspect 2134
Assemble and Install 2134
Cooling System 2136
Description 2136
Hydraulic Filter Assembly Repair 2136
Remove 2136
Clean and Inspect 2137
Install 2137
Fuel and Hydraulic Tanks Repair 2138
Inspect 2138
Clean 2138
Steam Method of Cleaning 2138
Chemical Solution Method of Cleaning 2139
Additional Preparations for Repair 2139
Small Leaks, Repair 2139
Large Leaks, Repair 2139
Preparations for Use After Repair 2140
Safety Labels 2140
tables 2075
Table 1 Gas Spring Installation, Lift Truck Models GLP/GDP16VX, 2087
Table 2 Gas Spring Installation, Lift Truck Models GLP/GDP20-35 2089
Table 3 Weight of Counterweights, Lift Truck Models GLC20-35VX 2099
Table 4 Weight of Counterweights, Lift Truck Models GC/GLC030VX 2099
Table 5 Weight of Counterweights, Lift Truck Models GLP/GDP16-1 2099
Table 6 Weight of Counterweights, Lift Truck Models GLP/GDP20-3 2099
524223756 0600YRM1122 (03 2020) US EN 2147
General 2151
Serial Number 2152
Engine Removal and Installation 2152
Cylinder Head, Camshaft, and Valve Mechanism Repair 2152
Remove 2152
Clean 2155
Inspect and Repair 2155
Cylinder Head 2155
Rocker Shaft Assembly 2155
Camshaft 2156
Valve Guides 2157
Valve Seats 2157
Valves 2158
Valve Springs 2158
Install 2159
Crankshaft and Main Bearings Repair 2163
Remove 2163
Inspect and Repair 2164
Crankshaft 2164
Main Bearings 2164
Install 2165
Pistons and Connecting Rods Repair 2166
Remove and Disassemble 2166
Clean 2166
Inspect and Repair 2166
Pistons 2166
Piston Rings 2166
Connecting Rods and Bearings 2167
Assemble and Install 2167
Cylinder Block Repair 2169
Oil Pump Repair 2170
Remove 2170
Disassemble 2171
Clean 2171
Inspect 2171
Assemble 2172
Install 2172
Cooling System Repair 2174
Thermostat 2174
Replace 2174
Fan Assembly 2174
Remove and Disassemble 2174
Assemble and Install 2175
Water Pump 2175
Remove 2175
Install 2176
Flywheel and Ring Gear Repair 2177
Remove 2177
Install 2177
Valve Adjustment 2177
Compression Pressure Check 2179
Engine Timing Adjustment 2180
Engine Specifications 2180
Engine Data 2180
Engine Speeds 2180
2007, and Later, Emission Compliant Engines 2180
All Engines Except 2007, and Later, Emission Compliant Engines 2181
Thermostat 2181
Cylinder Head 2181
Valve Mechanism 2181
Camshaft 2182
Crankshaft 2182
Connecting Rods 2182
Cylinder Block 2183
Pistons 2183
Oil Pump 2183
Torque Specifications 2184
524223757 0700YRM1123 (06 2016) US EN 2187
General 2191
Cooling System Checks 2191
Exhaust Leaks Into Cooling System 2191
Water Flow Restrictions in Radiator 2191
Radiator Hoses 2191
Water Pump 2192
Flushing the Cooling System 2192
Cooling System, Clean 2192
Radiator Replacement 2193
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) 2194
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 2209
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2212
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) 2215
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) 2222
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 2227
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2229
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) 2232
Fan Assembly Replacement 2244
Fan Removal 2244
Inspect 2259
Fan Installation 2259
524223759 0900YRM1125 (05 2005) US EN 2265
toc 2265
LPG Fuel System 2265
Safety Precautions Maintenance and Repair 2266
General 2269
Hoses Replacement 2269
LPG Tank Replacement 2269
Remove 2269
Install 2271
Fuel Filter 2272
Remove 2272
Clean and Inspect 2272
Install 2273
Relief Valve Replacement 2274
Remove and Install 2274
Carburetor Repair 2274
Remove 2274
Disassemble 2274
Clean 2276
Assemble 2276
Install 2276
Fuel Injector Repair 2277
Remove 2277
Clean and Inspect 2277
Install 2277
Governor Repair 2277
Remove 2277
Install 2277
Regulator Repair 2278
Remove 2278
Install 2278
Control System 2279
Engine Control Unit (ECU) 2279
Remove 2279
Install 2280
Engine Coolant Temperature (ECT) Sensor 2280
Remove 2280
Install 2280
Camshaft Position (CMP) Sensor 2280
Voltage Check 2280
Intake Air Temperature (IAT) Sensor 2281
Remove 2281
Install 2281
Manifold Absolute Pressure (MAP) Sensor 2282
Remove 2282
Install 2282
Oxygen Sensor 2282
Remove 2282
Install 2282
Throttle Position (TP) Sensor 2283
Remove 2283
Install 2283
524223761 0900YRM1127 (05 2005) US EN 2287
toc 2287
Gasoline Fuel System 2287
Safety Precautions Maintenance and Repair 2288
General 2291
Abbreviations 2291
Engine Tune-up 2291
Engine Tune-Up Preparation 2291
Idle Speed Adjustment 2291
Idle-Up Speed Check 2291
Intake-Air System 2293
Intake-Air System Manifold Vacuum Check 2293
Throttle Body 2294
Remove 2294
Install 2294
Electronic Governor 2294
Remove 2294
Install 2294
Intake-Air Control (IAC) Valve 2294
Remove 2294
Install 2294
Intake Manifold 2296
Remove 2296
Install 2296
Fuel System 2297
Before Repair Procedure 2297
Fuel Line Safety Procedure 2297
After Repair Procedure 2297
Fuel Hose, Install 2297
Fuel Leakage Check 2298
Fuel Line Pressure Check 2298
Fuel Injector 2299
Remove 2299
Install 2300
Pressure Regulator 2300
Remove 2300
Install 2301
Exhaust System 2301
Exhaust System, Inspect 2301
Three-Way Catalytic (TWC) Converter 2301
Remove and Install 2301
Exhaust Manifold 2301
Remove 2301
Install 2301
Positive Crankcase Ventilation (PCV) Valve 2303
Remove 2303
Inspect 2303
Install 2303
Control System 2303
Engine Control Unit (ECU) 2303
Remove 2303
Install 2305
Intake Air Temperature (IAT) Sensor 2306
Remove 2306
Install 2306
Mass Air Flow (MAF) Sensor 2306
Remove 2306
Install 2306
Throttle Position (TP) Sensor 2307
TP Sensor, Adjust 2307
Remove 2308
Install 2308
Engine Coolant Temperature (ECT) Sensor 2308
Remove 2308
Install 2308
Camshaft Position (CMP) Sensor 2309
Voltage Check 2309
Oxygen Sensor 2310
Remove 2310
Install 2310
Manifold Absolute Pressure (MAP)/Boost Sensor 2310
Remove 2310
Install 2310
Technical Data 2311
tables 2287
Table 1 PCV Valve Specifications 2303
Table 2 Closed Throttle Position Specifications 2308
Table 3 Gasoline Fuel Systems Technical Data 2311
524223762 1300YRM1129 (11 2018) US EN 2315
General 2319
Serial Number 2319
Charge Pump Repair 2319
Remove 2319
Inspect 2320
Install 2320
Torque Converter Replace 2320
Remove 2320
Install 2328
Front Cover Housing and Chain Drive Repair 2334
Remove 2334
Clean 2343
Inspect 2343
Install 2343
Clutch Packs Repair 2352
Remove and Disassemble 2352
Transmission, Remove and Disassemble 2352
Clean 2371
Inspect 2371
Assemble and Install 2372
Transmission, Assemble and Install 2380
Control Valve Repair 2386
Remove and Disassemble 2386
Clean 2390
Inspect 2390
Assemble and Install 2390
Foot Directional Control Pedal Repair 2391
Remove and Disassemble 2391
Assemble and Install 2395
Direction Control Lever 2396
Remove 2396
Install 2396
524223764 1600YRM1133 (07 2013) US EN 2401
toc 2401
Steering Axle 2401
Safety Precautions Maintenance and Repair 2402
General 2405
Steering Axle Assembly Repair 2407
Remove 2407
Disassemble 2408
Clean 2416
Inspect 2416
Assemble 2416
Install 2422
Spindles, Bearings, and Tie Rods Repair 2424
Spindles and Bearings 2424
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2424
Remove 2424
Disassemble 2426
Clean 2427
Inspect 2427
Assemble 2427
Install 2428
Spindles and Bearings 2431
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2431
Remove and Disassemble 2431
Assemble and Install 2432
Tie Rods 2432
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2432
Remove 2432
Install 2433
Tie Rods 2434
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2434
Remove 2434
Install 2440
Steering Cylinder Repair 2440
Remove and Disassemble 2440
Clean and Inspect 2441
Assemble and Install 2441
Torque Specifications 2442
524223765 1800YRM1135 (09 2018) US EN 2447
General 2451
Dry Brake System 2451
Wet Brake System 2451
Service Brakes Repair (Dry Brake) 2451
Remove and Disassemble 2452
Clean 2460
Inspect 2460
Assemble and Install 2461
Adjust 2468
Inching Overlap Adjustment 2468
Parking Brake Repair 2469
Remove and Disassemble 2469
Assemble and Install 2472
Adjust 2472
Master Cylinder Repair 2473
Remove (Dry Brake) 2473
Disassemble (Dry Brake) 2474
Clean and Inspect (Dry Brake) 2476
Assemble (Dry Brake) 2476
Bench Bleed Master Cylinder (Dry Brake) 2476
Install and Adjust (Dry Brake) 2476
Remove (Wet Brake) 2477
Disassemble (Wet Brake) 2479
Clean and Inspect (Wet Brake) 2480
Assemble (Wet Brake) 2481
Install and Adjust (Wet Brake) 2481
Service Brakes Adjustment (Dry Brake) 2482
Brake System Air Removal 2482
Using Pressure Bleed System 2482
Using Brake Pedal Pressure 2483
Brake Pedal Adjustment 2483
Free Pedal Adjustment 2484
Torque Specifications 2486
524223766 1900YRM1136 (01 2022) US EN 2489
General 2493
Hydraulic Gear Pump Assembly 2494
Variable Displacement Pump Assembly 2495
Single Gear Pump Assembly Repair 2496
Remove 2496
Disassemble 2502
Clean 2504
Inspect 2504
Assemble 2504
Install 2504
Tandem Gear Pump Assembly 2509
Remove 2509
Disassemble 2510
Clean 2513
Inspect 2513
Assemble 2513
Install 2514
Gear Pump Specifications 2515
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2521
Remove 2521
Disassemble 2531
Clean 2534
Inspect 2535
Assemble 2535
Install 2535
63 0 cc/rev – Variable Displacement Pump Repair 2540
Remove 2540
Disassemble 2543
Clean 2545
Inspect 2545
Assemble 2545
Install 2545
Variable Displacement Pump Checks and Adjustments (Single Pump) 2549
Margin Pressure Check 2549
Flow Compensator Adjustment 2550
Pressure Compensator Adjustment 2550
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2552
Variable Displacement Pump Specifications 2555
Torque Specifications 2557
Hydraulic Gear Pump 2557
Variable Displacement Pump 2558
Special Tools 2559
524223766 1900YRM1136 (11 2017) US EN 2561
General 2565
Hydraulic Gear Pump Assembly 2566
Variable Displacement Pump Assembly 2567
Single Gear Pump Assembly Repair 2567
Remove 2567
Disassemble 2574
Clean 2574
Inspect 2576
Assemble 2576
Install 2576
Tandem Gear Pump Assembly 2580
Remove 2581
Disassemble 2583
Clean 2585
Inspect 2585
Assemble 2585
Install 2586
Gear Pump Specifications 2586
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2592
Remove 2592
Disassemble 2602
Clean 2605
Inspect 2605
Assemble 2605
Install 2606
63 0 cc/rev – Variable Displacement Pump Repair 2609
Remove 2609
Disassemble 2612
Clean 2612
Inspect 2612
Assemble 2614
Install 2614
Variable Displacement Pump Checks and Adjustments (Single Pump) 2616
Margin Pressure Check 2616
Flow Compensator Adjustment 2617
Pressure Compensator Adjustment 2617
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2618
Variable Displacement Pump Specifications 2621
Torque Specifications 2622
Hydraulic Gear Pump 2623
Variable Displacement Pump 2624
Special Tools 2624
524223767 2000YRM1137 (01 2017) US EN 2629
General 2635
Electro-Hydraulic Main Control Valve 2636
Description 2636
Remove 2644
Electro-Hydraulic Control Valve Sections 2649
General 2649
Outlet Control Valve Section 2649
Remove 2649
Disassemble 2650
Clean 2652
Inspect 2652
Assemble 2652
Install 2653
Auxiliary Control Valve Sections 2653
Remove 2653
Disassemble 2660
Clean 2661
Inspect 2662
Assemble 2662
Install 2664
Tilt Control Valve Section 2665
Remove 2665
Disassemble 2665
Clean 2671
Inspect 2671
Assemble 2671
Install 2672
Lift/Lower Control Valve Section 2673
Remove 2673
Disassemble 2673
Clean 2682
Inspect 2682
Assemble 2682
Install 2683
Mid-Inlet Section 2683
Remove 2683
Clean 2684
Inspect 2684
Install 2684
Install 2684
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2689
Lift Pilot Pin 2689
Lower Pilot Pin 2693
Abnormal/Erroneous EHPV Adjustment 2695
Manual Main Control Valve 2696
Description 2696
Remove 2700
OPS Solenoid Assembly 2708
General 2708
Remove 2709
Clean and Inspect 2712
Install 2712
Manual Control Valve Sections 2713
General 2713
Outlet Control Valve Section 2713
Remove 2713
Disassemble 2713
Clean 2716
Inspect 2716
Assemble 2716
Install 2717
Auxiliary Control Valve Sections 2717
Remove 2717
Disassemble 2717
Clean 2720
Inspect 2720
Assemble 2720
Install 2721
Lift/Tilt Control Valve Section 2721
Remove 2721
Disassemble 2721
Clean 2728
Inspect 2728
Assemble 2729
Install 2730
Mid-Inlet Section 2731
Remove 2731
Clean 2731
Inspect 2731
Install 2731
Install 2732
Pressure Relief Valve Check and Adjustment 2738
Primary Relief Valve 2739
Secondary Relief Valve 2743
Steering Control Unit Repair 2750
Steering Control Unit, Remove 2750
Steering Control Unit, Disassemble 2754
Steering Control Unit, Clean 2756
Steering Control Unit, Inspect 2756
Steering Control Unit, Assemble 2756
Relief Valve, Disassemble 2757
Relief Valve, Clean 2757
Relief Valve, Inspect 2758
Relief Valve, Assemble 2758
Steering Control Unit, Install 2758
524223768 2100YRM1139 (02 2014) US EN 2763
524223769 2200YRM1128 (07 2020) US EN 2811
Series Code / Model Designation Reference Table 2817
General 2820
Deutsch Crimping Tool 2820
How to Strip a Wire for Use With Deutsch Crimping Tool 2820
How to Crimp With the Deutsch Crimping Tool 2821
Calibration Test for the Deutsch Crimping Tool 2823
Deutsch Connectors 2825
DT, DTM, and DTP Series Connectors 2825
HD Series Connectors 2867
Metri-Pack Connectors 2890
Remove and Install 2890
Micro-Pack Connectors 2892
Weather-Pack Connectors 2893
AMPSEAL Crimping Tools 2895
AMP Hand Crimping Tool With Certi-Crimp 2895
Description 2895
Stripping Wire for Use with AMP Hand Crimping Tool 2895
Insulation Crimp Adjustment 2896
Maintenance and Inspection for AMP Hand Crimping Tool 2896
AMP Hand Crimping Tool 2896
Crimp Height Inspection 2896
How to use AMP Hand Crimping Tool 2897
AMP Pro-Crimper II Tool 2897
Description 2897
Remove and Install Die Set and Locator Assembly 2898
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2899
Contact Support Adjustment 2899
Crimp Height Adjustment 2900
Maintenance and Inspection Procedures 2900
PRO-CRIMPER II Tool 2900
Crimp Height Inspection 2900
How to Use AMP PRO-CRIMPER II Tool 2901
AMPSEAL Connector Assemblies 2902
Description for Plug Connector Assembly 2902
Seal Plug 2903
Contact Crimping 2903
Description for Plug Connector and Header Assembly 2908
Voltage Reading 2910
Seal Plug 2910
Contact Crimping 2910
AMP Superseal 1 5 Crimping Tools 2917
Mini Mic Receptacle and Tab Contacts 2917
Description 2917
Crimping Conditions and Measurements 2917
Insertion of Rubber Seal on Cable 2919
AMP Hand Application Tool 2924
Description 2924
Maintenance and Inspection 2924
Crimp Height Inspection 2924
Crimp Height Adjustment 2925
How to Use AMP Hand Application Tool 2925
AMP Pro-Crimper II Tool 2926
Description 2926
Remove and Install Die Set and Locator Assembly 2927
Adjustments 2927
Contact Support 2927
Crimp Height 2928
Inspections and Maintenance 2929
Crimp Height Inspection 2929
Visual Inspection 2929
Maintenance 2930
How to Use Pro-Crimper II Tool 2930
AMP Superseal 1 5 Connector Assemblies 2931
Description 2931
Repair and Maintenance 2938
Panel Mount Option 2938
AMP Fastin-Faston Hand Tools 2939
Description – AMP Double Action Hand Tool 2939
Maintenance and Inspection Procedures 2939
Daily Maintenance 2939
Periodic Tool Inspection 2940
Lubrication 2940
Visual Inspection 2940
Crimp Height Inspection 2940
Certi-Crimp Ratchet Inspection 2941
How to Use AMP Double Action Hand Tool 2942
Description – AMP Extraction Tool 2943
Maintenance and Inspection 2943
How to Use AMP Extraction Tool 2944
AMP Fastin-Faston Receptacles and Housings 2945
Description 2945
Wire Repair 2952
Wire Splicing Requirements 2952
Deutsch Jiffy Splice 2953
Twisted/Shielded Cable and Leads Repair 2958
Special Tools 2961
524223770 2200YRM1130 (03 2020) US EN 2969
General 2973
Description 2973
Dash Display Menu Access 2973
Menu Navigation 2974
Standard Display 2974
Main Menu 2974
Passwords Menu 2975
Password Administration 2975
Add Password 2975
Delete Password 2976
Edit Password 2976
Other Password Functions 2977
Operator Passwords – Enable/Disable 2977
Password Time-Out Delay 2977
Passwords – Number Wrong to Disable 2978
Lockout Reset Password 2978
View Password Log 2979
View Versions 2980
VSM Versions 2980
Dash Display Versions 2981
Engine Controller Version 2982
Transmission (Xmsn) Controller Version 2983
Truck Serial Number 2984
Diagnostics 2985
View Fault Log 2985
Set Travel and Braking 2986
Speed Limit 2986
Acceleration Rate 2987
Auto-Deceleration Rate 2987
Set Power Reversal Rate 2988
Set Inching/Brake Overlap 2989
Setup Display Menu 2990
Set Operator Language 2990
Set Units 2991
Set Time Format (12/24 Hour) 2991
Set Daylight Saving Time 2991
Set Time 2994
Set Date Format 2995
Set Date 2995
Setup Hydraulics 2996
Return to Set Tilt Delay/On/Off 2996
Setup General Items 2997
Light Shutdown Time-Out 2997
Impact Sensor – Enable/Disable 2998
Impact Sensor – Soft Impact Settings 2999
Impact Sensor – Hard Impact Settings 3000
Adjust Impact Sensor Settings 3000
Initial Adjustment of Soft and Hard Impact Settings 3002
Readjustment of Soft and Hard Impact Settings 3002
Impact Sensor – Impact Alarm/Shutdown Reset 3003
Impact Sensor – Alarm Time Duration and Deactivation 3004
Impact Sensor – View Impact Event Log 3005
Engine Mode Indicator 3006
Generation 1 (ECO-eLo ONLY) 3006
Generation 2 3007
Operator Checklist 3008
Operator Checklist Off-On Mode 3008
Edit Operator Checklist 3008
Set Operator Checklist Expiration 3009
View Checklist Log 3009
Clear Operator Checklist Log 3010
Clear Operator Checklist Fault 3010
Calibrations 3011
Set Tilt Stop Point 3011
Calibrate Loaded Weight 3011
524223771 2200YRM1131 (03 2020) US EN 3013
Series Code / Model Designation Reference Table 3019
General 3021
Description 3021
Dash Display Menu Access 3021
Menu Navigation 3022
Main Menu 3022
Passwords 3023
Adding Passwords 3023
Hourmeters 3025
View Versions 3026
VSM Versions 3026
Dash Display Versions 3027
Engine Controller Version 3028
Transmission (Xmsn) Controller Version 3029
Truck Serial Number 3030
Truck Configuration 3031
Diagnostics 3032
Clear Fault Log 3032
View Fault Log 3033
No-Run Data Display 3034
Engine Accelerator and Throttle Data Display 3034
Engine Speeds and Governor Data Display 3035
Engine Fuel and Emissions Data Display 3036
Engine General Data Display 3038
XMSN/Brake Data Display 3039
Hydraulic Data Display 3042
General Truck Data Display 3044
Set Travel and Braking 3045
Speed Limit 3045
Acceleration Rate 3046
Auto-Deceleration Rate 3047
Set Power Reversal Rate 3047
Set Inching/Brake Overlap 3048
Setup Hydraulics 3048
Lift Maximum Speed 3049
Lower Maximum Speed 3049
Tilt Maximum Speed 3050
Auxiliary Function One, Direction A, Maximum Speed 3052
Auxiliary Function One, Direction B, Maximum Speed 3054
Auxiliary Function Two, Direction A, Maximum Speed 3054
Auxiliary Function Two, Direction B, Maximum Speed 3055
Auxiliary Function Three, Direction A, Maximum Speed 3056
Auxiliary Function Three, Direction B, Maximum Speed 3056
Lift/Lower Ramp Rate 3057
Hydraulic Auxiliary Ramp Rate 3057
Return to Set Tilt Delay/On/Off 3058
Hydraulic Input Device 3059
Auxiliary Solenoid 3059
Dual Function 3060
Setup Display 3061
Set Service Language 3061
Setup General Items 3061
Motion Alarm Activation Type 3062
Light Shutdown Time-Out 3063
Restore Default Settings 3063
Restore Engine Controller Default Calibration 3064
Impact Sensor – Enable/Disable 3064
Impact Sensor – Soft Impact Settings 3065
Impact Sensor – Hard Impact Settings 3066
Adjust Impact Sensor Settings 3067
Initial Adjustment of Soft and Hard Impact Settings 3069
Readjustment of Soft and Hard Impact Settings 3069
Impact Sensor – Impact Alarm/Shutdown Reset 3070
Impact Sensor – Alarm Time Duration and Deactivation 3071
Impact Sensor – View Impact Event Log 3072
Engine Mode Indicator 3072
Generation 1 (ECO-eLo ONLY) 3072
Generation 2 3073
Diesel Particulate Filter (DPF) Display 3074
General Description 3074
Passive Regeneration Only 3074
Regeneration Level 0 3074
Auto/Active Regeneration Inhibited 3075
Auto/Active Regeneration 3075
Regeneration Level 1 3075
Parked Regeneration Request 3076
Regeneration Level 2 3076
Warning Level 3076
Regeneration Level 3 3076
Service Level 3077
Regeneration Level 4 3077
Display, Diesel Particulate Filter (DPF), Revised 3077
Operator Interface 3077
Refer to Operator Manual 3077
CAN Communication Lost 3078
Passive Regeneration Only 3078
Regeneration Level 0 3078
Auto/Active Regeneration Inhibited 3078
Auto/Active Regeneration 3079
Regeneration Level 1 3079
Idle-up Auto/Active Regeneration 3079
Parked Regeneration Request 3079
Regeneration Level 2 3079
Warning Level 3081
Regeneration Level 3 3081
Service Level 3081
Regeneration Level 4 3081
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3081
Display, Diesel Particulate Filter (DPF), Stage V Engine 3081
Operator Interface 3082
Refer to Operator Manual 3082
CAN Communication Lost 3082
Passive Regeneration Only 3082
Regeneration Level 0 3082
Auto/Active Regeneration Inhibited 3083
Auto/Active Regeneration 3083
Regeneration Level 1 3083
Idle-up Auto/Active Regeneration 3084
Parked Regeneration Request 3084
Regeneration Level 2 3084
Warning Level 3085
Regeneration Level 3 3085
Service Level 3086
Regeneration Level 4 3086
Stage V Content 3086
Emissions System Malfunction 3086
Ash Load 3086
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3087
Operator Interface 3087
Refer to Operator Manual 3087
CAN Communication Lost 3088
Passive Regeneration Only 3088
Regeneration Level 0 3088
Auto/Active Regeneration Inhibited 3088
Auto/Active Regeneration 3089
Regeneration Level 1 3089
Idle-up Auto/Active Regeneration 3089
Parked Regeneration Request 3089
Regeneration Level 2 3089
Warning Level 3091
Regeneration Level 3 3091
Service Level 3091
Regeneration Level 4 3091
Calibrations 3092
Calibrate Transmission Valve 3094
Set Tilt Stop Point 3094
Calibrate Loaded Weight 3094
Calibrate Travel Speed Sensor 3095
Calibrate Mazda LP and Gas Accelerator Pedal 3095
524223772 2200YRM1142 (01 2020) US EN 3097
General 3107
Display Switch Cluster 3110
Remove 3110
Install 3113
Direction Control and Turn Signal Levers 3113
Remove 3113
Install 3115
Key Switch 3115
Remove 3115
Install 3116
Display Switch Cluster Panel Bezel and Overlay 3116
Remove 3116
Install 3116
Steering Column Repair 3116
Remove 3116
Disassemble 3119
Assemble 3119
Install 3119
Sensors and Switches 3120
General 3120
Dash and Kick Panel, Remove and Install 3120
Remove 3120
Install 3121
Accelerator Pedal Position Sensor 3122
Remove 3122
Install 3125
Brake Fluid Level Switch 3126
Remove 3126
Install 3128
Service Brake Pedal Position Sensor 3129
Remove 3129
Install 3132
Parking Brake Sensor 3133
Remove 3133
Install 3134
Service Brake Pressure Sensor 3135
Remove 3135
Install 3137
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3138
Remove 3138
Install 3138
Sensor Microswitch (Foot Directional Control Pedal) 3139
Remove 3139
Install 3142
Low Coolant Level Sensor 3143
Remove 3143
Install 3146
Fuel Level Sensor, Gas and Diesel Engines Only 3147
Remove 3147
Install 3148
Armrest Switch 3148
Remove 3148
Install 3150
Seat Sensor (Operator Presence System) 3150
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) 3150
Remove 3150
Install 3151
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3151
Remove 3151
Install 3152
Full Suspension Seats; All Lift Truck Models 3152
Remove 3152
Install 3152
Hood Shut Off Switch 3152
Remove 3152
Install 3155
Remote Key Switch 3156
Remove 3156
Install 3156
Hydraulic Filter Pressure Switch 3157
Remove 3157
Install 3159
Transmission Speed Sensor 3159
Remove 3159
Install 3162
Transmission Pressure Sensors 3163
Remove 3163
Install 3165
Transmission Temperature Sensor 3166
Remove 3166
Install 3168
Engine Speed Sensor 3170
Remove 3170
Install 3170
Intermediate Speed Sensor 3171
Remove 3171
Install 3171
Return to Set Tilt (Tilt Angle) Sensor 3171
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) 3171
Remove 3171
Install 3172
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) 3173
Remove 3173
Install 3174
Rear Horn Button Switch 3174
Remove 3174
Install 3175
Impact Sensor 3176
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) 3176
Remove 3176
Install 3179
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) 3179
Remove 3179
Install 3180
Load Weight Sensor 3181
Remove 3181
Install 3182
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3183
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3183
Crankshaft Position (CKP) Sensor 3183
Camshaft Position (CMP) Sensor 3183
Oil Pressure Sensor 3183
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3183
Engine Coolant Temperature (ECT) Sensor 3184
Air Flow Restriction Switch 3184
Remove for GM 2 4L Gas and LPG Trucks 3184
Install for GM 2 4L Gas and LPG Trucks 3184
Oxygen Sensor 3185
Remove 3185
Install 3188
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3189
Crankshaft Position (CKP) Sensor 3189
Camshaft Position (CMP) Sensor 3189
Oil Pressure Sensor 3189
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3189
Engine Coolant Temperature (ECT) Sensor 3189
Air Flow Restriction Switch 3189
Oxygen Sensor 3189
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3189
Low LPG Pressure Switch 3189
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3190
Air Filter Restriction Switch 3190
Remove 3190
Install 3190
Oil Pressure Sensor 3190
Remove 3190
Install 3190
Engine Speed Sensor 3190
Remove 3190
Install 3190
Engine Coolant Temperature (ECT) Sensor 3190
Remove 3190
Install 3190
Throttle Position Sensor (TPS) 3193
Remove 3193
Install 3194
Fuel/Water Separator Sensor 3194
Remove 3194
Install 3194
Glow Plug Relay 3195
Remove 3195
Install 3197
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3197
Air Filter Restriction Switch 3197
Remove 3197
Install 3197
Engine Oil Pressure Sensor 3202
Remove 3202
Install 3202
Engine Speed Sensor 3202
Remove 3202
Install 3203
Engine Coolant Temperature (ECT) Sensor 3203
Remove 3203
Install 3204
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3205
Remove 3205
Install 3205
Fuel/Water Separator Sensor 3206
Remove 3206
Install 3206
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3207
Intake Air Temperature Sensor 3207
Remove 3207
Install 3208
Intake Air Pressure Sensor 3208
Remove 3208
Install 3208
Air Inlet Heater 3208
Remove 3208
Install 3209
Engine Oil Pressure Sensor 3209
Remove 3209
Install 3209
Engine Coolant Temperature (ECT) Sensor 3209
Remove 3209
Install 3209
Crankshaft Position Sensor 3210
Remove 3210
Install 3210
Adjust Shim Procedure 3211
Camshaft Position Sensor 3212
Remove 3212
Install 3212
Air Flow Restriction Sensor 3213
Remove 3213
Install 3213
Fuel/Water Separator 3213
Remove 3213
Install 3214
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3214
Intake Air Temperature Sensor 3218
Remove 3218
Install 3219
Boost Sensor 3219
Remove 3219
Install 3220
Throttle Valve Assembly and Air Intake Heater 3220
Remove 3220
Install 3220
Engine Coolant Temperature (ECT) Sensor 3221
Remove 3221
Install 3221
Engine Oil Pressure Sensor 3221
Remove 3221
Install 3222
Crankshaft Position Sensor 3222
Remove 3222
Install 3222
Adjust Shim Procedure 3223
Camshaft Position Sensor 3224
Remove 3224
Install 3225
Differential Pressure Sensor 3225
Remove 3225
Install 3225
Mass Air Flow Sensor 3226
Remove 3226
Install 3227
Fuel/Water Separator 3227
Remove 3227
Install 3228
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3228
Engine Coolant Temperature (ECT) Sensor 3229
Remove 3229
Install 3229
Throttle Position Sensor 3230
Engine Oil Pressure Sensor 3230
Remove 3230
Install 3230
Engine Speed Sensor 3230
Remove 3230
Install 3230
Fuel Shut Off Solenoid 3230
Remove 3230
Install 3230
Vehicle System Manager (VSM) 3231
General 3231
VSM Replacement 3231
Remove 3231
Install 3233
Programming a New VSM and/or Display Switch Cluster 3233
General 3233
PC Service Tool Software 3234
Data Transferring 3234
New VSM 3234
New (Blank) Display Switch Cluster 3234
Used (Non-Blank) Display Switch Cluster 3234
Power Distribution Module (PDM) and Component Parts 3236
Remove 3236
PDM as a Unit 3236
Install 3240
PDM as a Unit 3240
Remove and Install 3241
PDM Component Parts 3241
Transmission Control Unit 3241
Remove 3241
Install 3245
Battery 3247
Remove 3247
Install 3247
Lights 3248
Work Lights (Front and Rear) 3248
Remove 3248
Install 3248
Strobe Light 3249
Remove 3249
Install 3249
LED Tail, Backup, and Brake Lights 3250
Remove 3250
Install 3251
Front Marker/Turn Signal Lights 3252
Replacing Whole Front Marker/Turn Signal Light Assembly 3252
Remove 3252
Install 3252
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3253
Remove 3253
Install 3253
Diesel Particulate Filter (DPF) Display 3253
Remove 3253
Clean and Inspect 3254
Install 3254
Electronic-Hydraulic Controls – Generation 1 3255
E-Hydraulic Controls – Test 3255
Mini-Levers 3255
Full Stroke Test 3255
Function Returns to Neutral Test 3255
Push Button Switch 3255
General 3256
Mini-Lever Replacement 3256
Remove 3256
Clean and Inspect 3257
Install 3257
Push Button Switch Replacement 3258
Remove 3258
Install 3260
Mini-Lever Module (MLM) 3260
Remove 3260
Install 3260
Joystick 3261
Remove and Disassemble 3261
Inspect 3261
Assemble and Install 3261
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3262
General 3262
Mini-levers, Remove and Install 3262
Armrest Assembly 3263
Remove 3263
Install 3266
Horn Button 3266
Remove 3266
Install 3266
Direction Control Switch 3267
Remove 3267
Install 3267
push (override) buttons and Toggle Switch 3267
Remove 3268
Install 3269
Joystick 3270
Remove and Disassemble 3270
Inspect 3270
Assemble and Install 3270
Joystick Armrest Slider Assembly 3271
Remove 3271
Install 3272
Electronic-Hydraulic Controls, After January, 2020 3272
E-Hydraulic Controls – TEST 3272
Mini-Levers 3272
Full Stroke Test 3272
Function Returns to Neutral Test 3272
Push (Override) Button 3273
General 3273
Mini-levers, Remove and Install 3273
Armrest Assembly 3274
Remove 3274
Install 3277
Horn Button 3277
Remove 3277
Install 3277
Direction Control Switch 3277
Remove 3277
Install 3278
Push (Override) buttons and Toggle Switch 3278
Remove 3279
Install 3281
Special Tools 3282
524223773 2200YRM1143 (05 2005) US EN 3285
toc 3285
Electrical System 3285
Safety Precautions Maintenance and Repair 3286
Ignition System 3289
General 3289
Ignition Timing Adjustment, Gasoline and LPG 3289
Spark Plugs Check 3289
Spark Plug Wires Check 3289
Distributor Repair 3292
Remove 3292
Disassemble 3293
Inspect 3293
Assemble 3294
Install 3294
Igniter 3295
Remove 3295
Test 3295
Install 3295
Camshaft Position (CMP) Sensor 3296
Voltage Check 3296
Ignition Coil Check 3297
Primary Coil Winding 3297
Secondary Coil Winding 3297
Starter Repair 3298
General 3298
Remove 3298
No-Load Test 3299
Magnetic Switch Test 3299
Pull-Out Test 3299
Holding Coil Test 3300
Return Test 3300
Pinion Movement Inspection 3300
Install 3300
Alternator Repair 3301
General 3301
Charging System Inspection 3301
Output Current Check 3302
No-Load Adjusted Voltage Check 3302
Remove 3303
Inspect 3303
Rectifier Check 3303
Install 3304
tables 3285
Table 1 Spark Plug Wire 3289
Table 2 Starter Specifications 3298
Table 3 Problem Diagnosis Chart 3299
Table 4 Specifications 3302
Table 5 Rectifier Check Table 3303
524223776 4000YRM1148 (09 2015) US EN 3307
General 3311
Safety Procedures When Working Near Mast 3312
Fork Replacement 3314
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3314
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3316
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3317
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3317
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3318
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3319
Carriages Repair 3320
Standard Carriage 3320
Remove 3320
Repair 3321
Install 3321
Standard Carriage, Remove 3322
Hang-On Sideshift Carriage, Remove 3323
Standard Carriage and Hang-On Sideshift Carriage, Repair 3324
Standard Carriage, Install 3325
Hang-On Sideshift Carriage, Install 3325
Integral Sideshift Carriage 3326
Remove 3326
Clean and Inspect 3329
Repair 3330
Install 3330
Fork Positioner 3331
Remove 3331
Clean and Inspect 3336
Disassemble and Assemble 3336
Install 3336
Fork Positioner Hydraulic Hose Adjustment 3337
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3339
Connecting Attachment Hydraulic Quick Disconnect Hoses 3339
Mast Repair 3340
Mast, Remove 3340
Two-Stage LFL and Two-Stage FFL Masts 3343
Disassemble 3343
Clean and Inspect 3353
Three-Stage FFL Mast 3354
Disassemble 3354
Clean and Inspect 3362
Two-Stage LFL and Two-Stage FFL Mast 3364
Assemble 3364
Three-Stage FFL Mast 3367
Assemble 3367
Four-Stage FFL Mast – Manufactured Before July, 2009 3369
Disassemble 3369
Clean and Inspect 3374
Assemble 3376
Four-Stage FFL Mast – Manufactured After July, 2009 3377
Disassemble 3377
Clean and Inspect 3384
Assemble 3387
Mast, Install 3388
Header Hose Arrangement 3391
Two-Stage LFL 3391
Two-Stage FFL 3399
Three-Stage FFL 3414
Standard 3414
Optional Equipment Lift Truck GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 3431
Four-Stage FFL Mast – Manufactured Before July, 2009 3439
Four-Stage FFL Mast – Manufactured After July, 2009 3448
Adjustment 3455
Lift Chains Adjustment 3455
Carriage Adjustments 3458
Mast Adjustments 3458
Load Roller Adjustment 3458
Mast Side Kicking Adjustment 3461
524223779 8000YRM1152 (03 2020) US EN 3465
General Information About Diagrams and Schematics 3469
Symbol Definitions 3469
Diagrams Manual Applications 3470
Diagrams and Schematics 3472
524223780 8000YRM1134 (03 2020) US EN 3535
Series Code / Model Designation Reference Table 3541
Description 3543
Proc_Cal_001: Service Password Entry 3545
When to Perform 3545
Why Perform 3545
How to Perform 3545
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3546
When to Perform 3546
Calibration Order 3546
Why Perform 3546
How to Perform 3547
Proc_Cal_003: Save and Exit 3548
When to Perform 3548
Why Perform 3548
How to Perform 3548
Proc_Cal_004: Lift Valve Output Threshold 3549
When to Perform 3549
Calibration Order 3549
Why Perform 3549
How to Perform 3550
Proc_Cal_005: Lower Valve Output Threshold 3552
When to Perform 3552
Calibration Order 3552
Why Perform 3552
How to Perform 3552
Proc_Cal_006: Tilt Back Valve Output Threshold 3555
When to Perform 3555
Calibration Order 3555
Why Perform 3555
How to Perform 3555
Proc_Cal_007: Tilt Forward Valve Output Threshold 3558
When to Perform 3558
Calibration Order 3558
Why Perform 3558
How to Perform 3558
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3561
When to Perform 3561
Calibration Order 3561
Why Perform 3561
How to Perform 3561
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3564
When to Perform 3564
Calibration Order 3564
Why Perform 3564
How to Perform 3564
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3567
When to Perform 3567
Calibration Order 3567
Why Perform 3567
How to Perform 3567
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3570
When to Perform 3570
Calibration Order 3570
Why Perform 3570
How to Perform 3570
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3573
When to Perform 3573
Calibration Order 3573
Why Perform 3573
How to Perform 3573
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3576
When to Perform 3576
Calibration Order 3576
Why Perform 3576
How to Perform 3576
Proc_Cal_014: Load Weight Zero Point 3580
When to Perform 3580
Calibration Order 3580
Why Perform 3580
How to Perform 3580
Proc_Cal_015: Loaded Weight Calibration 3582
When to Perform 3582
Calibration Order 3582
Why Perform 3582
How to Perform 3582
Proc_Cal_016: Transmission Valve Calibration 3585
Applicable System/Option 3585
When to Perform 3585
Calibration Order 3585
Why Perform 3585
How to Perform 3585
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3587
Applicable System/Option 3587
When to Perform 3587
Calibration Order 3587
Why Perform 3587
How to Perform 3587
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3589
Applicable System/Option 3589
When to Perform 3589
Calibration Order 3589
Why Perform 3589
How to Perform 3590
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3591
Required Tools 3591
When to Perform 3591
Calibration Order 3591
Why Perform 3592
How to Perform 3592
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3593
When to Perform 3593
Why Perform 3593
How to Perform 3593
Proc_Cal_026: Travel Speed Calibration 3595
When to Perform 3595
Calibration Order 3595
Why Perform 3595
How to Perform 3595
524240453 0600YRM1205 (01 2017) US EN 3599
General 3605
Engine Identification 3605
Major Engine Component Identification 3605
Location of Labels 3606
Engine Removal and Installation 3607
Cylinder Head Assembly Repair 3607
Glow Plugs 3610
Remove 3610
Install 3610
Valve Cover 3610
Remove 3610
Clean and Inspect 3611
Install 3611
Rocker Arm Assembly 3611
Remove 3611
Disassemble 3612
Clean and Inspect 3613
Push Rods 3613
Rocker Arm Assembly 3613
Assemble 3613
Install 3614
Valve Clearance Adjustments 3614
Cylinder Head Assembly 3615
Remove 3615
Disassemble 3620
Valves and Valve Springs, Remove 3620
Valve Guides, Remove 3620
Clean and Inspect 3621
Cylinder Head 3621
Valve Guides 3622
Valves 3622
Valve Sink 3622
Valve Seat 3623
Valve Springs 3623
Assemble 3624
Valve Guides, Install 3624
Valves and Valve Springs, Install 3624
Install 3625
Timing Gear Case and Timing Gears Repair 3626
Timing Gear Case Cover 3627
Remove 3627
Clean and Inspect 3627
Install 3628
Timing Gears 3628
Crankshaft Gear 3629
Remove 3629
Install 3629
Idler Gear 3629
Remove 3629
Inspect 3630
Install 3630
Camshaft Gear 3630
Remove 3630
Install 3631
Timing Gear Case 3631
Remove 3631
Clean and Inspect 3632
Install 3632
Drive Train, Camshaft, and Cylinder Block Repair 3633
Remove 3633
Disassemble 3634
Pistons and Connecting Rods 3634
Crankshaft 3634
Camshaft 3637
Clean and Inspect 3638
Cylinder Block 3638
Honing and Boring 3641
Pistons 3642
Piston Pin 3642
Connecting Rod 3643
Tappets 3643
Crankshaft 3644
Camshaft 3645
Camshaft Bushing 3646
Assemble 3646
Camshaft 3646
Crankshaft 3646
Pistons and Connecting Rods 3647
Install 3648
Lubrication System Repair 3649
Engine Oil and Oil Filter Change 3649
Oil Pan 3649
Remove 3649
Install 3650
Oil Suction Tube 3650
Remove 3650
Clean 3651
Install 3651
Oil Pump 3651
Remove 3651
Clean and Inspect 3652
Outer Rotor Outside Clearance 3652
Outer Rotor to Inner Rotor Tip Clearance 3653
Outer Rotor Side Clearance 3653
Rotor Shaft Clearance 3653
Install 3654
Fuel System Repair 3654
Fuel Injectors 3655
Remove 3655
Inspect 3656
Clean 3656
Test 3656
Install 3659
Electronic Throttle System 3659
Remove 3659
Install 3662
Inspect 3663
Adjust 3664
Manual Throttle System 3665
Fuel Injection Pump 3665
Remove 3665
Clean and Inspect 3669
Install 3669
Check/Adjust Fuel Injection Timing 3670
Cooling System Repair 3672
V-Belt 3672
Remove 3672
Inspect 3672
Install 3672
Adjust 3672
Water Pump 3674
4TNE92-NMHA, 4TNE92-NMHA/580090035, 4TNE92-SNMU, and 4TNE98-SNMU Engines 3674
Remove 3674
Install 3675
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/580090036, and 4TNE98-BNMH Engines 3676
Remove 3676
Install 3677
Thermostat 3679
Remove 3679
Inspect 3680
Install 3680
Flywheel and Flywheel Housing 3680
Flywheel 3681
Remove 3681
Install 3682
Flywheel Housing 3682
Remove 3682
Install 3682
Electrical Equipment Repair 3684
Alternator 3684
Remove 3684
Bench Test 3686
Regulate Voltage Check 3686
No Load Test 3688
Output Test 3688
Install 3688
Starter 3689
Remove 3690
No Load Test 3690
Install 3691
Engine Specifications 3692
Engine Data 3692
Engine Tuning 3700
Cylinder Head 3700
Intake/Exhaust Valve and Guide 3701
Valve Spring 3701
Rocker Arm and Shaft 3701
Push Rod 3702
Gear Train and Camshaft 3702
Camshaft 3702
Idle Gear Shaft and Bushing 3702
Backlash of Each Gear 3703
Cylinder Block 3703
Crankshaft 3703
Thrust Bearing 3704
Piston 3704
Piston Ring 3704
Connecting Rod 3705
Rod Small End 3705
Tappet 3705
Oil Pump 3706
Engine Oil Pressure 3706
Outer Rotor Outside Clearance 3706
Outer Rotor Side Clearance 3706
Outer Rotor to Inner Rotor Tip Clearance 3706
Rotor Shaft Clearance 3706
Standard Torque Specifications 3707
Standard Torque Chart 3707
Special Torque Specifications 3708
Special Tools 3709
524240454 1400YRM1206 (11 2008) US EN 3717
toc 3717
Drive Axle and Differential Assembly Repair 3717
Safety Precautions Maintenance and Repair 3718
General 3721
Drive Axle Repair 3721
Remove and Disassemble 3721
Clean and Inspect 3723
Assemble and Install 3723
Differential Repair 3726
Remove 3726
Differential Assembly From Center Section Assembly 3726
Drive Pinion, Pinion Gear, and Bearings From Center Section 3730
Disassemble 3735
Differential Assembly 3735
Drop Box Housing 3739
Center Section 3740
Clean and Inspect 3742
Assemble 3742
Center Section 3742
Drop Box Housing 3745
Differential Assembly 3746
Install 3750
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 3750
Drive Pinion, Pinion Gear, and Bearings Into Center Section 3752
Differential Assembly Into Center Section 3755
Ring Gear Backlash, Adjust 3760
Ring Gear, Runout Check 3762
Gear Set, Tooth Contact Pattern Check 3762
Torque Specifications 3765
tables 3717
Table 1 Pinion Variation Numbers Examples 3751
Table 2 Ring and Pinion Tooth Contact Adjustment 3762
Table 3 Correct Tooth Contact 3763
Table 4 Incorrect Tooth Contact 3764
524240455 8000YRM1207 (08 2019) US EN 3769
General 3775
Serial Number Data 3775
How to Move Disabled Lift Truck 3775
How to Tow Lift Truck 3775
How to Put Lift Truck on Blocks 3776
How to Raise Drive Tires 3776
How to Raise Steering Tires 3777
How to Clean a Lift Truck 3777
Maintenance Schedule 3778
Maintenance Procedures Every 8 Hours or Daily 3797
How to Make Checks With Engine Stopped 3797
Tires and Wheels 3797
Safety Labels 3798
Mast, Carriage, Lift Chains, Header Hoses, Attachment 3798
Operator Restraint System 3799
Emergency Locking Retractor (ELR) 3799
Adjust Seat – Full Suspension 3800
Adjust Seat – Internal Suspension 3801
Hood and Seat Latches 3802
Engine Compartment 3802
Fuel, Oil, and Coolant Leaks, Check 3802
Hydraulic Hoses 3802
Coolant Hoses 3802
Steering Column Gas Cylinder 3802
Transmission 3802
Hydraulic System Oil 3803
Engine Oil 3803
Air Filter 3807
Forks 3807
Remove 3807
Inspect 3809
Install 3809
Adjust 3810
How to Make Checks With Engine Running 3811
Indicator Lights, Horn, Fuses, and Relays 3811
Service Brakes 3813
Brake Fluid Level 3813
Operation, Check 3813
Parking Brake 3814
Engine Oil Pressure 3814
Cooling System 3815
Steering System 3815
Control Levers and Pedals 3816
Lift System, Operate 3816
First Service After First 100 Hours of Operation 3817
Mazda Engine Oil and Oil Filter 3817
Yanmar Engine Oil and Oil Filter 3817
Maintenance Procedures Every 250 Hours or 6 Months 3817
Mazda Engine Oil and Filter 3817
Drive Belt 3818
Mazda 2 0L Engines 3818
Fan and Alternator Drive Belt 3818
Drain Tar From LPG Regulator (Except 2007 Mazda Emission Compliant Engines) 3818
Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engines Only) 3819
Maintenance Procedures Every 500 Hours or 6 Months 3820
Hydraulic System Oil 3820
Hydraulic Tank Breather 3820
Inspect 3820
Battery 3821
Yanmar Engine Oil and Oil Filter 3821
Drive Belt 3821
Yanmar Diesel Engine 3821
Fan and Alternator Drive Belt 3821
PCV Valve 3822
Clean Debris From Radiator Core 3822
Transmission Oil Level 3822
Forks 3824
Mast Lubrication 3824
Header Hose Checks 3829
Lift Chain Lubrication 3829
Tilt Cylinder Lubrication 3829
Master Brake Cylinder Rod End Pin Lubrication 3830
Manual Hydraulic Levers Lubrication 3830
Brake Fluid 3830
Tie Rod Lubrication 3831
Differential and Drive Axle Oil (Dry Brake) 3831
Maintenance Procedures Every 1000 Hours or 6 Months 3832
Valve Clearance, Check and Adjust 3832
Ignition System 3832
Mazda EnginesFE 3832
LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 3833
LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines Only 3833
Remove 3833
Clean/Inspect 3834
Install 3834
Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant Engines Only 3834
Remove and Replace 3834
Fuel Filter Replacement, Yanmar Engine 3835
Priming the Fuel System (Yanmar) 3836
Lift Chains Wear Check 3837
Lift Chain Lubrication 3837
Integral Sideshift Carriage, Check Bearings 3838
Integral Sideshift Carriage, Check Lower Mounting Hooks 3838
Steering Axle 3839
Control Levers and Pedals 3839
Maintenance Procedures Every 2000 Hours or Annually 3840
Hydraulic System 3840
Hydraulic Filter, Replace 3840
Hydraulic Tank Breather, Replace 3841
Air Filter 3841
PCV Valve 3843
Oxygen Sensor 3843
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 3845
Remove and Replace 3845
Gasoline Fuel Filter 3845
Remove and Replace for Lift Trucks Equipped with GFI 3845
Timing Belt 3845
Mazda Engines 3845
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 3845
Gasoline Fuel Injector, Mazda Engines 3845
Fuel Injector, Yanmar Engines 3846
Forks 3846
Integral Sideshift Carriage 3846
Bearings, Replace 3846
Transmission Oil and Filter (Dry Brake), Replace 3846
Iron Transmission Housing 3846
Aluminum Transmission Housing 3847
Remove 3847
Clean and Inspect 3850
Install 3850
Brake Fluid (Master Cylinder), Change 3851
Brake Fluid (Dry Brake), Remove 3852
Steer Axle, Wheel Bearings Lubrication 3852
Service Brakes (Dry Brake) 3852
Differential (Dry Brake) 3853
Maintenance Procedures Every 4000 Hours or 2 Years 3854
Hydraulic Oil, Replace 3854
Cooling System 3855
Safety Procedures When Working Near Mast 3856
Hood Latch Check 3858
Lift Chain Adjustments 3859
Jump-Starting the Lift Truck 3861
Jump-Starting Using a Battery Charger 3861
Jump-Starting a Lift Truck Using Another Lift Truck 3861
Welding Repairs 3861
Overhead Guard Changes 3862
Wheel Repair 3862
General 3862
How to Change Solid Rubber Tire (GC Series) 3862
Remove and Install Tire on Wheel 3862
Pneumatic Tire With Tube, Repair 3863
Remove Wheels From Lift Truck 3863
Remove Tire From Wheel 3864
Install Wheel in Tire 3867
Add Air to Pneumatic Tires With Tube 3869
Wheels, Install 3870
Pneumatic Tubeless Tire, Repair 3870
Remove Wheels From Lift Truck 3870
Add Air to Pneumatic Tubeless Tire 3875
Wheels, Install 3875
Solid Rubber Tires on Pneumatic Wheels, Change 3876
Adhesives and Sealants 3879
524240456 8000YRM1208 (08 2019) US EN 3881
Lift Truck Lifting Capacity 3885
Counterweight Weights 3885
Tire Sizes 3885
Capacities 3886
Electrical System 3890
Transmission Oil Pressures 3891
Hydraulic System Relief Pressures 3892
Steering System 3893
Stall Speeds (in RPM ±100 rpm) 3894
Mazda (Except 2007 Emission Compliant Engines) 3894
Mazda (2007 Emission Compliant Engines Only) 3894
Yanmar 2 6L 3894
Mast Speeds 3894
Tilt Angles 3895
Front End Equipment – Mast Creep 3896
Mast Creep 3896
Engine Specifications 3897
Torque Specifications 3898
Frame 3898
Mast 3898
Steering System, Cushion Tire Trucks 3898
Steering System, Pneumatic Tire Trucks 3898
Drive Axle 3898
Transmission – Iron Housing 3899
Transmission – Aluminum Housing 3899
Engine – Mazda FE 3900
Engine – Yanmar 2 6L Diesel 3901
524289373 0900YRM1325 (12 2009) US EN 3903
toc 3903
Gasoline Fuel System 3903
Safety Precautions Maintenance and Repair 3904
General 3907
Abbreviations 3907
Intake-Air System 3907
Intake-Air System Manifold Vacuum Check 3907
Throttle Body 3908
Remove 3908
Install 3909
Intake Manifold 3909
Remove 3909
Install 3909
Fuel System 3910
Before Repair Procedure 3910
Fuel Line Safety Procedure 3910
After Repair Procedure 3913
Fuel Hose, Install 3913
Fuel Leakage Check 3913
Fuel Line Pressure Check 3914
Fuel Injectors 3915
Remove 3915
Install 3915
Pressure Regulator 3917
Remove 3917
Install 3917
Exhaust System 3918
Counterweight Exhaust System 3918
Remove and Disassemble 3918
Inspect 3918
Assemble and Install 3918
Overhead Exhaust System 3920
Remove and Disassemble 3920
Inspect 3920
Assemble and Install 3920
Exhaust Manifold 3922
Remove 3922
Install 3922
Positive Crankcase Ventilation (PCV) Valve 3924
Remove 3924
Inspect 3924
Install 3924
Oxygen Sensor 3925
Remove 3925
Install 3925
Control System 3927
Engine Control Unit (ECU) 3927
Remove 3927
Install 3928
Fuel Level Sensor 3929
Remove 3929
Install 3929
Technical Data 3930
tables 3903
Table 1 PCV Valve Specifications 3924
Table 2 Gasoline Fuel Systems Technical Data 3930
524289374 0900YRM1326 (04 2018) US EN 3933
General 3939
LPG Tank and Bracket Replacement 3939
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) 3939
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) 3941
Remove LPG Tank for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 3942
LPG Tank Install for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 3944
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) 3945
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) 3947
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) 3948
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) 3950
Remove LPG Bracket for Lift Truck Models and GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 3951
Install LPG Bracket for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 3951
Fuel Filter Unit Repair 3951
Fuel Filter Element 3951
Remove 3951
Clean/Inspect 3952
Install 3952
Fuel Filter Housing 3952
Remove 3952
Disassemble 3955
Assemble 3957
Install 3958
Electronic Throttle Body Repair 3958
Remove 3958
Install 3960
Electronic Pressure Regulator (EPR) Repair 3960
Remove 3961
Disassemble 3965
Assemble 3967
Install 3968
LPG Shutoff Valve Assembly 3968
Remove 3968
Install 3972
Fuel Mixer Repair 3974
Remove 3974
Install 3977
Control System 3977
Engine Control Unit (ECU) 3977
Remove 3977
Install 3979
Low LPG Pressure Switch 3979
Remove 3979
Install 3980
LPG Low Level Sensor 3980
Remove 3981
Install 3984
Exhaust System 3985
Counterweight Exhaust System 3985
Remove and Disassemble 3985
Inspect 3987
Assemble and Install 3987
Overhead Exhaust System 3987
Remove and Disassemble 3988
Inspect 3990
Assemble and Install 3990
Exhaust Manifold 3991
Remove 3991
Install 3992
Positive Crankcase Ventilation (PCV) Valve 3993
Remove 3993
Inspect 3993
Install 3993
Oxygen Sensor 3993
Remove 3993
Install 3995
LPG Fuel Testing 3996
General 3996
Available Fuel Tests 3996
Composition Test (ASTM D-2163) 3996
Ammonia Test (ASTM D-4490) 3996
Basic Nitrogen Test (ASTM UOP269-90) 3996
Residues Test (ASTM D-2158) 3996
Vapor Pressure Test (ASTM D-2598) 3996
Sulfur Compounds Test (ASTM D-5623) 3997
Methanol Test (ASTM D-4864) 3997
Copper Corrosion (ASTM D-1838) 3997
Where To Send LPG Fuel Samples For Testing 3997
524289375 2200YRM1327 (09 2012) US EN 4001
General 4005
Ignition System 4005
General 4005
Ignition Timing Adjustment, Gasoline and LPG 4005
Spark Plugs Check 4010
Spark Plug Wires Check 4010
Coil Replacement 4011
Remove 4011
Inspect 4012
Install 4012
Starter Repair 4013
General 4013
Remove 4013
No-Load Test 4014
Magnetic Switch Test 4015
Pull-Out Test 4015
Holding Coil Test 4015
Return Test 4015
Pinion Movement Inspection 4016
Install 4016
Alternator Repair 4016
General 4016
Charging System Inspection 4018
Output Current Check 4018
No-Load Adjusted Voltage Check 4019
Remove 4020
Inspect 4020
Rectifier Check 4020
Install 4021
Engine Sensors and Switches 4022
Oil Pressure Sensor, Gas and LPG Engines 4022
Remove 4022
Install 4022
Air Filter Restriction Switch, Gas and LPG Engines 4022
Remove 4022
Install 4022
Cam Angle Sensor, Gas and LPG Engines 4023
Remove 4023
Install 4024
Voltage Check 4024
Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Engines 4025
Remove 4025
Install 4026
Intake Air Temperature (IAT) Sensor, LPG Engines 4027
Remove 4027
Install 4027
Intake Air Temperature (IAT) Sensor, Gas Engines 4027
Remove 4027
Install 4027
Fuel Temperature Sensor, LPG Engines 4030
Remove 4030
Install 4030
Engine Coolant Temperature (ECT) Sensor 4031
2007 Emissions Compliant Gas Engines 4031
Remove 4031
Install 4031
2007 and 2010 Emissions Compliant LPG Engines 4032
Remove 4032
Install 4032
2010 Emissions Compliant Gas and LPG Engines 4034
Remove 4034
Install 4034
524306203 0100YRM1290 (04 2014) US EN 4039
524329117 8000YRM1387 (03 2020) US EN 4143
General Information About Diagrams and Schematics 4147
Symbol Definitions 4147
Diagrams Manual Applications 4148
Diagrams and Schematics 4150
550001092 8000YRM1409 (03 2020) US EN 4215
General Information About Diagrams and Schematics 4219
Symbol Definitions 4219
Diagrams Manual Applications 4220
Diagrams and Schematics 4222
550010194 1300YRM1421 (08 2013) US EN 4303
toc 4303
Single Speed PowerShift 4303
Safety Precautions Maintenance and Repair 4304
General 4307
Serial Number 4307
Hydraulic Gear Pump 4308
Remove 4308
Install 4308
Charge Pump Repair 4309
Original Charge Pump 4309
Remove 4309
Disassemble 4310
Clean 4310
Inspect 4310
Assemble 4310
Install 4310
New Charge Pump, Manufactured After July, 2013 4311
Remove 4311
Clean 4312
Inspect 4312
Install 4313
Torque Converter Replacement 4315
Remove 4315
Clean and Inspect 4315
Install 4315
Stator Support Assembly Repair 4316
Remove 4316
Disassemble 4321
Clean 4322
Inspect 4322
Assemble 4323
Install 4323
Clutch Packs Repair 4325
Remove 4325
Engine, Torque Converter, and Transmission Assembly 4325
Transmission Components 4326
Disassemble 4328
Transmission 4328
Housings 4328
Forward Clutch Pack 4331
Reverse Clutch Pack 4336
Clean 4342
Inspect 4342
Assemble 4343
Transmission 4343
Reverse Clutch Pack 4343
Forward Clutch Pack 4350
Housings 4356
Install 4358
Transmission Components 4358
Engine, Torque Converter, and Transmission Assembly 4361
Inching Overlap Adjustment 4361
Proportional and Enable Solenoid Valves 4362
Proportional Valves 4362
Remove 4362
Disassemble 4364
Clean and Inspect 4364
Assemble 4364
Install 4364
Enable Solenoid Valve 4364
Remove 4364
Disassemble 4364
Clean and Inspect 4364
Assemble 4365
Install 4365
Foot Directional Control Pedal Repair 4365
Remove and Disassembly 4365
Clean and Inspect 4369
Assemble and Install 4369
550030170 1300YRM1447 (08 2013) US EN 4373
toc 4373
Single Speed Powershift 4373
Safety Precautions Maintenance and Repair 4374
General 4377
Serial Number 4377
Hydraulic Gear Pump 4378
Remove 4378
Install 4378
Housing Fittings Replacement 4378
Remove 4378
Disassemble 4379
Assemble 4379
Install 4379
Charge Pump Repair 4379
Lift Trucks Manufactured Before July, 2013 4379
Remove 4379
Disassemble 4381
Clean 4381
Inspect 4381
Assemble 4381
Install 4381
Lift Trucks Manufactured After July, 2013 4383
Remove 4383
Clean 4383
Inspect 4383
Install 4384
Torque Converter Replacement 4387
Remove 4387
Clean and Inspect 4387
Install 4387
Stator Support Assembly Repair 4389
Remove 4389
Disassemble 4394
Clean 4398
Inspect 4398
Assemble 4399
Install 4399
Clutch Packs Repair 4402
Remove 4402
Disassemble 4403
Housings 4403
Clutch Packs 4408
Forward Clutch Pack 4408
Reverse Clutch Pack 4413
Clean 4419
Inspect 4419
Assemble 4420
Clutch Packs 4420
Reverse Clutch Pack 4420
Forward Clutch Pack 4427
Housings 4434
Install 4434
Drive Chains and Sprockets 4440
Remove 4440
Clean 4442
Inspect 4442
Install 4442
Proportional and Enable Solenoid Valves 4443
Proportional Valves 4443
Remove 4443
Disassemble 4443
Clean and Inspect 4443
Assemble 4446
Install 4446
Enable Solenoid Valve 4446
Remove 4446
Disassemble 4447
Clean and Inspect 4447
Assemble 4447
Install 4447
Foot Directional Control Pedal Repair 4449
Remove and Disassemble 4449
Clean and Inspect 4453
Assemble and Install 4453
550043436 1300YRM1529 (11 2018) US EN 4459
General 4463
Serial Number 4463
Charge Pump Repair 4463
Lift Trucks Manufactured Before July, 2013 4463
Remove 4463
Inspect 4463
Install 4463
Lift Trucks Manufactured After July, 2013 4464
Remove 4464
Inspect 4464
Install 4464
Torque Converter Replace 4465
Remove 4465
Install 4474
Housings and Chain Drive Repair 4480
Remove 4480
Clean 4491
Inspect 4491
Install 4491
Clutch Packs Repair 4498
Remove and Disassemble 4498
Transmission, Remove and Disassemble 4498
Clean 4517
Inspect 4517
Assemble and Install 4518
Transmission, Assemble and Install 4526
Control Valve Repair 4530
Remove and Disassemble 4530
Clean 4534
Inspect 4534
Assemble and Install 4534
Foot Directional Control Pedal Repair 4535
Remove and Disassemble 4535
Assemble and Install 4539
Direction Control Lever 4540
Remove 4540
Install 4540
550055283 8000YRM1585 (07 2020) US EN 4545
General Information About Diagrams and Schematics 4549
Symbol Definitions 4549
Diagrams Manual Applications 4550
Diagrams and Schematics 4552
550073240 1900YRM1620 (01 2023) US EN 4641
Proper Flushing after Major Hydraulic Repairs 4647
Introduction 4647
The Phases of Wear 4647
Causes of Hydraulic System Failure 4647
Progression of Contaminant Caused Hydraulic System Failure 4648
Hydraulic System Flushing Techniques 4648
Double Oil and Filter Change 4648
Mechanical Cleaning 4649
Cleaning of Components 4649
How to Clean Tubes and Hoses 4649
Filter Caddy 4649
Start-Up Procedure for Cleaned System 4650
Contaminated Oil Coolers 4650
Additional Filter Caddy Functions 4651
How to Handle Different Fluids 4651
Water Removal Filters 4651
Fluid Conditioning and System Flushing Procedures 4652
Operation of the Filter Caddy 4652
Filter Caddy operation 4652
Fluid Conditioning Procedure 4652
Filter Caddy Start-Up 4653
System Flushing Procedure 4653
Component Cleaning Procedure 4654
Reservoir Cleaning Procedure 4654
Cylinder Cleaning Procedure 4654
Hose and Tube Cleaning Procedure 4654
Valve Cleaning Procedure 4655
Front-End Attachment Cleaning Procedure 4656
System Flushing Procedure 4656
Filter Caddy Start-Up 4657
System Start-Up and Flushing 4657
Reservoir Fluid Cleaning Times 4658
Dealing With Different Fluid Types 4659
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4659
Filter Caddy Maintenance 4659
Servicing the Strainer 4659
DC Motor 4659
Hydraulic Oil Sampling Method and Procedure 4660
Hydraulic Oil Sampling Method 4660
Objective 4660
General Guidelines 4660
Synopsis 4661
Hydraulic Oil Analysis Report Guidelines 4662
Sampling Conditions 4662
Equipment 4662
Sampling Procedure 4663
Hydraulic Oil Sampling 4663
Sample Labeling 4663
Results Documentation 4663
550073240 1900YRM1620 (03 2020) US EN 4665
Proper Flushing after Major Hydraulic Repairs 4669
Introduction 4669
The Phases of Wear 4669
Causes of Hydraulic System Failure 4669
Progression of Contaminant Caused Hydraulic System Failure 4670
Hydraulic System Flushing Techniques 4670
Double Oil and Filter Change 4670
Mechanical Cleaning 4671
Cleaning of Components 4671
How to Clean Tubes and Hoses 4671
Filter Caddy 4671
Start-Up Procedure for Cleaned System 4672
Contaminated Oil Coolers 4672
Additional Filter Caddy Functions 4672
How to Handle Different Fluids 4672
Water Removal Filters 4673
Fluid Conditioning and System Flushing Procedures 4673
Operation of the Filter Caddy 4673
Filter Caddy operation 4673
Fluid Conditioning Procedure 4674
Filter Caddy Start-Up 4674
System Flushing Procedure 4675
Component Cleaning Procedure 4675
Reservoir Cleaning Procedure 4675
Cylinder Cleaning Procedure 4675
Hose and Tube Cleaning Procedure 4676
Valve Cleaning Procedure 4676
Front-End Attachment Cleaning Procedure 4677
System Flushing Procedure 4677
Filter Caddy Start-Up 4678
System Start-Up and Flushing 4678
Reservoir Fluid Cleaning Times 4679
Dealing With Different Fluid Types 4679
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4679
Filter Caddy Maintenance 4680
Servicing the Strainer 4680
DC Motor 4680
Hydraulic Oil Sampling Method and Procedure 4680
Hydraulic Oil Sampling Method 4680
Objective 4680
General Guidelines 4680
Synopsis 4681
Hydraulic Oil Analysis Report Guidelines 4682
Sampling Conditions 4683
Equipment 4683
Sampling Procedure 4683
Hydraulic Oil Sampling 4683
Sample Labeling 4684
Results Documentation 4684
550096331 8000YRM1689 (03 2020) US EN 4687
General Information About Diagrams and Schematics 4691
Symbol Definitions 4691
Diagrams Manual Applications 4692
Diagrams and Schematics 4694