Yale Forklift C878 (GLP60-70VX, GDP60-70VX Europe) Service Manual PDF

Yale Forklift C878 (GLP60-70VX, GDP60-70VX Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift C878 (GLP60-70VX, GDP60-70VX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4592
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift C878 (GLP60-70VX, GDP60-70VX Europe) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797 8000YRM0231 (03 2020) 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
524208014 2200YRM1097 (03 2020) US EN 43
Series Code / Model Designation Reference Table 47
Description 48
Distributor Ignition (DI) System 48
Crankshaft Position (CKP) Sensor 48
Camshaft Position (CMP) Sensor 48
Ignition Coil and Ignition Control Module (ICM) 48
Secondary Ignition Components 48
Spark Plugs and Wires 49
Spark Plug Wire Inspection 49
Spark Plug Wire Replacement 49
Remove 49
Install 50
Spark Plug Inspection 50
Usage 50
Inspection 50
Visual Inspection 52
Spark Plug Replacement 52
Remove 52
Install 52
Distributor Repair 53
Inspect 53
Overhaul 53
Disassemble 53
Assemble 56
Replace 57
Remove 57
Install Procedure 1 59
Install Procedure 2 60
Ignition Coil Replacement 61
Remove 61
Install 61
Ignition Control Module Replacement 62
Remove 62
Install 62
Starter Replacement 63
Remove 63
Install 66
Sensors and Switches 67
Gas and LPG Trucks 67
Crankshaft Position (CKP) Sensor 67
Remove 67
Install 67
Camshaft Position (CMP) Sensor 68
Remove 68
Install 70
Oil Pressure Sensor 70
Remove 70
Install 71
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 72
Remove 72
Install 72
Engine Coolant Temperature (ECT) Sensor 73
Remove 73
Install 74
Air Flow Restriction Switch 74
Remove 74
Install 75
Specifications and Special Tools 76
524221866 9000YRM1112 (10 2020) US EN 81
SECTION 9010 Operational Diagnostic Procedures 97
Group 05 – Operational Checkout 99
SECTION 9020 Engine 117
Group 10 – Principles of Operation 127
Group 30 – Observed Symptoms 325
Group 40 – Tests and Adjustments 427
SECTION 9030 Electrical System 459
Group 03 – General Maintenance and Diagnostic Data 483
Group 10 – Principles of Operation 577
Group 20 – Diagnostic Trouble Codes 601
Group 30 – Observed Symptoms 1573
SECTION 9040 Drive Train 1629
Group 10 – Principles of Operation 1633
Group 30 – Observed Symptoms 1689
Group 40 – Tests and Adjustments 1739
SECTION 9050 Hydraulic Systems 1749
Group 10 – Principles of Operation 1753
Group 30 – Observed Symptoms 1811
Group 33 – Observed Symptoms-Gear Pump 1813
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1901
Group 40 – Tests and Adjustments 1945
Group 43 – Tests and Adjustments-Gear Pump 1947
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1971
SECTION 9060 Operators Station 1989
Group 10 – Principles of Operation 1991
SECTION 9070 Front End (Mast) and Chassis 2027
Group 10 – Principles of Operation 2029
Group 30 – Observed Symptoms 2051
SECTION 9080 Supplementary Data 2109
Group 50 – Abbreviations and Acronyms 2111
Group 60 – Special Tools List 2119
Group 70 – Fault Mode Indicator Reference 2129
Group 80 – Supplier Specification Data 2131
524223757 0700YRM1123 (06 2016) US EN 2135
General 2139
Cooling System Checks 2139
Exhaust Leaks Into Cooling System 2139
Water Flow Restrictions in Radiator 2139
Radiator Hoses 2139
Water Pump 2140
Flushing the Cooling System 2140
Cooling System, Clean 2140
Radiator Replacement 2141
Radiator, Remove GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2142
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2157
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2160
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 2163
Radiator, Install for Lift Truck Models GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2170
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2175
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2177
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2180
Fan Assembly Replacement 2192
Fan Removal 2192
Inspect 2207
Fan Installation 2207
524223764 1600YRM1133 (07 2013) US EN 2213
toc 2213
Steering Axle 2213
Safety Precautions Maintenance and Repair 2214
General 2217
Steering Axle Assembly Repair 2219
Remove 2219
Disassemble 2220
Clean 2228
Inspect 2228
Assemble 2228
Install 2234
Spindles, Bearings, and Tie Rods Repair 2236
Spindles and Bearings 2236
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2236
Remove 2236
Disassemble 2238
Clean 2239
Inspect 2239
Assemble 2239
Install 2240
Spindles and Bearings 2243
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2243
Remove and Disassemble 2243
Assemble and Install 2244
Tie Rods 2244
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2244
Remove 2244
Install 2245
Tie Rods 2246
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2246
Remove 2246
Install 2252
Steering Cylinder Repair 2252
Remove and Disassemble 2252
Clean and Inspect 2253
Assemble and Install 2253
Torque Specifications 2254
524223766 1900YRM1136 (01 2022) US EN 2259
General 2263
Hydraulic Gear Pump Assembly 2264
Variable Displacement Pump Assembly 2265
Single Gear Pump Assembly Repair 2266
Remove 2266
Disassemble 2272
Clean 2274
Inspect 2274
Assemble 2274
Install 2274
Tandem Gear Pump Assembly 2279
Remove 2279
Disassemble 2280
Clean 2283
Inspect 2283
Assemble 2283
Install 2284
Gear Pump Specifications 2285
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2291
Remove 2291
Disassemble 2301
Clean 2304
Inspect 2305
Assemble 2305
Install 2305
63 0 cc/rev – Variable Displacement Pump Repair 2310
Remove 2310
Disassemble 2313
Clean 2315
Inspect 2315
Assemble 2315
Install 2315
Variable Displacement Pump Checks and Adjustments (Single Pump) 2319
Margin Pressure Check 2319
Flow Compensator Adjustment 2320
Pressure Compensator Adjustment 2320
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2322
Variable Displacement Pump Specifications 2325
Torque Specifications 2327
Hydraulic Gear Pump 2327
Variable Displacement Pump 2328
Special Tools 2329
524223766 1900YRM1136 (11 2017) US EN 2331
General 2335
Hydraulic Gear Pump Assembly 2336
Variable Displacement Pump Assembly 2337
Single Gear Pump Assembly Repair 2337
Remove 2337
Disassemble 2344
Clean 2344
Inspect 2346
Assemble 2346
Install 2346
Tandem Gear Pump Assembly 2350
Remove 2351
Disassemble 2353
Clean 2355
Inspect 2355
Assemble 2355
Install 2356
Gear Pump Specifications 2356
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2362
Remove 2362
Disassemble 2372
Clean 2375
Inspect 2375
Assemble 2375
Install 2376
63 0 cc/rev – Variable Displacement Pump Repair 2379
Remove 2379
Disassemble 2382
Clean 2382
Inspect 2382
Assemble 2384
Install 2384
Variable Displacement Pump Checks and Adjustments (Single Pump) 2386
Margin Pressure Check 2386
Flow Compensator Adjustment 2387
Pressure Compensator Adjustment 2387
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2388
Variable Displacement Pump Specifications 2391
Torque Specifications 2392
Hydraulic Gear Pump 2393
Variable Displacement Pump 2394
Special Tools 2394
524223767 2000YRM1137 (01 2017) US EN 2399
General 2405
Electro-Hydraulic Main Control Valve 2406
Description 2406
Remove 2414
Electro-Hydraulic Control Valve Sections 2419
General 2419
Outlet Control Valve Section 2419
Remove 2419
Disassemble 2420
Clean 2422
Inspect 2422
Assemble 2422
Install 2423
Auxiliary Control Valve Sections 2423
Remove 2423
Disassemble 2430
Clean 2431
Inspect 2432
Assemble 2432
Install 2434
Tilt Control Valve Section 2435
Remove 2435
Disassemble 2435
Clean 2441
Inspect 2441
Assemble 2441
Install 2442
Lift/Lower Control Valve Section 2443
Remove 2443
Disassemble 2443
Clean 2452
Inspect 2452
Assemble 2452
Install 2453
Mid-Inlet Section 2453
Remove 2453
Clean 2454
Inspect 2454
Install 2454
Install 2454
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2459
Lift Pilot Pin 2459
Lower Pilot Pin 2463
Abnormal/Erroneous EHPV Adjustment 2465
Manual Main Control Valve 2466
Description 2466
Remove 2470
OPS Solenoid Assembly 2478
General 2478
Remove 2479
Clean and Inspect 2482
Install 2482
Manual Control Valve Sections 2483
General 2483
Outlet Control Valve Section 2483
Remove 2483
Disassemble 2483
Clean 2486
Inspect 2486
Assemble 2486
Install 2487
Auxiliary Control Valve Sections 2487
Remove 2487
Disassemble 2487
Clean 2490
Inspect 2490
Assemble 2490
Install 2491
Lift/Tilt Control Valve Section 2491
Remove 2491
Disassemble 2491
Clean 2498
Inspect 2498
Assemble 2499
Install 2500
Mid-Inlet Section 2501
Remove 2501
Clean 2501
Inspect 2501
Install 2501
Install 2502
Pressure Relief Valve Check and Adjustment 2508
Primary Relief Valve 2509
Secondary Relief Valve 2513
Steering Control Unit Repair 2520
Steering Control Unit, Remove 2520
Steering Control Unit, Disassemble 2524
Steering Control Unit, Clean 2526
Steering Control Unit, Inspect 2526
Steering Control Unit, Assemble 2526
Relief Valve, Disassemble 2527
Relief Valve, Clean 2527
Relief Valve, Inspect 2528
Relief Valve, Assemble 2528
Steering Control Unit, Install 2528
524223769 2200YRM1128 (01 2023) US EN 2533
Series Code / Model Designation Reference Table 2541
General 2543
Deutsch Crimping Tool 2544
How to Strip a Wire for Use With Deutsch Crimping Tool 2544
How to Crimp With the Deutsch Crimping Tool 2545
Calibration Test for the Deutsch Crimping Tool 2547
Deutsch Connectors 2549
DT, DTM, and DTP Series Connectors 2549
HD Series Connectors 2592
Metri-Pack Connectors 2614
Remove and Install 2614
Micro-Pack Connectors 2617
Weather-Pack Connectors 2618
AMPSEAL Crimping Tools 2620
AMP Hand Crimping Tool With Certi-Crimp 2620
Description 2620
Stripping Wire for Use with AMP Hand Crimping Tool 2621
Insulation Crimp Adjustment 2622
Maintenance and Inspection for AMP Hand Crimping Tool 2622
AMP Hand Crimping Tool 2622
Crimp Height Inspection 2622
How to use AMP Hand Crimping Tool 2623
AMP Pro-Crimper II Tool 2623
Description 2623
Remove and Install Die Set and Locator Assembly 2624
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2624
Contact Support Adjustment 2625
Crimp Height Adjustment 2626
Maintenance and Inspection Procedures 2626
PRO-CRIMPER II Tool 2626
Crimp Height Inspection 2626
How to Use AMP PRO-CRIMPER II Tool 2627
AMPSEAL Connector Assemblies 2628
Description for Plug Connector Assembly 2628
Seal Plug 2629
Contact Crimping 2629
Description for Plug Connector and Header Assembly 2634
Voltage Reading 2637
Seal Plug 2637
Contact Crimping 2637
AMP Superseal 1 5 Crimping Tools 2644
Mini Mic Receptacle and Tab Contacts 2644
Description 2644
Crimping Conditions and Measurements 2644
Insertion of Rubber Seal on Cable 2646
AMP Hand Application Tool 2651
Description 2651
Maintenance and Inspection 2651
Crimp Height Inspection 2651
Crimp Height Adjustment 2652
How to Use AMP Hand Application Tool 2652
AMP Pro-Crimper II Tool 2653
Description 2653
Remove and Install Die Set and Locator Assembly 2653
Adjustments 2654
Contact Support 2654
Crimp Height 2655
Inspections and Maintenance 2656
Crimp Height Inspection 2656
Visual Inspection 2656
Maintenance 2657
How to Use Pro-Crimper II Tool 2657
AMP Superseal 1 5 Connector Assemblies 2658
Description 2658
Repair and Maintenance 2665
Panel Mount Option 2665
AMP Fastin-Faston Hand Tools 2666
Description – AMP Double Action Hand Tool 2666
Maintenance and Inspection Procedures 2666
Daily Maintenance 2666
Periodic Tool Inspection 2667
Lubrication 2667
Visual Inspection 2667
Crimp Height Inspection 2667
Certi-Crimp Ratchet Inspection 2668
How to Use AMP Double Action Hand Tool 2669
Description – AMP Extraction Tool 2670
Maintenance and Inspection 2671
How to Use AMP Extraction Tool 2671
AMP Fastin-Faston Receptacles and Housings 2673
Description 2673
Wire Repair 2681
Wire Splicing Requirements 2681
Deutsch Jiffy Splice 2682
Twisted/Shielded Cable and Leads Repair 2688
Special Tools 2690
524223769 2200YRM1128 (07 2020) US EN 2699
Series Code / Model Designation Reference Table 2705
General 2708
Deutsch Crimping Tool 2708
How to Strip a Wire for Use With Deutsch Crimping Tool 2708
How to Crimp With the Deutsch Crimping Tool 2709
Calibration Test for the Deutsch Crimping Tool 2711
Deutsch Connectors 2713
DT, DTM, and DTP Series Connectors 2713
HD Series Connectors 2755
Metri-Pack Connectors 2778
Remove and Install 2778
Micro-Pack Connectors 2780
Weather-Pack Connectors 2781
AMPSEAL Crimping Tools 2783
AMP Hand Crimping Tool With Certi-Crimp 2783
Description 2783
Stripping Wire for Use with AMP Hand Crimping Tool 2783
Insulation Crimp Adjustment 2784
Maintenance and Inspection for AMP Hand Crimping Tool 2784
AMP Hand Crimping Tool 2784
Crimp Height Inspection 2784
How to use AMP Hand Crimping Tool 2785
AMP Pro-Crimper II Tool 2785
Description 2785
Remove and Install Die Set and Locator Assembly 2786
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2787
Contact Support Adjustment 2787
Crimp Height Adjustment 2788
Maintenance and Inspection Procedures 2788
PRO-CRIMPER II Tool 2788
Crimp Height Inspection 2788
How to Use AMP PRO-CRIMPER II Tool 2789
AMPSEAL Connector Assemblies 2790
Description for Plug Connector Assembly 2790
Seal Plug 2791
Contact Crimping 2791
Description for Plug Connector and Header Assembly 2796
Voltage Reading 2798
Seal Plug 2798
Contact Crimping 2798
AMP Superseal 1 5 Crimping Tools 2805
Mini Mic Receptacle and Tab Contacts 2805
Description 2805
Crimping Conditions and Measurements 2805
Insertion of Rubber Seal on Cable 2807
AMP Hand Application Tool 2812
Description 2812
Maintenance and Inspection 2812
Crimp Height Inspection 2812
Crimp Height Adjustment 2813
How to Use AMP Hand Application Tool 2813
AMP Pro-Crimper II Tool 2814
Description 2814
Remove and Install Die Set and Locator Assembly 2815
Adjustments 2815
Contact Support 2815
Crimp Height 2816
Inspections and Maintenance 2817
Crimp Height Inspection 2817
Visual Inspection 2817
Maintenance 2818
How to Use Pro-Crimper II Tool 2818
AMP Superseal 1 5 Connector Assemblies 2819
Description 2819
Repair and Maintenance 2826
Panel Mount Option 2826
AMP Fastin-Faston Hand Tools 2827
Description – AMP Double Action Hand Tool 2827
Maintenance and Inspection Procedures 2827
Daily Maintenance 2827
Periodic Tool Inspection 2828
Lubrication 2828
Visual Inspection 2828
Crimp Height Inspection 2828
Certi-Crimp Ratchet Inspection 2829
How to Use AMP Double Action Hand Tool 2830
Description – AMP Extraction Tool 2831
Maintenance and Inspection 2831
How to Use AMP Extraction Tool 2832
AMP Fastin-Faston Receptacles and Housings 2833
Description 2833
Wire Repair 2840
Wire Splicing Requirements 2840
Deutsch Jiffy Splice 2841
Twisted/Shielded Cable and Leads Repair 2846
Special Tools 2849
524223770 2200YRM1130 (03 2020) US EN 2857
General 2861
Description 2861
Dash Display Menu Access 2861
Menu Navigation 2862
Standard Display 2862
Main Menu 2862
Passwords Menu 2863
Password Administration 2863
Add Password 2863
Delete Password 2864
Edit Password 2864
Other Password Functions 2865
Operator Passwords – Enable/Disable 2865
Password Time-Out Delay 2865
Passwords – Number Wrong to Disable 2866
Lockout Reset Password 2866
View Password Log 2867
View Versions 2868
VSM Versions 2868
Dash Display Versions 2869
Engine Controller Version 2870
Transmission (Xmsn) Controller Version 2871
Truck Serial Number 2872
Diagnostics 2873
View Fault Log 2873
Set Travel and Braking 2874
Speed Limit 2874
Acceleration Rate 2875
Auto-Deceleration Rate 2875
Set Power Reversal Rate 2876
Set Inching/Brake Overlap 2877
Setup Display Menu 2878
Set Operator Language 2878
Set Units 2879
Set Time Format (12/24 Hour) 2879
Set Daylight Saving Time 2879
Set Time 2882
Set Date Format 2883
Set Date 2883
Setup Hydraulics 2884
Return to Set Tilt Delay/On/Off 2884
Setup General Items 2885
Light Shutdown Time-Out 2885
Impact Sensor – Enable/Disable 2886
Impact Sensor – Soft Impact Settings 2887
Impact Sensor – Hard Impact Settings 2888
Adjust Impact Sensor Settings 2888
Initial Adjustment of Soft and Hard Impact Settings 2890
Readjustment of Soft and Hard Impact Settings 2890
Impact Sensor – Impact Alarm/Shutdown Reset 2891
Impact Sensor – Alarm Time Duration and Deactivation 2892
Impact Sensor – View Impact Event Log 2893
Engine Mode Indicator 2894
Generation 1 (ECO-eLo ONLY) 2894
Generation 2 2895
Operator Checklist 2896
Operator Checklist Off-On Mode 2896
Edit Operator Checklist 2896
Set Operator Checklist Expiration 2897
View Checklist Log 2897
Clear Operator Checklist Log 2898
Clear Operator Checklist Fault 2898
Calibrations 2899
Set Tilt Stop Point 2899
Calibrate Loaded Weight 2899
524223771 2200YRM1131 (03 2020) US EN 2901
Series Code / Model Designation Reference Table 2907
General 2909
Description 2909
Dash Display Menu Access 2909
Menu Navigation 2910
Main Menu 2910
Passwords 2911
Adding Passwords 2911
Hourmeters 2913
View Versions 2914
VSM Versions 2914
Dash Display Versions 2915
Engine Controller Version 2916
Transmission (Xmsn) Controller Version 2917
Truck Serial Number 2918
Truck Configuration 2919
Diagnostics 2920
Clear Fault Log 2920
View Fault Log 2921
No-Run Data Display 2922
Engine Accelerator and Throttle Data Display 2922
Engine Speeds and Governor Data Display 2923
Engine Fuel and Emissions Data Display 2924
Engine General Data Display 2926
XMSN/Brake Data Display 2927
Hydraulic Data Display 2930
General Truck Data Display 2932
Set Travel and Braking 2933
Speed Limit 2933
Acceleration Rate 2934
Auto-Deceleration Rate 2935
Set Power Reversal Rate 2935
Set Inching/Brake Overlap 2936
Setup Hydraulics 2936
Lift Maximum Speed 2937
Lower Maximum Speed 2937
Tilt Maximum Speed 2938
Auxiliary Function One, Direction A, Maximum Speed 2940
Auxiliary Function One, Direction B, Maximum Speed 2942
Auxiliary Function Two, Direction A, Maximum Speed 2942
Auxiliary Function Two, Direction B, Maximum Speed 2943
Auxiliary Function Three, Direction A, Maximum Speed 2944
Auxiliary Function Three, Direction B, Maximum Speed 2944
Lift/Lower Ramp Rate 2945
Hydraulic Auxiliary Ramp Rate 2945
Return to Set Tilt Delay/On/Off 2946
Hydraulic Input Device 2947
Auxiliary Solenoid 2947
Dual Function 2948
Setup Display 2949
Set Service Language 2949
Setup General Items 2949
Motion Alarm Activation Type 2950
Light Shutdown Time-Out 2951
Restore Default Settings 2951
Restore Engine Controller Default Calibration 2952
Impact Sensor – Enable/Disable 2952
Impact Sensor – Soft Impact Settings 2953
Impact Sensor – Hard Impact Settings 2954
Adjust Impact Sensor Settings 2955
Initial Adjustment of Soft and Hard Impact Settings 2957
Readjustment of Soft and Hard Impact Settings 2957
Impact Sensor – Impact Alarm/Shutdown Reset 2958
Impact Sensor – Alarm Time Duration and Deactivation 2959
Impact Sensor – View Impact Event Log 2960
Engine Mode Indicator 2960
Generation 1 (ECO-eLo ONLY) 2960
Generation 2 2961
Diesel Particulate Filter (DPF) Display 2962
General Description 2962
Passive Regeneration Only 2962
Regeneration Level 0 2962
Auto/Active Regeneration Inhibited 2963
Auto/Active Regeneration 2963
Regeneration Level 1 2963
Parked Regeneration Request 2964
Regeneration Level 2 2964
Warning Level 2964
Regeneration Level 3 2964
Service Level 2965
Regeneration Level 4 2965
Display, Diesel Particulate Filter (DPF), Revised 2965
Operator Interface 2965
Refer to Operator Manual 2965
CAN Communication Lost 2966
Passive Regeneration Only 2966
Regeneration Level 0 2966
Auto/Active Regeneration Inhibited 2966
Auto/Active Regeneration 2967
Regeneration Level 1 2967
Idle-up Auto/Active Regeneration 2967
Parked Regeneration Request 2967
Regeneration Level 2 2967
Warning Level 2969
Regeneration Level 3 2969
Service Level 2969
Regeneration Level 4 2969
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2969
Display, Diesel Particulate Filter (DPF), Stage V Engine 2969
Operator Interface 2970
Refer to Operator Manual 2970
CAN Communication Lost 2970
Passive Regeneration Only 2970
Regeneration Level 0 2970
Auto/Active Regeneration Inhibited 2971
Auto/Active Regeneration 2971
Regeneration Level 1 2971
Idle-up Auto/Active Regeneration 2972
Parked Regeneration Request 2972
Regeneration Level 2 2972
Warning Level 2973
Regeneration Level 3 2973
Service Level 2974
Regeneration Level 4 2974
Stage V Content 2974
Emissions System Malfunction 2974
Ash Load 2974
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2975
Operator Interface 2975
Refer to Operator Manual 2975
CAN Communication Lost 2976
Passive Regeneration Only 2976
Regeneration Level 0 2976
Auto/Active Regeneration Inhibited 2976
Auto/Active Regeneration 2977
Regeneration Level 1 2977
Idle-up Auto/Active Regeneration 2977
Parked Regeneration Request 2977
Regeneration Level 2 2977
Warning Level 2979
Regeneration Level 3 2979
Service Level 2979
Regeneration Level 4 2979
Calibrations 2980
Calibrate Transmission Valve 2982
Set Tilt Stop Point 2982
Calibrate Loaded Weight 2982
Calibrate Travel Speed Sensor 2983
Calibrate Mazda LP and Gas Accelerator Pedal 2983
524223772 2200YRM1142 (01 2020) US EN 2985
General 2995
Display Switch Cluster 2998
Remove 2998
Install 3001
Direction Control and Turn Signal Levers 3001
Remove 3001
Install 3003
Key Switch 3003
Remove 3003
Install 3004
Display Switch Cluster Panel Bezel and Overlay 3004
Remove 3004
Install 3004
Steering Column Repair 3004
Remove 3004
Disassemble 3007
Assemble 3007
Install 3007
Sensors and Switches 3008
General 3008
Dash and Kick Panel, Remove and Install 3008
Remove 3008
Install 3009
Accelerator Pedal Position Sensor 3010
Remove 3010
Install 3013
Brake Fluid Level Switch 3014
Remove 3014
Install 3016
Service Brake Pedal Position Sensor 3017
Remove 3017
Install 3020
Parking Brake Sensor 3021
Remove 3021
Install 3022
Service Brake Pressure Sensor 3023
Remove 3023
Install 3025
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3026
Remove 3026
Install 3026
Sensor Microswitch (Foot Directional Control Pedal) 3027
Remove 3027
Install 3030
Low Coolant Level Sensor 3031
Remove 3031
Install 3034
Fuel Level Sensor, Gas and Diesel Engines Only 3035
Remove 3035
Install 3036
Armrest Switch 3036
Remove 3036
Install 3038
Seat Sensor (Operator Presence System) 3038
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) 3038
Remove 3038
Install 3039
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3039
Remove 3039
Install 3040
Full Suspension Seats; All Lift Truck Models 3040
Remove 3040
Install 3040
Hood Shut Off Switch 3040
Remove 3040
Install 3043
Remote Key Switch 3044
Remove 3044
Install 3044
Hydraulic Filter Pressure Switch 3045
Remove 3045
Install 3047
Transmission Speed Sensor 3047
Remove 3047
Install 3050
Transmission Pressure Sensors 3051
Remove 3051
Install 3053
Transmission Temperature Sensor 3054
Remove 3054
Install 3056
Engine Speed Sensor 3058
Remove 3058
Install 3058
Intermediate Speed Sensor 3059
Remove 3059
Install 3059
Return to Set Tilt (Tilt Angle) Sensor 3059
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) 3059
Remove 3059
Install 3060
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) 3061
Remove 3061
Install 3062
Rear Horn Button Switch 3062
Remove 3062
Install 3063
Impact Sensor 3064
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) 3064
Remove 3064
Install 3067
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) 3067
Remove 3067
Install 3068
Load Weight Sensor 3069
Remove 3069
Install 3070
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3071
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3071
Crankshaft Position (CKP) Sensor 3071
Camshaft Position (CMP) Sensor 3071
Oil Pressure Sensor 3071
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3071
Engine Coolant Temperature (ECT) Sensor 3072
Air Flow Restriction Switch 3072
Remove for GM 2 4L Gas and LPG Trucks 3072
Install for GM 2 4L Gas and LPG Trucks 3072
Oxygen Sensor 3073
Remove 3073
Install 3076
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3077
Crankshaft Position (CKP) Sensor 3077
Camshaft Position (CMP) Sensor 3077
Oil Pressure Sensor 3077
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3077
Engine Coolant Temperature (ECT) Sensor 3077
Air Flow Restriction Switch 3077
Oxygen Sensor 3077
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3077
Low LPG Pressure Switch 3077
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3078
Air Filter Restriction Switch 3078
Remove 3078
Install 3078
Oil Pressure Sensor 3078
Remove 3078
Install 3078
Engine Speed Sensor 3078
Remove 3078
Install 3078
Engine Coolant Temperature (ECT) Sensor 3078
Remove 3078
Install 3078
Throttle Position Sensor (TPS) 3081
Remove 3081
Install 3082
Fuel/Water Separator Sensor 3082
Remove 3082
Install 3082
Glow Plug Relay 3083
Remove 3083
Install 3085
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3085
Air Filter Restriction Switch 3085
Remove 3085
Install 3085
Engine Oil Pressure Sensor 3090
Remove 3090
Install 3090
Engine Speed Sensor 3090
Remove 3090
Install 3091
Engine Coolant Temperature (ECT) Sensor 3091
Remove 3091
Install 3092
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3093
Remove 3093
Install 3093
Fuel/Water Separator Sensor 3094
Remove 3094
Install 3094
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3095
Intake Air Temperature Sensor 3095
Remove 3095
Install 3096
Intake Air Pressure Sensor 3096
Remove 3096
Install 3096
Air Inlet Heater 3096
Remove 3096
Install 3097
Engine Oil Pressure Sensor 3097
Remove 3097
Install 3097
Engine Coolant Temperature (ECT) Sensor 3097
Remove 3097
Install 3097
Crankshaft Position Sensor 3098
Remove 3098
Install 3098
Adjust Shim Procedure 3099
Camshaft Position Sensor 3100
Remove 3100
Install 3100
Air Flow Restriction Sensor 3101
Remove 3101
Install 3101
Fuel/Water Separator 3101
Remove 3101
Install 3102
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3102
Intake Air Temperature Sensor 3106
Remove 3106
Install 3107
Boost Sensor 3107
Remove 3107
Install 3108
Throttle Valve Assembly and Air Intake Heater 3108
Remove 3108
Install 3108
Engine Coolant Temperature (ECT) Sensor 3109
Remove 3109
Install 3109
Engine Oil Pressure Sensor 3109
Remove 3109
Install 3110
Crankshaft Position Sensor 3110
Remove 3110
Install 3110
Adjust Shim Procedure 3111
Camshaft Position Sensor 3112
Remove 3112
Install 3113
Differential Pressure Sensor 3113
Remove 3113
Install 3113
Mass Air Flow Sensor 3114
Remove 3114
Install 3115
Fuel/Water Separator 3115
Remove 3115
Install 3116
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3116
Engine Coolant Temperature (ECT) Sensor 3117
Remove 3117
Install 3117
Throttle Position Sensor 3118
Engine Oil Pressure Sensor 3118
Remove 3118
Install 3118
Engine Speed Sensor 3118
Remove 3118
Install 3118
Fuel Shut Off Solenoid 3118
Remove 3118
Install 3118
Vehicle System Manager (VSM) 3119
General 3119
VSM Replacement 3119
Remove 3119
Install 3121
Programming a New VSM and/or Display Switch Cluster 3121
General 3121
PC Service Tool Software 3122
Data Transferring 3122
New VSM 3122
New (Blank) Display Switch Cluster 3122
Used (Non-Blank) Display Switch Cluster 3122
Power Distribution Module (PDM) and Component Parts 3124
Remove 3124
PDM as a Unit 3124
Install 3128
PDM as a Unit 3128
Remove and Install 3129
PDM Component Parts 3129
Transmission Control Unit 3129
Remove 3129
Install 3133
Battery 3135
Remove 3135
Install 3135
Lights 3136
Work Lights (Front and Rear) 3136
Remove 3136
Install 3136
Strobe Light 3137
Remove 3137
Install 3137
LED Tail, Backup, and Brake Lights 3138
Remove 3138
Install 3139
Front Marker/Turn Signal Lights 3140
Replacing Whole Front Marker/Turn Signal Light Assembly 3140
Remove 3140
Install 3140
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3141
Remove 3141
Install 3141
Diesel Particulate Filter (DPF) Display 3141
Remove 3141
Clean and Inspect 3142
Install 3142
Electronic-Hydraulic Controls – Generation 1 3143
E-Hydraulic Controls – Test 3143
Mini-Levers 3143
Full Stroke Test 3143
Function Returns to Neutral Test 3143
Push Button Switch 3143
General 3144
Mini-Lever Replacement 3144
Remove 3144
Clean and Inspect 3145
Install 3145
Push Button Switch Replacement 3146
Remove 3146
Install 3148
Mini-Lever Module (MLM) 3148
Remove 3148
Install 3148
Joystick 3149
Remove and Disassemble 3149
Inspect 3149
Assemble and Install 3149
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3150
General 3150
Mini-levers, Remove and Install 3150
Armrest Assembly 3151
Remove 3151
Install 3154
Horn Button 3154
Remove 3154
Install 3154
Direction Control Switch 3155
Remove 3155
Install 3155
push (override) buttons and Toggle Switch 3155
Remove 3156
Install 3157
Joystick 3158
Remove and Disassemble 3158
Inspect 3158
Assemble and Install 3158
Joystick Armrest Slider Assembly 3159
Remove 3159
Install 3160
Electronic-Hydraulic Controls, After January, 2020 3160
E-Hydraulic Controls – TEST 3160
Mini-Levers 3160
Full Stroke Test 3160
Function Returns to Neutral Test 3160
Push (Override) Button 3161
General 3161
Mini-levers, Remove and Install 3161
Armrest Assembly 3162
Remove 3162
Install 3165
Horn Button 3165
Remove 3165
Install 3165
Direction Control Switch 3165
Remove 3165
Install 3166
Push (Override) buttons and Toggle Switch 3166
Remove 3167
Install 3169
Special Tools 3170
524223779 8000YRM1152 (03 2020) US EN 3173
General Information About Diagrams and Schematics 3177
Symbol Definitions 3177
Diagrams Manual Applications 3178
Diagrams and Schematics 3180
524223780 8000YRM1134 (03 2020) US EN 3243
Series Code / Model Designation Reference Table 3249
Description 3251
Proc_Cal_001: Service Password Entry 3253
When to Perform 3253
Why Perform 3253
How to Perform 3253
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3254
When to Perform 3254
Calibration Order 3254
Why Perform 3254
How to Perform 3255
Proc_Cal_003: Save and Exit 3256
When to Perform 3256
Why Perform 3256
How to Perform 3256
Proc_Cal_004: Lift Valve Output Threshold 3257
When to Perform 3257
Calibration Order 3257
Why Perform 3257
How to Perform 3258
Proc_Cal_005: Lower Valve Output Threshold 3260
When to Perform 3260
Calibration Order 3260
Why Perform 3260
How to Perform 3260
Proc_Cal_006: Tilt Back Valve Output Threshold 3263
When to Perform 3263
Calibration Order 3263
Why Perform 3263
How to Perform 3263
Proc_Cal_007: Tilt Forward Valve Output Threshold 3266
When to Perform 3266
Calibration Order 3266
Why Perform 3266
How to Perform 3266
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3269
When to Perform 3269
Calibration Order 3269
Why Perform 3269
How to Perform 3269
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3272
When to Perform 3272
Calibration Order 3272
Why Perform 3272
How to Perform 3272
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3275
When to Perform 3275
Calibration Order 3275
Why Perform 3275
How to Perform 3275
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3278
When to Perform 3278
Calibration Order 3278
Why Perform 3278
How to Perform 3278
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3281
When to Perform 3281
Calibration Order 3281
Why Perform 3281
How to Perform 3281
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3284
When to Perform 3284
Calibration Order 3284
Why Perform 3284
How to Perform 3284
Proc_Cal_014: Load Weight Zero Point 3288
When to Perform 3288
Calibration Order 3288
Why Perform 3288
How to Perform 3288
Proc_Cal_015: Loaded Weight Calibration 3290
When to Perform 3290
Calibration Order 3290
Why Perform 3290
How to Perform 3290
Proc_Cal_016: Transmission Valve Calibration 3293
Applicable System/Option 3293
When to Perform 3293
Calibration Order 3293
Why Perform 3293
How to Perform 3293
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3295
Applicable System/Option 3295
When to Perform 3295
Calibration Order 3295
Why Perform 3295
How to Perform 3295
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3297
Applicable System/Option 3297
When to Perform 3297
Calibration Order 3297
Why Perform 3297
How to Perform 3298
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3299
Required Tools 3299
When to Perform 3299
Calibration Order 3299
Why Perform 3300
How to Perform 3300
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3301
When to Perform 3301
Why Perform 3301
How to Perform 3301
Proc_Cal_026: Travel Speed Calibration 3303
When to Perform 3303
Calibration Order 3303
Why Perform 3303
How to Perform 3303
524223780 8000YRM1134 (05 2022) US EN 3307
Series Code / Model Designation Reference Table 3313
Description 3316
Proc_Cal_001: Service Password Entry 3318
When to Perform 3318
Why Perform 3318
How to Perform 3318
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3319
When to Perform 3319
Calibration Order 3319
Why Perform 3319
How to Perform 3319
Proc_Cal_003: Save and Exit 3321
When to Perform 3321
Why Perform 3321
How to Perform 3321
Proc_Cal_004: Lift Valve Output Threshold 3322
When to Perform 3322
Calibration Order 3322
Why Perform 3322
How to Perform 3322
Proc_Cal_005: Lower Valve Output Threshold 3325
When to Perform 3325
Calibration Order 3325
Why Perform 3325
How to Perform 3325
Proc_Cal_006: Tilt Back Valve Output Threshold 3328
When to Perform 3328
Calibration Order 3328
Why Perform 3328
How to Perform 3328
Proc_Cal_007: Tilt Forward Valve Output Threshold 3331
When to Perform 3331
Calibration Order 3331
Why Perform 3331
How to Perform 3331
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3334
When to Perform 3334
Calibration Order 3334
Why Perform 3334
How to Perform 3334
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3337
When to Perform 3337
Calibration Order 3337
Why Perform 3337
How to Perform 3337
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3340
When to Perform 3340
Calibration Order 3340
Why Perform 3340
How to Perform 3340
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3343
When to Perform 3343
Calibration Order 3343
Why Perform 3343
How to Perform 3343
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3346
When to Perform 3346
Calibration Order 3346
Why Perform 3346
How to Perform 3346
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3349
When to Perform 3349
Calibration Order 3349
Why Perform 3349
How to Perform 3349
Proc_Cal_014: Load Weight Zero Point 3352
When to Perform 3352
Calibration Order 3352
Why Perform 3352
How to Perform 3352
Proc_Cal_015: Loaded Weight Calibration 3354
When to Perform 3354
Calibration Order 3354
Why Perform 3354
How to Perform 3354
Proc_Cal_016: Transmission Valve Calibration 3357
Applicable System/Option 3357
When to Perform 3357
Calibration Order 3357
Why Perform 3357
How to Perform 3357
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3359
Applicable System/Option 3359
When to Perform 3359
Calibration Order 3359
Why Perform 3359
How to Perform 3359
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3362
Applicable System/Option 3362
When to Perform 3362
Calibration Order 3362
Why Perform 3362
How to Perform 3362
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3365
Required Tools 3365
When to Perform 3365
Calibration Order 3365
Why Perform 3365
How to Perform 3365
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3367
When to Perform 3367
Why Perform 3367
How to Perform 3367
Proc_Cal_026: Travel Speed Calibration 3369
When to Perform 3369
Calibration Order 3369
Why Perform 3369
How to Perform 3369
524262275 0900YRM1242 (04 2018) US EN 3373
General 3379
Hoses Replacement 3379
LPG Tank and Bracket Replacement 3380
LPG Tank, Lift Truck Models GLC40, 45, 55VX; GLC55SVX; GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813, H813), and GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879) 3380
Remove 3380
Install 3383
LPG Tank Bracket, Lift Truck Models GLC40, 45, 55VX; GLC55SVX; GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813, H813), and GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879) 3384
Remove 3384
Install 3384
LPG Tank Bracket Alignment Pin, Lift Truck Models GLC40, 45, 55VX; GLC55SVX; GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813, H813), and GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879) 3384
Remove 3384
Install 3386
LPG Tank, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3387
Remove 3387
Install 3389
LPG Tank Bracket, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3389
Remove 3389
Install 3389
High Pressure Fuel Filter Unit Repair 3389
Fuel Filter Element 3390
Remove 3390
Clean/Inspect 3391
Install 3391
Fuel Filter Housing 3391
Remove 3391
Disassemble 3392
Assemble 3392
Install 3392
Electronic Throttle Body Repair 3393
Remove 3393
Clean/Inspect 3394
Install 3394
Fuel Injector Repair 3395
Fuel Rail 3395
Remove for Lift Trucks Built Before January, 2010 3395
Remove for Lift Trucks Built After January, 2010 3397
Install for Lift Trucks Built Before January, 2010 3398
Install for Lift Trucks Built After January, 2010 3399
Fuel Injectors and Adapters 3399
Remove for Lift Trucks Built Before January, 2010 3399
Remove for Lift Trucks Built After January, 2010 3401
Clean 3402
Install for Lift Trucks Built Before January, 2010 3402
Install for Lift Trucks Built After January, 2010 3404
LPG Regulator Repair 3404
LPG Regulator 3404
Remove for Lift Trucks Built Before January, 2010 3404
Remove for Lift Trucks Built After January, 2010 3405
Install for Lift Trucks Built Before January, 2010 3407
Install for Lift Trucks Built After January, 2010 3407
LPG Regulator Fuel Filter 3408
Remove 3408
Install 3409
Lock-Off Solenoid and Cartridge 3409
Remove 3409
Install 3410
Control System 3410
Electronic Control Unit (ECU) and Injector Driver Modules Assembly 3410
Remove 3410
Install 3411
Electronic Control Unit (ECU) 3412
Remove 3412
Install 3412
Injector Driver Modules 3413
Remove 3413
Install 3413
Fuel Pressure Sensor 3414
Remove 3414
Install 3414
Low LPG Pressure Switch 3414
Remove 3414
Install 3415
LPG Pressure Sensor 3415
Remove 3415
Install 3416
Oxygen Sensor 3416
Exhaust System Repair 3417
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 3417
Remove for Lift Trucks Built Before January, 2010 3417
Remove for Lift Trucks Built After January, 2010 3419
Inspect 3421
Install for Lift Trucks Built Before January, 2010 3421
Install for Lift Trucks Built After January, 2010 3421
GM 4 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) 3422
Remove for Lift Trucks Built Before January, 2010 3422
Remove for Lift Trucks Built After January, 2010 3424
Inspect 3427
Install for Lift Trucks Built Before January, 2010 3427
Install for Lift Trucks Built After January, 2010 3428
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3429
Remove for Lift Trucks Built Before January, 2010 3429
Remove for Lift Trucks Built After January, 2010 3432
Inspect 3433
Install for Lift Trucks Built Before January, 2010 3434
Install for Lift Trucks Built After January, 2010 3434
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3435
Remove for Lift Trucks Built Before January, 2010 3435
Remove for Lift Trucks Built After January, 2010 3438
Inspect 3439
Install for Lift Trucks Built Before January, 2010 3440
Install for Lift Trucks Built After January, 2010 3440
Oxygen Sensor 3441
Remove 3441
Install 3442
LPG Fuel Testing 3442
General 3442
Available Fuel Tests 3442
Composition Test (ASTM D-2163) 3442
Ammonia Test (ASTM D-4490) 3443
Basic Nitrogen Test (ASTM UOP269-90) 3443
Residues Test (ASTM D-2158) 3443
Vapor Pressure Test (ASTM D-2598) 3443
Sulfur Compounds Test (ASTM D-5623) 3443
Methanol Test (ASTM D-4864) 3443
Copper Corrosion (ASTM D-1838) 3443
Where To Send LPG Fuel Samples For Testing 3443
524262276 0900YRM1244 (06 2012) US EN 3447
toc 3447
Gasoline Fuel System 3447
Safety Precautions Maintenance and Repair 3448
General 3451
Electronic Throttle Body Repair 3451
Electronic Throttle Body 3451
Remove 3451
Clean/Inspect 3451
Install 3452
Fuel System Repair 3453
Before Repair Procedure 3453
After Repair Procedure 3453
Fuel Leakage Check for Lift Trucks Built Before January, 2010 3453
Fuel Leakage Check for Lift Trucks Built After January, 2010 3454
Fuel Line Pressure Check 3456
Fuel Injector Repair 3457
Remove 3457
Install 3467
Control System 3468
Electronic Control Unit (ECU) 3468
Remove for Lift Trucks Built Before January, 2010 3468
Remove for Lift Trucks Built After January, 2010 3469
Install for Lift Trucks Built Before January, 2010 3470
Install for Lift Trucks Built After January, 2010 3471
Exhaust System Repair 3472
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; ( 3472
Remove for Lift Trucks Built Before January, 2010 3472
Remove for Lift Trucks Built After January, 2010 3474
Inspect 3474
Install for Lift Trucks Built Before January, 2010 3476
Install for Lift Trucks Built After January, 2010 3476
GM 4 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45 3477
Remove for Lift Trucks Built Before January, 2010 3477
Remove for Lift Trucks Built After January, 2010 3479
Inspect 3481
Install for Lift Trucks Built Before January, 2010 3481
Install for Lift Trucks Built After January, 2010 3482
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (G 3483
Remove for Lift Trucks Built Before January, 2010 3483
Remove for Lift Trucks Built After January, 2010 3485
Inspect 3487
Install for Lift Trucks Built Before January, 2010 3487
Install for Lift Trucks Built After January, 2010 3488
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (G 3488
Remove for Lift Trucks Built Before January, 2010 3488
Remove for Lift Trucks Built After January, 2010 3491
Inspect 3491
Install for Lift Trucks Built Before January, 2010 3493
Install for Lift Trucks Built After January, 2010 3493
Oxygen Sensor 3494
Remove 3494
Install 3494
524262279 1800YRM1247 (09 2018) US EN 3497
General 3501
Dry Brake System 3501
Wet Brake System 3502
Service Brakes Repair (Dry Brake) 3506
Remove and Disassemble 3506
Clean 3508
Inspect 3509
Assemble and Install 3509
Adjust 3513
Parking Brake Repair 3513
Dry Brake System 3514
Remove and Disassembly 3514
Assemble and Install 3516
Wet Brake System 3516
Remove and Install 3517
Assemble and Install 3523
Adjust 3523
Dry Brake System 3523
Wet Brake System 3524
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3524
Master Cylinder Repair 3525
Remove 3525
Disassemble 3530
Clean and Inspect 3531
Assemble 3532
Install and Adjust 3532
Accumulator 3534
Pre-Charge Check 3535
Remove 3536
Install 3538
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3538
Remove 3539
Modulating Brake Valve 3540
Disassemble 3540
Clean and Inspect 3542
Assemble 3542
Accumulator Charge Valve 3543
Disassemble 3543
Clean and Inspect 3545
Assemble 3545
Install 3546
Pressure Checks 3547
Accumulator Charge Valve Check 3547
Accumulator Check 3547
Service Brakes Adjustment (Dry Brake) 3548
Service Brakes Adjustment 3548
Brake System Air Removal 3549
Using Pressure Bleed System 3549
Using Brake Pedal Pressure 3550
Lift Truck Models with Master Cylinder 3550
Lift Truck Models with Modulating Brake Valve 3550
Brake Pedal Adjustment 3551
For Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3551
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3552
Free Pedal Adjustment 3554
Torque Specifications 3555
524265337 0600YRM1251 (09 2015) US EN 3559
General 3565
Engine Removal and Installation 3565
Cylinder Head Repair 3565
Remove and Disassemble 3565
Clean and Inspect 3567
Valve Oil Seals 3570
Remove and Disassemble 3570
Cylinder Leak Down Test 3570
Clean and Inspect 3571
Assemble and Install 3571
Valve Guides and Seats, Repairs 3573
Valves, Repair 3573
Valve Seats, Repair 3574
Valve Springs 3575
Assemble and Install 3576
Engine Block Cleaning and Inspection 3579
Clean and Inspect 3580
Piston Bore Preparation 3582
Engine Mounts Installation 3582
Remove 3582
Clean and Inspect 3583
Install 3583
Lubrication System Repair 3584
Oil Pump, Remove and Disassemble 3584
Clean and Inspect 3585
Oil Pump, Assemble and Install 3586
Oil Pan, Install 3588
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 3590
Timing Cover 3590
Remove 3590
Install 3592
Timing Sprockets 3592
Remove 3592
Install 3592
Camshaft 3592
Remove 3592
Inspect 3593
Install 3593
Balance Shaft 3594
Remove 3594
Install 3595
Valve Lifters 3596
Remove 3596
Clean and Inspect 3596
Install 3597
Crankshaft Repair 3597
Remove 3598
Inspect and Repair 3598
How to Check Clearance Between Main Bearings and Their Journals 3599
Install 3600
Piston and Connecting Rod Assemblies Repair 3602
Connecting Rod Bearings, Replace 3602
Piston and Connecting Rod Assemblies, Remove 3603
Disassemble 3603
Piston, Clean and Inspect 3604
Cylinder Bores, Inspect and Repair 3604
Piston Rings 3605
Assemble 3606
Piston and Connecting Rod Assemblies, Install 3606
Flywheel and Flywheel Housing Repair 3606
Flywheel, Remove 3607
Clean 3607
Inspect 3607
Flywheel, Install 3608
Coolant Pump Repair 3608
Remove 3608
Clean and Inspect 3609
Install 3609
Thermostat Replacement 3609
Remove 3610
Thermostat Operation Check 3610
Install 3610
Starter Replacement 3611
3611
Remove 3611
Install 3614
Fan Assembly Replacement 3615
Remove 3615
Inspect 3617
Install 3617
Drive Belt Installation 3618
Remove 3618
Clean 3618
Inspect 3618
Installation 3619
Compression Check 3620
Engine Specifications 3620
Engine Data 3620
Cylinder Head 3620
Hydraulic Valve Lifter 3621
Camshaft 3621
Pistons 3621
Crankshaft 3622
Connecting Rods 3622
Balance Shaft 3623
Cooling System 3623
Lubrication System 3623
Torque Specifications 3624
524265342 4000YRM1250 (09 2018) US EN 3629
Safety Procedures When Working Near Mast 3635
Fork Replacement 3637
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3637
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3639
Remove, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 3640
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3641
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3642
Install, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017 GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 3643
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3643
Checks, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 3645
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3645
Fixed Carriage Replacement 3647
Remove, Carriage With Hook Forks 3647
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3656
Install, Carriage With Hook Forks 3657
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3657
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3658
Connecting Attachment Hydraulic Quick Disconnect Hoses 3658
Integral Sideshift Carriage Repair 3659
Remove, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 3659
Disassemble 3659
Clean and Inspect 3662
Assemble 3662
Install, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 3663
Hang On Sideshift Carriage Repair 3663
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 3663
Disassemble 3675
Clean and Inspect 3684
Assemble 3685
Install 3686
Bolzoni Hang-On Sideshift Carriage Repair 3688
Remove 3688
Disassemble Carriage 3690
Clean and Inspect 3693
Assemble 3693
Install 3696
Fork Positioner 3698
Two-Stage Mast With Limited Free-Lift Repair 3699
Remove 3699
Disassemble 3703
Clean and Inspect 3706
Assemble 3723
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3725
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), and ERC35-55HG (ERC70-120HH) (C839) 3726
Header Hose Alignment 3738
Two-Stage Mast With Full Free-Lift Repair 3748
Remove 3748
Disassemble 3750
Clean and Inspect 3762
Assemble 3763
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 3765
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and ERC35-55HG (ERC70-120HH) (C839) 3768
Header Hose Installation and Adjustment 3772
Installation 3772
Adjustment 3772
Three-Stage Mast With Full Free-Lift Repair 3773
Remove 3773
Disassemble 3775
Clean and Inspect 3805
Assemble 3806
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX, (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3810
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), and ERC35-55HG (ERC70-120HH) (C839) 3815
Header Hose Alignment for GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813), and ERC35-55HG (ERC70-120HH) (C839) 3822
Header Hose Alignment for GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 3828
Mast Operation Check 3832
Tilt Cylinder Adjustment 3832
Lift Chains Adjustment 3833
Mast Adjustments 3834
Load Roller Adjustment 3834
Mast Side Kicking Adjustment 3836
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 3837
Carriage Adjustments 3840
524288194 1300YRM1317 (03 2020) US EN 3843
Transmission Repair 3847
Remove 3847
Torque Converter, Remove 3847
Disassemble 3848
Clean and Inspect 3897
Housings 3897
Oil Seals and Gaskets 3897
Bearings 3897
Gears and Shafts 3898
Assemble 3898
Torque Converter, Install 3939
Install 3940
Control Valve Repair 3941
Remove 3941
Disassemble 3941
Clean 3943
Inspect 3943
Assemble 3943
Install 3944
Torque Specification 3945
524288212 8000YRM1320 (06 2019) US EN 3947
Lift Truck Lifting Capacity 3951
Counterweight Weights 3951
Tire Sizes 3951
Capacities 3952
Electrical System 3959
Transmission Oil Pressures 3960
Hydraulic System Relief Pressures 3964
Steering System 3965
Stall Speeds (in RPM ±100 rpm) 3966
GM 4 3L Gas GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3966
GM 4 3L LPG GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3966
GM 4 3L Gas GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3966
GM 4 3L LPG GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3966
Cummins 4 5L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879) 3967
Cummins QSB 3 3L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879) 3967
Cummins 4 5L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878) 3967
Cummins QSB 3 3L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3967
Mast Speeds 3968
Tilt Angles 3969
Front End Equipment – Mast Creep 3970
Mast Creep 3970
Engine Specifications 3970
Torque Specifications 3972
Frame 3972
Mast, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3972
Mast, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3973
Hang On Sideshift Carriage With Fork Positioner, Lift Truck Models Manufactured After August, 2012GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3973
Steering System 3973
Transmission 3974
Engine – GM 4 3L 3974
Engine – Cummins 4 5L and QSB 3 3L Diesel 3975
524288879 0100YRM1321 (11 2016) US EN 3977
General 3981
Description 3982
Side Covers, Seat, Dash, and Hood Replacement 3983
Side Covers 3983
Remove 3983
Install 3983
Seat and Seat Plate 3984
Remove Seat 3984
Remove Seat Plate 3984
Install Seat Plate 3984
Install Seat 3984
Operator Restraint System 3988
Emergency Locking Retractor (ELR) 3988
Seat Plate and Seat Rail Check 3988
Steering Column, Dash, Kick Panel, and Seal Plate 3988
Remove 3988
Install 3991
Hood Support and Door Assembly 3993
Remove 3993
Install 3993
Hood Door Assembly 3998
Remove 3998
Install 3998
Steering Column 3999
Description 3999
Steering Column Repair 3999
Remove 3999
Disassemble 4000
Clean 4003
Inspect 4003
Assemble 4003
Install 4003
LPG Tank and Bracket Assembly 4003
Counterweight Replacement 4004
Remove 4004
Install 4005
Tow Pin, Remove and Install 4007
Overhead Guard Replacement 4007
Remove 4007
Install 4009
Engine Replacement 4009
Remove Engine 4009
Remove Transmission 4034
Remove Engine and Transmission 4037
Install Engine 4040
Install Transmission 4044
Install Engine and Transmission 4045
Electronic Throttle Replacement 4048
Cummins 4 5L Diesel Engine With Electronic Throttle 4049
Remove 4049
Install 4049
Pull Actuator Linkage Adjustment 4054
Low Idle Adjustment 4054
Throttle Pedal and Cable Adjustment 4054
Cummins 4 5L Diesel Engine 4055
Exhaust System Repair 4056
GM 4 3L Engine for Lift Truck Models GLP60VX, GLP70VX (GP/GLP135VX, GP/GLP155VX) (C878, D878) 4057
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909) 4057
Cummins QSB 3 3L Engine for Lift Truck Models GDP60VX, GDP70VX (GDP135VX, GDP155VX) (C878, D878), GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 4057
Remove 4057
Inspect 4059
Install 4059
Cummins 4 5L Diesel Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 4059
Remove 4059
Inspect 4061
Install 4061
Cooling System 4061
Description 4061
Hydraulic Filter Assembly Repair 4061
Remove 4062
Install 4062
Fuel and Hydraulic Tanks Repair 4064
Inspect 4064
Clean 4064
Steam Method of Cleaning 4064
Chemical Solution Method of Cleaning 4065
Additional Preparations for Repair 4065
Small Leaks, Repair 4066
Large Leaks, Repair 4066
Preparations for Use After Repair 4066
Safety Labels 4066
524288884 8000YRM1322 (12 2018) US EN 4075
General 4081
Serial Number Data 4081
How to Move Disabled Lift Truck 4082
How to Tow Lift Truck 4082
How to Put Lift Truck on Blocks 4083
How to Raise Drive Tires 4083
How to Raise Steering Tires 4083
How to Clean a Lift Truck 4084
Maintenance Schedule 4085
Maintenance Procedures Every 8 Hours or Daily 4106
How to Make Checks With Engine Stopped 4106
Tires and Wheels 4106
Safety Labels 4106
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4107
Operator Restraint System 4107
Emergency Locking Retractor (ELR) 4107
Adjust Seat – Full Suspension 4108
Adjust Seat – Internal Suspension 4110
Seat Plate and Seat Rails 4110
Engine Compartment 4110
Paper Application 4110
Fuel, Oil, and Coolant Leaks, Check 4111
Hydraulic Hoses 4111
Coolant Hoses 4111
Steering Column Gas Cylinder 4111
Transmission 4111
Hydraulic System Oil 4112
Engine Oil 4113
Air Filter 4119
Forks 4119
Remove 4119
Inspect 4119
Install 4120
Adjust 4120
Hang On Sideshift Carriage 4120
How to Make Checks With Engine Running 4122
Indicator Lights, Horn, Fuses, and Relays 4122
Service Brakes 4125
Brake Oil Level 4125
Operation, Check 4125
Parking Brake 4125
Engine Oil Pressure 4126
Cooling System 4126
Steering System 4127
Control Levers and Pedals 4127
Lift System, Operate 4127
Air Filter 4128
Fuel/Water Separator Filter, Cummins 4 5L and QSB 3 3L Diesel Engine 4128
First Service After First 100 Hours of Operation 4128
GM 4 3L Engine Oil and Oil Filter 4128
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 4129
Maintenance Procedures Every 250 Hours or 6 Months 4130
GM 4 3L Engine Oil and Oil Filter Change 4130
Drive Belt 4130
GM 4 3L Engine 4130
Fan and Alternator Drive Belt 4130
Drain Tar From LPG Regulator 4131
Drain Tar From LPG Converter 4132
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine 4133
Maintenance Procedures Every 500 Hours or 6 Months 4134
Hydraulic System Oil 4135
Hydraulic Tank Breather 4138
Inspect 4138
Battery 4138
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 4138
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 4139
Remove 4139
Install 4139
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 4141
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 4142
Controlled Venting 4142
Manual Bleeding 4142
Low Idle Speed Adjustment, Cummins 4 5L Engine Only 4142
Drive Belt 4143
Cummins 4 5L and QSB 3 3L Diesel Engine 4143
Fan and Alternator Drive Belt 4143
Clean Debris From Radiator Core 4144
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 4144
Wet Brake Center Body Oil Level Check 4145
Forks 4147
Mast Lubrication 4148
Header Hose Checks 4152
Lift Chain Lubrication 4152
Tilt Cylinder Lubrication 4152
Master Brake Cylinder Rod End Pin Lubrication 4154
Manual Hydraulic Levers Lubrication 4154
Brake Oil 4154
Tie Rod Lubrication 4155
Parking Brake Adjustment 4156
Maintenance Procedures Every 1000 Hours or 6 Months 4157
Valve Clearance, Check and Adjust 4157
Ignition System 4157
GM 4 3L Engine 4157
LPG Fuel Filter Element Replace, GM 4 3L Engine 4157
Remove 4157
Install 4158
In-Line Filter Replacement, Cummins 4 5L Engine 4158
Remove 4158
Install 4159
Lift Chains Wear Check 4160
Lift Chain Lubrication 4160
Hang On Sideshift Carriage, Check Sliding Surfaces 4161
Steering Axle Spindle Bearings 4164
Control Levers and Pedals 4165
Inspect Engine Electrical System, Connectors 4165
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 4166
Parking Brake Lever Lubrication, Wet Brake Axle 4170
Normal Operating Environment 4170
Heavy Duty or Contaminated Environment 4171
Remove 4171
Clean and Inspect 4172
Install 4172
Maintenance Procedures Every 2000 Hours or Annually 4173
Hydraulic System 4173
Hydraulic Filter Assembly, Replace 4173
Install 4174
Hydraulic Tank Breather, Replace 4175
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 4177
Cooling System Check 4177
Air Filter 4179
Oxygen Sensor, GM 4 3L Engine Equipped With GFI Installed 4180
LPG Regulator Fuel Filter, GM 4 3L Engines with GFI Installed 4181
Remove 4181
Install 4182
Gasoline Fuel Filter 4182
Remove and Replace 4182
LPG Fuel Injector, GM 4 3L Engines with GFI Installed 4183
Gasoline Fuel Injector, GM Engines 4183
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 4183
Forks 4183
Brake Oil (Master Cylinder), Change 4183
Test Regulator PressureLPG/GAS 4184
Check Throttle Shaft for Sticking 4184
Inspect Exhaust Manifold and Piping for Leaks 4184
Transmission Automatic Clutch Calibration 4184
Brake System Accumulator 4184
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 4184
Wheel Bearings 4185
Steer Wheels, Lubrication 4185
Maintenance Procedures Every 4000 Hours or 2 Years 4185
Hydraulic Oil, Replace 4186
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 4188
Safety Procedures When Working Near Mast 4190
Fuel Filter Water Removal 4193
Lift Chain Adjustments 4193
Jump-Starting the Lift Truck 4195
Jump-Starting Using a Battery Charger 4195
Jump-Starting a Lift Truck Using Another Lift Truck 4195
Welding Repairs 4196
Overhead Guard Changes 4196
Wheel and Tire Replacement 4196
General 4196
Pneumatic Tire With Tube, Repair 4196
Remove Wheels From Lift Truck 4196
Remove Tire From Wheel 4197
Install Wheel in Tire 4200
Install Tire on Two-Piece Wheel 4202
Add Air to Pneumatic Tires With Tube 4203
Install the Wheels 4203
Dual Drive Wheels, Install 4204
Pneumatic Tubeless Tire, Repair 4205
Remove Wheels From Lift Truck 4205
Add Air to Pneumatic Tubeless Tire 4210
Wheels, Install 4210
Solid Rubber Tires on Pneumatic Wheels, Change 4210
Adhesives and Sealants 4214
524294873 1300YRM1343 (11 2019) US EN 4217
Transmission Repair 4221
Remove 4221
Torque Converter, Remove 4221
Disassemble 4222
Clean and Inspect 4262
Housings 4262
Oil Seals and Gaskets 4262
Bearings 4263
Gears and Shafts 4263
Assemble 4263
Torque Converter, Install 4301
Install 4302
Control Valve Repair 4303
Remove 4303
Disassemble 4303
Control Valve Assembly 4303
Control Valve Body 4303
Clean 4306
Inspect 4306
Assemble 4306
Control Valve Body 4306
Control Valve Assembly 4306
Install 4307
Torque Specification 4309
524294878 2100YRM1328 (09 2018) US EN 4311
General 4315
Safety Procedures When Working Near Mast 4315
Tilt Cylinder Repair 4317
Remove 4317
Disassemble 4322
Clean 4324
Inspect 4324
Assemble 4324
Install 4326
Tilt Cylinders, Adjust 4328
Tilt Cylinder Leak Check 4329
Lift Cylinder Repair 4330
Remove 4330
Disassemble 4340
Clean 4343
Inspect 4343
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4343
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4343
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4344
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4344
Free-Lift Cylinder Repair 4345
Remove 4345
Disassemble 4351
Clean 4353
Inspect 4353
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4354
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4354
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4354
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4355
Sideshift Cylinder Repair 4356
Remove 4356
Disassemble 4357
Clean 4360
Inspect 4360
Assemble 4361
Install 4362
Bolzoni Sideshift Cylinder Repair 4363
Remove 4363
Disassemble 4363
Clean 4364
Inspect 4364
Assemble 4365
Install 4365
Fork Positioner Cylinder Repair 4365
Remove 4366
Disassemble 4369
Clean 4373
Inspect 4373
Assemble 4374
Install 4375
Lift Cylinder Leak Check 4376
Seal Kit Installation 4376
External Installation (Seal and Back-Up Ring) 4376
Internal Installation (Piston Rod Assembly) 4377
Special Tools 4378
Torque Specifications 4379
For Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4379
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4379
524296605 1400YRM1344 (03 2020) US EN 4383
General 4387
Identification Plate 4387
Drive Axle Removal 4387
Planetary Reduction Gear Repair 4399
Clean and Inspect 4409
Brake Repair 4418
Clean and Inspect 4431
Wet Brake Noise Reduction 4441
General 4441
Adding Additive To Transmission 4442
Differential Repair 4443
Clean and Inspect 4454
Bevel Pinion 4466
Clean and Inspect 4470
Drive Axle Installation 4480
Special Tools 4491
Torque Specifications 4492
524306203 0100YRM1290 (04 2014) US EN 4495
550073240 1900YRM1620 (01 2023) US EN 4599
Proper Flushing after Major Hydraulic Repairs 4605
Introduction 4605
The Phases of Wear 4605
Causes of Hydraulic System Failure 4605
Progression of Contaminant Caused Hydraulic System Failure 4606
Hydraulic System Flushing Techniques 4606
Double Oil and Filter Change 4606
Mechanical Cleaning 4607
Cleaning of Components 4607
How to Clean Tubes and Hoses 4607
Filter Caddy 4607
Start-Up Procedure for Cleaned System 4608
Contaminated Oil Coolers 4608
Additional Filter Caddy Functions 4609
How to Handle Different Fluids 4609
Water Removal Filters 4609
Fluid Conditioning and System Flushing Procedures 4610
Operation of the Filter Caddy 4610
Filter Caddy operation 4610
Fluid Conditioning Procedure 4610
Filter Caddy Start-Up 4611
System Flushing Procedure 4611
Component Cleaning Procedure 4612
Reservoir Cleaning Procedure 4612
Cylinder Cleaning Procedure 4612
Hose and Tube Cleaning Procedure 4612
Valve Cleaning Procedure 4613
Front-End Attachment Cleaning Procedure 4614
System Flushing Procedure 4614
Filter Caddy Start-Up 4615
System Start-Up and Flushing 4615
Reservoir Fluid Cleaning Times 4616
Dealing With Different Fluid Types 4617
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4617
Filter Caddy Maintenance 4617
Servicing the Strainer 4617
DC Motor 4617
Hydraulic Oil Sampling Method and Procedure 4618
Hydraulic Oil Sampling Method 4618
Objective 4618
General Guidelines 4618
Synopsis 4619
Hydraulic Oil Analysis Report Guidelines 4620
Sampling Conditions 4620
Equipment 4620
Sampling Procedure 4621
Hydraulic Oil Sampling 4621
Sample Labeling 4621
Results Documentation 4621
550073240 1900YRM1620 (03 2020) US EN 4623
Proper Flushing after Major Hydraulic Repairs 4627
Introduction 4627
The Phases of Wear 4627
Causes of Hydraulic System Failure 4627
Progression of Contaminant Caused Hydraulic System Failure 4628
Hydraulic System Flushing Techniques 4628
Double Oil and Filter Change 4628
Mechanical Cleaning 4629
Cleaning of Components 4629
How to Clean Tubes and Hoses 4629
Filter Caddy 4629
Start-Up Procedure for Cleaned System 4630
Contaminated Oil Coolers 4630
Additional Filter Caddy Functions 4630
How to Handle Different Fluids 4630
Water Removal Filters 4631
Fluid Conditioning and System Flushing Procedures 4631
Operation of the Filter Caddy 4631
Filter Caddy operation 4631
Fluid Conditioning Procedure 4632
Filter Caddy Start-Up 4632
System Flushing Procedure 4633
Component Cleaning Procedure 4633
Reservoir Cleaning Procedure 4633
Cylinder Cleaning Procedure 4633
Hose and Tube Cleaning Procedure 4634
Valve Cleaning Procedure 4634
Front-End Attachment Cleaning Procedure 4635
System Flushing Procedure 4635
Filter Caddy Start-Up 4636
System Start-Up and Flushing 4636
Reservoir Fluid Cleaning Times 4637
Dealing With Different Fluid Types 4637
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4637
Filter Caddy Maintenance 4638
Servicing the Strainer 4638
DC Motor 4638
Hydraulic Oil Sampling Method and Procedure 4638
Hydraulic Oil Sampling Method 4638
Objective 4638
General Guidelines 4638
Synopsis 4639
Hydraulic Oil Analysis Report Guidelines 4640
Sampling Conditions 4641
Equipment 4641
Sampling Procedure 4641
Hydraulic Oil Sampling 4641
Sample Labeling 4642
Results Documentation 4642