Yale Forklift D878 (GLPGDP60VX, GLPGDP70VX Europe) Service Manual PDF

Yale Forklift D878 (GLPGDP60VX, GLPGDP70VX Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift D878 (GLPGDP60VX, GLPGDP70VX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4468
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift D878 (GLPGDP60VX, GLPGDP70VX Europe) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797 8000YRM0231 (03 2020) UK EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524208014 2200YRM1097 (03 2020) UK EN 43
Series Code / Model Designation Reference Table 47
Description 48
Distributor Ignition (DI) System 48
Crankshaft Position (CKP) Sensor 48
Camshaft Position (CMP) Sensor 48
Ignition Coil and Ignition Control Module (ICM) 48
Secondary Ignition Components 48
Spark Plugs and Wires 49
Spark Plug Wire Inspection 49
Spark Plug Wire Replacement 49
Remove 49
Install 50
Spark Plug Inspection 50
Usage 50
Inspection 50
Visual Inspection 52
Spark Plug Replacement 52
Remove 52
Install 52
Distributor Repair 53
Inspect 53
Overhaul 53
Disassemble 53
Assemble 56
Replace 57
Remove 57
Install Procedure 1 59
Install Procedure 2 60
Ignition Coil Replacement 61
Remove 61
Install 61
Ignition Control Module Replacement 62
Remove 62
Install 62
Starter Replacement 63
Remove 63
Install 66
Sensors and Switches 67
Gas and LPG Trucks 67
Crankshaft Position (CKP) Sensor 67
Remove 67
Install 67
Camshaft Position (CMP) Sensor 68
Remove 68
Install 70
Oil Pressure Sensor 70
Remove 70
Install 71
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 72
Remove 72
Install 72
Engine Coolant Temperature (ECT) Sensor 73
Remove 73
Install 74
Air Flow Restriction Switch 74
Remove 74
Install 75
Specifications and Special Tools 76
524221866 9000YRM1112 (10 2020) UK EN 81
SECTION 9010 Operational Diagnostic Procedures 97
Group 05 – Operational Checkout 99
SECTION 9020 Engine 117
Group 10 – Principles of Operation 127
Group 30 – Observed Symptoms 325
Group 40 – Tests and Adjustments 427
SECTION 9030 Electrical System 459
Group 03 – General Maintenance and Diagnostic Data 483
Group 10 – Principles of Operation 577
Group 20 – Diagnostic Trouble Codes 601
Group 30 – Observed Symptoms 1573
SECTION 9040 Drive Train 1629
Group 10 – Principles of Operation 1633
Group 30 – Observed Symptoms 1689
Group 40 – Tests and Adjustments 1739
SECTION 9050 Hydraulic Systems 1749
Group 10 – Principles of Operation 1753
Group 30 – Observed Symptoms 1811
Group 33 – Observed Symptoms-Gear Pump 1813
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1901
Group 40 – Tests and Adjustments 1945
Group 43 – Tests and Adjustments-Gear Pump 1947
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1971
SECTION 9060 Operators Station 1989
Group 10 – Principles of Operation 1991
SECTION 9070 Front End (Mast) and Chassis 2027
Group 10 – Principles of Operation 2029
Group 30 – Observed Symptoms 2051
SECTION 9080 Supplementary Data 2109
Group 50 – Abbreviations and Acronyms 2111
Group 60 – Special Tools List 2119
Group 70 – Fault Mode Indicator Reference 2129
Group 80 – Supplier Specification Data 2131
524223757 0700YRM1123 (06 2016) UK EN 2135
General 2139
Cooling System Checks 2139
Exhaust Leaks Into Cooling System 2139
Water Flow Restrictions in Radiator 2139
Radiator Hoses 2139
Water Pump 2140
Flushing the Cooling System 2140
Cooling System, Clean 2140
Radiator Replacement 2141
Radiator, Remove GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2142
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2157
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2160
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 2163
Radiator, Install for Lift Truck Models GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2170
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2175
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2177
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2180
Fan Assembly Replacement 2192
Fan Removal 2192
Inspect 2207
Fan Installation 2207
524223764 1600YRM1133 (07 2013) UK EN 2213
toc 2213
Steering Axle 2213
Safety Precautions Maintenance and Repair 2214
General 2217
Steering Axle Assembly Repair 2219
Remove 2219
Disassemble 2220
Clean 2228
Inspect 2228
Assemble 2228
Install 2234
Spindles, Bearings, and Tie Rods Repair 2236
Spindles and Bearings 2236
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2236
Remove 2236
Disassemble 2238
Clean 2239
Inspect 2239
Assemble 2239
Install 2240
Spindles and Bearings 2243
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2243
Remove and Disassemble 2243
Assemble and Install 2244
Tie Rods 2244
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2244
Remove 2244
Install 2245
Tie Rods 2246
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2246
Remove 2246
Install 2252
Steering Cylinder Repair 2252
Remove and Disassemble 2252
Clean and Inspect 2253
Assemble and Install 2253
Torque Specifications 2254
524223766 1900YRM1136 (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) UK 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) UK 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) UK 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) UK 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) UK 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) UK 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
524223780 8000YRM1134 (03 2020) UK EN 3173
Series Code / Model Designation Reference Table 3179
Description 3181
Proc_Cal_001: Service Password Entry 3183
When to Perform 3183
Why Perform 3183
How to Perform 3183
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3184
When to Perform 3184
Calibration Order 3184
Why Perform 3184
How to Perform 3185
Proc_Cal_003: Save and Exit 3186
When to Perform 3186
Why Perform 3186
How to Perform 3186
Proc_Cal_004: Lift Valve Output Threshold 3187
When to Perform 3187
Calibration Order 3187
Why Perform 3187
How to Perform 3188
Proc_Cal_005: Lower Valve Output Threshold 3190
When to Perform 3190
Calibration Order 3190
Why Perform 3190
How to Perform 3190
Proc_Cal_006: Tilt Back Valve Output Threshold 3193
When to Perform 3193
Calibration Order 3193
Why Perform 3193
How to Perform 3193
Proc_Cal_007: Tilt Forward Valve Output Threshold 3196
When to Perform 3196
Calibration Order 3196
Why Perform 3196
How to Perform 3196
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3199
When to Perform 3199
Calibration Order 3199
Why Perform 3199
How to Perform 3199
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3202
When to Perform 3202
Calibration Order 3202
Why Perform 3202
How to Perform 3202
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3205
When to Perform 3205
Calibration Order 3205
Why Perform 3205
How to Perform 3205
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3208
When to Perform 3208
Calibration Order 3208
Why Perform 3208
How to Perform 3208
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3211
When to Perform 3211
Calibration Order 3211
Why Perform 3211
How to Perform 3211
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3214
When to Perform 3214
Calibration Order 3214
Why Perform 3214
How to Perform 3214
Proc_Cal_014: Load Weight Zero Point 3218
When to Perform 3218
Calibration Order 3218
Why Perform 3218
How to Perform 3218
Proc_Cal_015: Loaded Weight Calibration 3220
When to Perform 3220
Calibration Order 3220
Why Perform 3220
How to Perform 3220
Proc_Cal_016: Transmission Valve Calibration 3223
Applicable System/Option 3223
When to Perform 3223
Calibration Order 3223
Why Perform 3223
How to Perform 3223
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3225
Applicable System/Option 3225
When to Perform 3225
Calibration Order 3225
Why Perform 3225
How to Perform 3225
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3227
Applicable System/Option 3227
When to Perform 3227
Calibration Order 3227
Why Perform 3227
How to Perform 3228
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3229
Required Tools 3229
When to Perform 3229
Calibration Order 3229
Why Perform 3230
How to Perform 3230
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3231
When to Perform 3231
Why Perform 3231
How to Perform 3231
Proc_Cal_026: Travel Speed Calibration 3233
When to Perform 3233
Calibration Order 3233
Why Perform 3233
How to Perform 3233
524223780 8000YRM1134 (05 2022) US EN 3237
Series Code / Model Designation Reference Table 3243
Description 3246
Proc_Cal_001: Service Password Entry 3248
When to Perform 3248
Why Perform 3248
How to Perform 3248
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3249
When to Perform 3249
Calibration Order 3249
Why Perform 3249
How to Perform 3249
Proc_Cal_003: Save and Exit 3251
When to Perform 3251
Why Perform 3251
How to Perform 3251
Proc_Cal_004: Lift Valve Output Threshold 3252
When to Perform 3252
Calibration Order 3252
Why Perform 3252
How to Perform 3252
Proc_Cal_005: Lower Valve Output Threshold 3255
When to Perform 3255
Calibration Order 3255
Why Perform 3255
How to Perform 3255
Proc_Cal_006: Tilt Back Valve Output Threshold 3258
When to Perform 3258
Calibration Order 3258
Why Perform 3258
How to Perform 3258
Proc_Cal_007: Tilt Forward Valve Output Threshold 3261
When to Perform 3261
Calibration Order 3261
Why Perform 3261
How to Perform 3261
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3264
When to Perform 3264
Calibration Order 3264
Why Perform 3264
How to Perform 3264
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3267
When to Perform 3267
Calibration Order 3267
Why Perform 3267
How to Perform 3267
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3270
When to Perform 3270
Calibration Order 3270
Why Perform 3270
How to Perform 3270
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3273
When to Perform 3273
Calibration Order 3273
Why Perform 3273
How to Perform 3273
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3276
When to Perform 3276
Calibration Order 3276
Why Perform 3276
How to Perform 3276
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3279
When to Perform 3279
Calibration Order 3279
Why Perform 3279
How to Perform 3279
Proc_Cal_014: Load Weight Zero Point 3282
When to Perform 3282
Calibration Order 3282
Why Perform 3282
How to Perform 3282
Proc_Cal_015: Loaded Weight Calibration 3284
When to Perform 3284
Calibration Order 3284
Why Perform 3284
How to Perform 3284
Proc_Cal_016: Transmission Valve Calibration 3287
Applicable System/Option 3287
When to Perform 3287
Calibration Order 3287
Why Perform 3287
How to Perform 3287
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3289
Applicable System/Option 3289
When to Perform 3289
Calibration Order 3289
Why Perform 3289
How to Perform 3289
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3292
Applicable System/Option 3292
When to Perform 3292
Calibration Order 3292
Why Perform 3292
How to Perform 3292
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3295
Required Tools 3295
When to Perform 3295
Calibration Order 3295
Why Perform 3295
How to Perform 3295
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3297
When to Perform 3297
Why Perform 3297
How to Perform 3297
Proc_Cal_026: Travel Speed Calibration 3299
When to Perform 3299
Calibration Order 3299
Why Perform 3299
How to Perform 3299
524262275 0900YRM1242 (04 2018) UK EN 3303
General 3309
Hoses Replacement 3309
LPG Tank and Bracket Replacement 3310
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) 3310
Remove 3310
Install 3313
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) 3314
Remove 3314
Install 3314
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) 3314
Remove 3314
Install 3316
LPG Tank, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3317
Remove 3317
Install 3319
LPG Tank Bracket, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3319
Remove 3319
Install 3319
High Pressure Fuel Filter Unit Repair 3319
Fuel Filter Element 3320
Remove 3320
Clean/Inspect 3321
Install 3321
Fuel Filter Housing 3321
Remove 3321
Disassemble 3322
Assemble 3322
Install 3322
Electronic Throttle Body Repair 3323
Remove 3323
Clean/Inspect 3324
Install 3324
Fuel Injector Repair 3325
Fuel Rail 3325
Remove for Lift Trucks Built Before January, 2010 3325
Remove for Lift Trucks Built After January, 2010 3327
Install for Lift Trucks Built Before January, 2010 3328
Install for Lift Trucks Built After January, 2010 3329
Fuel Injectors and Adapters 3329
Remove for Lift Trucks Built Before January, 2010 3329
Remove for Lift Trucks Built After January, 2010 3331
Clean 3332
Install for Lift Trucks Built Before January, 2010 3332
Install for Lift Trucks Built After January, 2010 3334
LPG Regulator Repair 3334
LPG Regulator 3334
Remove for Lift Trucks Built Before January, 2010 3334
Remove for Lift Trucks Built After January, 2010 3335
Install for Lift Trucks Built Before January, 2010 3337
Install for Lift Trucks Built After January, 2010 3337
LPG Regulator Fuel Filter 3338
Remove 3338
Install 3339
Lock-Off Solenoid and Cartridge 3339
Remove 3339
Install 3340
Control System 3340
Electronic Control Unit (ECU) and Injector Driver Modules Assembly 3340
Remove 3340
Install 3341
Electronic Control Unit (ECU) 3342
Remove 3342
Install 3342
Injector Driver Modules 3343
Remove 3343
Install 3343
Fuel Pressure Sensor 3344
Remove 3344
Install 3344
Low LPG Pressure Switch 3344
Remove 3344
Install 3345
LPG Pressure Sensor 3345
Remove 3345
Install 3346
Oxygen Sensor 3346
Exhaust System Repair 3347
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 3347
Remove for Lift Trucks Built Before January, 2010 3347
Remove for Lift Trucks Built After January, 2010 3349
Inspect 3351
Install for Lift Trucks Built Before January, 2010 3351
Install for Lift Trucks Built After January, 2010 3351
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) 3352
Remove for Lift Trucks Built Before January, 2010 3352
Remove for Lift Trucks Built After January, 2010 3354
Inspect 3357
Install for Lift Trucks Built Before January, 2010 3357
Install for Lift Trucks Built After January, 2010 3358
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3359
Remove for Lift Trucks Built Before January, 2010 3359
Remove for Lift Trucks Built After January, 2010 3362
Inspect 3363
Install for Lift Trucks Built Before January, 2010 3364
Install for Lift Trucks Built After January, 2010 3364
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3365
Remove for Lift Trucks Built Before January, 2010 3365
Remove for Lift Trucks Built After January, 2010 3368
Inspect 3369
Install for Lift Trucks Built Before January, 2010 3370
Install for Lift Trucks Built After January, 2010 3370
Oxygen Sensor 3371
Remove 3371
Install 3372
LPG Fuel Testing 3372
General 3372
Available Fuel Tests 3372
Composition Test (ASTM D-2163) 3372
Ammonia Test (ASTM D-4490) 3373
Basic Nitrogen Test (ASTM UOP269-90) 3373
Residues Test (ASTM D-2158) 3373
Vapor Pressure Test (ASTM D-2598) 3373
Sulfur Compounds Test (ASTM D-5623) 3373
Methanol Test (ASTM D-4864) 3373
Copper Corrosion (ASTM D-1838) 3373
Where To Send LPG Fuel Samples For Testing 3373
524262279 1800YRM1247 (09 2018) UK EN 3377
General 3381
Dry Brake System 3381
Wet Brake System 3382
Service Brakes Repair (Dry Brake) 3386
Remove and Disassemble 3386
Clean 3388
Inspect 3389
Assemble and Install 3389
Adjust 3393
Parking Brake Repair 3393
Dry Brake System 3394
Remove and Disassembly 3394
Assemble and Install 3396
Wet Brake System 3396
Remove and Install 3397
Assemble and Install 3403
Adjust 3403
Dry Brake System 3403
Wet Brake System 3404
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3404
Master Cylinder Repair 3405
Remove 3405
Disassemble 3410
Clean and Inspect 3411
Assemble 3412
Install and Adjust 3412
Accumulator 3414
Pre-Charge Check 3415
Remove 3416
Install 3418
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3418
Remove 3419
Modulating Brake Valve 3420
Disassemble 3420
Clean and Inspect 3422
Assemble 3422
Accumulator Charge Valve 3423
Disassemble 3423
Clean and Inspect 3425
Assemble 3425
Install 3426
Pressure Checks 3427
Accumulator Charge Valve Check 3427
Accumulator Check 3427
Service Brakes Adjustment (Dry Brake) 3428
Service Brakes Adjustment 3428
Brake System Air Removal 3429
Using Pressure Bleed System 3429
Using Brake Pedal Pressure 3430
Lift Truck Models with Master Cylinder 3430
Lift Truck Models with Modulating Brake Valve 3430
Brake Pedal Adjustment 3431
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) 3431
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3432
Free Pedal Adjustment 3434
Torque Specifications 3435
524265342 4000YRM1250 (09 2018) UK EN 3439
Safety Procedures When Working Near Mast 3445
Fork Replacement 3447
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3447
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3449
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) 3450
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3451
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3452
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) 3453
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3453
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) 3455
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3455
Fixed Carriage Replacement 3457
Remove, Carriage With Hook Forks 3457
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3466
Install, Carriage With Hook Forks 3467
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3467
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3468
Connecting Attachment Hydraulic Quick Disconnect Hoses 3468
Integral Sideshift Carriage Repair 3469
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) 3469
Disassemble 3469
Clean and Inspect 3472
Assemble 3472
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) 3473
Hang On Sideshift Carriage Repair 3473
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) 3473
Disassemble 3485
Clean and Inspect 3494
Assemble 3495
Install 3496
Bolzoni Hang-On Sideshift Carriage Repair 3498
Remove 3498
Disassemble Carriage 3500
Clean and Inspect 3503
Assemble 3503
Install 3506
Fork Positioner 3508
Two-Stage Mast With Limited Free-Lift Repair 3509
Remove 3509
Disassemble 3513
Clean and Inspect 3516
Assemble 3533
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) 3535
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) 3536
Header Hose Alignment 3548
Two-Stage Mast With Full Free-Lift Repair 3558
Remove 3558
Disassemble 3560
Clean and Inspect 3572
Assemble 3573
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) 3575
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) 3578
Header Hose Installation and Adjustment 3582
Installation 3582
Adjustment 3582
Three-Stage Mast With Full Free-Lift Repair 3583
Remove 3583
Disassemble 3585
Clean and Inspect 3615
Assemble 3616
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) 3620
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) 3625
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) 3632
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) 3638
Mast Operation Check 3642
Tilt Cylinder Adjustment 3642
Lift Chains Adjustment 3643
Mast Adjustments 3644
Load Roller Adjustment 3644
Mast Side Kicking Adjustment 3646
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 3647
Carriage Adjustments 3650
524288212 8000YRM1320 (06 2019) UK EN 3653
Lift Truck Lifting Capacity 3657
Counterweight Weights 3657
Tire Sizes 3657
Capacities 3658
Electrical System 3665
Transmission Oil Pressures 3666
Hydraulic System Relief Pressures 3670
Steering System 3671
Stall Speeds (in RPM ±100 rpm) 3672
GM 4 3L Gas GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3672
GM 4 3L LPG GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3672
GM 4 3L Gas GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3672
GM 4 3L LPG GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3672
Cummins 4 5L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879) 3673
Cummins QSB 3 3L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879) 3673
Cummins 4 5L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878) 3673
Cummins QSB 3 3L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3673
Mast Speeds 3674
Tilt Angles 3675
Front End Equipment – Mast Creep 3676
Mast Creep 3676
Engine Specifications 3676
Torque Specifications 3678
Frame 3678
Mast, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3678
Mast, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3679
Hang On Sideshift Carriage With Fork Positioner, Lift Truck Models Manufactured After August, 2012GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3679
Steering System 3679
Transmission 3680
Engine – GM 4 3L 3680
Engine – Cummins 4 5L and QSB 3 3L Diesel 3681
524288879 0100YRM1321 (11 2016) UK EN 3683
General 3687
Description 3688
Side Covers, Seat, Dash, and Hood Replacement 3689
Side Covers 3689
Remove 3689
Install 3689
Seat and Seat Plate 3690
Remove Seat 3690
Remove Seat Plate 3690
Install Seat Plate 3690
Install Seat 3690
Operator Restraint System 3694
Emergency Locking Retractor (ELR) 3694
Seat Plate and Seat Rail Check 3694
Steering Column, Dash, Kick Panel, and Seal Plate 3694
Remove 3694
Install 3697
Hood Support and Door Assembly 3699
Remove 3699
Install 3699
Hood Door Assembly 3704
Remove 3704
Install 3704
Steering Column 3705
Description 3705
Steering Column Repair 3705
Remove 3705
Disassemble 3706
Clean 3709
Inspect 3709
Assemble 3709
Install 3709
LPG Tank and Bracket Assembly 3709
Counterweight Replacement 3710
Remove 3710
Install 3711
Tow Pin, Remove and Install 3713
Overhead Guard Replacement 3713
Remove 3713
Install 3715
Engine Replacement 3715
Remove Engine 3715
Remove Transmission 3740
Remove Engine and Transmission 3743
Install Engine 3746
Install Transmission 3750
Install Engine and Transmission 3751
Electronic Throttle Replacement 3754
Cummins 4 5L Diesel Engine With Electronic Throttle 3755
Remove 3755
Install 3755
Pull Actuator Linkage Adjustment 3760
Low Idle Adjustment 3760
Throttle Pedal and Cable Adjustment 3760
Cummins 4 5L Diesel Engine 3761
Exhaust System Repair 3762
GM 4 3L Engine for Lift Truck Models GLP60VX, GLP70VX (GP/GLP135VX, GP/GLP155VX) (C878, D878) 3763
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909) 3763
Cummins QSB 3 3L Engine for Lift Truck Models GDP60VX, GDP70VX (GDP135VX, GDP155VX) (C878, D878), GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 3763
Remove 3763
Inspect 3765
Install 3765
Cummins 4 5L Diesel Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3765
Remove 3765
Inspect 3767
Install 3767
Cooling System 3767
Description 3767
Hydraulic Filter Assembly Repair 3767
Remove 3768
Install 3768
Fuel and Hydraulic Tanks Repair 3770
Inspect 3770
Clean 3770
Steam Method of Cleaning 3770
Chemical Solution Method of Cleaning 3771
Additional Preparations for Repair 3771
Small Leaks, Repair 3772
Large Leaks, Repair 3772
Preparations for Use After Repair 3772
Safety Labels 3772
524288887 8000YRM1322 (05 2019) UK EN 3781
General 3787
Serial Number Data 3787
How to Move Disabled Lift Truck 3787
How to Tow Lift Truck 3787
How to Put Lift Truck on Blocks 3788
How to Raise Drive Tires 3788
How to Raise Steering Tires 3789
How to Clean a Lift Truck 3790
Maintenance Schedule 3790
Maintenance Procedures Every 8 Hours or Daily 3807
How to Make Checks With Engine Stopped 3807
Tires and Wheels 3807
Safety Labels 3807
Mast, Carriage, Lift Chains, Header Hoses, Attachment 3808
Operator Restraint System 3808
Emergency Locking Retractor (ELR) 3808
Adjust Seat – Full Suspension 3809
Adjust Seat – Internal Suspension 3810
Seat Plate and Seat Rails 3810
Engine Compartment 3811
Paper Application 3811
Fuel, Oil, and Coolant Leaks, Check 3811
Hydraulic Hoses 3812
Coolant Hoses 3812
Steering Column Gas Cylinder 3812
Transmission 3812
Hydraulic System Oil 3812
Engine Oil 3814
Air Filter 3819
Forks 3819
Remove 3819
Inspect 3819
Install 3820
Adjust 3820
Hang On Sideshift Carriage 3820
How to Make Checks With Engine Running 3822
Indicator Lights, Horn, Fuses, and Relays 3822
Service Brakes 3825
Brake Oil Level 3825
Operation, Check 3825
Parking Brake 3825
Engine Oil Pressure 3826
Cooling System 3826
Steering System 3827
Control Levers and Pedals 3827
Lift System, Operate 3827
Air Filter 3828
Fuel/Water Separator Filter, Cummins 4 5L and QSB 3 3L Diesel Engine 3828
First Service After First 100 Hours of Operation 3828
GM 4 3L Engine Oil and Oil Filter 3828
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 3829
Maintenance Procedures Every 500 Hours or 1 Year 3829
Hydraulic System Oil 3829
Hydraulic Tank Breather 3831
Inspect 3831
Battery 3832
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 3832
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 3833
Remove 3833
Install 3833
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 3835
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 3835
Controlled Venting 3835
Manual Bleeding 3835
Low Idle Speed Adjustment, Cummins 4 5L Engine Only 3836
GM 4 3L Engine Oil and Oil Filter 3836
Drain Tar From LPG Regulator 3837
Drain Tar From LPG Converter 3837
Drive Belt 3838
Cummins 4 5L and QSB 3 3L Diesel Engine and GM 4 3L Engine 3838
Fan and Alternator Drive Belt 3838
Clean Debris From Radiator Core 3840
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 3840
Wet Brake Center Body Oil Level Check 3841
Forks 3843
Mast Lubrication 3844
Header Hose Checks 3848
Lift Chain Lubrication 3848
Tilt Cylinder Lubrication 3848
Master Brake Cylinder Rod End Pin Lubrication 3849
Manual Hydraulic Levers Lubrication 3850
Brake Oil 3850
Tie Rod Lubrication 3851
Parking Brake Adjustment 3852
Maintenance Procedures Every 1000 Hours or 1 Year 3853
Valve Clearance, Check and Adjust 3853
Ignition System 3853
GM 4 3L Engine 3853
LPG Fuel Filter Element Replace, GM 4 3L Engine 3853
Remove 3853
Install 3854
In-Line Filter Replacement, Cummins 4 5L Engine 3854
Remove 3854
Install 3855
Lift Chains Wear Check 3856
Lift Chain Lubrication 3856
Hang On Sideshift Carriage, Check Sliding Surfaces 3856
Steering Axle Spindle Bearings 3860
Control Levers and Pedals 3861
Inspect Engine Electrical System, Connectors 3861
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 3862
Parking Brake Lever Lubrication, Wet Brake Axle 3866
Normal Operating Environment 3866
Heavy Duty or Contaminated Environment 3867
Remove 3867
Clean and Inspect 3868
Install 3868
Maintenance Procedures Every 2000 Hours or Annually 3869
Hydraulic System 3869
Hydraulic Filter Assembly, Replace 3869
Install 3870
Hydraulic Tank Breather, Replace 3871
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 3873
Cooling System Check 3873
Air Filter 3875
Oxygen Sensor, GM 4 3L Engine Equipped With GFI Installed 3876
LPG Regulator Fuel Filter, GM 4 3L Engines with GFI Installed 3877
Remove 3877
Install 3878
LPG Fuel Injector, GM 4 3L Engines with GFI Installed 3878
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 3878
Forks 3878
Brake Oil (Master Cylinder), Change 3879
Test Regulator PressureLPG 3879
Check Throttle Shaft for Sticking 3879
Inspect Exhaust Manifold and Piping for Leaks 3880
Transmission Automatic Clutch Calibration 3880
Brake System Accumulator 3880
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 3880
Wheel Bearings 3881
Steer Wheels, Lubrication 3881
Maintenance Procedures Every 4000 Hours or 2 Years 3881
Hydraulic Oil, Replace 3881
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 3883
Safety Procedures When Working Near Mast 3886
Fuel Filter Water Removal 3888
Lift Chain Adjustments 3888
Jump-Starting the Lift Truck 3890
Jump-Starting Using a Battery Charger 3890
Jump-Starting a Lift Truck Using Another Lift Truck 3890
Welding Repairs 3891
Overhead Guard Changes 3891
Wheel and Tire Replacement 3891
General 3891
Pneumatic Tire With Tube, Repair 3891
Remove Wheels From Lift Truck 3891
Remove Tire From Wheel 3892
Install Wheel in Tire 3895
Install Tire on Two-Piece Wheel 3897
Add Air to Pneumatic Tires With Tube 3898
Install the Wheels 3898
Dual Drive Wheels, Install 3898
Pneumatic Tubeless Tire, Repair 3900
Remove Wheels From Lift Truck 3900
Add Air to Pneumatic Tubeless Tire 3905
Wheels, Install 3905
Solid Rubber Tires on Pneumatic Wheels, Change 3905
Snap-On-Tire, Change 3909
Easy Mounting Style Solid Rubber Tires on Pneumatic Wheels, Change 3911
Adhesives and Sealants 3916
524294878 2100YRM1328 (09 2018) UK EN 3921
General 3925
Safety Procedures When Working Near Mast 3925
Tilt Cylinder Repair 3927
Remove 3927
Disassemble 3932
Clean 3934
Inspect 3934
Assemble 3934
Install 3936
Tilt Cylinders, Adjust 3938
Tilt Cylinder Leak Check 3939
Lift Cylinder Repair 3940
Remove 3940
Disassemble 3950
Clean 3953
Inspect 3953
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) 3953
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3953
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) 3954
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3954
Free-Lift Cylinder Repair 3955
Remove 3955
Disassemble 3961
Clean 3963
Inspect 3963
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) 3964
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3964
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) 3964
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3965
Sideshift Cylinder Repair 3966
Remove 3966
Disassemble 3967
Clean 3970
Inspect 3970
Assemble 3971
Install 3972
Bolzoni Sideshift Cylinder Repair 3973
Remove 3973
Disassemble 3973
Clean 3974
Inspect 3974
Assemble 3975
Install 3975
Fork Positioner Cylinder Repair 3975
Remove 3976
Disassemble 3979
Clean 3983
Inspect 3983
Assemble 3984
Install 3985
Lift Cylinder Leak Check 3986
Seal Kit Installation 3986
External Installation (Seal and Back-Up Ring) 3986
Internal Installation (Piston Rod Assembly) 3987
Special Tools 3988
Torque Specifications 3989
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) 3989
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3989
524296605 1400YRM1344 (03 2020) UK EN 3993
General 3997
Identification Plate 3997
Drive Axle Removal 3997
Planetary Reduction Gear Repair 4009
Clean and Inspect 4019
Brake Repair 4028
Clean and Inspect 4041
Wet Brake Noise Reduction 4051
General 4051
Adding Additive To Transmission 4052
Differential Repair 4053
Clean and Inspect 4064
Bevel Pinion 4076
Clean and Inspect 4080
Drive Axle Installation 4090
Special Tools 4101
Torque Specifications 4102
524306203 0100YRM1290 (04 2014) UK EN 4105
524329117 8000YRM1387 (03 2020) UK EN 4209
General Information About Diagrams and Schematics 4213
Symbol Definitions 4213
Diagrams Manual Applications 4214
Diagrams and Schematics 4216
550001092 8000YRM1409 (03 2020) UK EN 4281
General Information About Diagrams and Schematics 4285
Symbol Definitions 4285
Diagrams Manual Applications 4286
Diagrams and Schematics 4288
550043871 0900YRM1556 (04 2018) UK EN 4369
General 4373
LPG Tank and Bracket 4373
LPG Tank, Lift Truck Models GLC40-55VX; GLC55SVX; GLC080-120VX; GLC080-100VXBCS; GLC120SVX; GLC120VXPRS) (E818, F818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080-120VX) (G813, H813, J813, K813), and GLC60-70VX (GLC135-155VX) (D879, E879, F879) 4373
Remove 4373
Install 4381
LPG Tank Bracket, Lift Truck Models GLC40-55VX; GLC55SVX (GLC080-120VX; GLC080-100VXBCS, GLC120SVX; GLC120VXPRS) (E818, F818), GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (G813, H813, J813, K813), and GLC60-70VX (GLC135-155VX) (D879, E879, F879) 4382
Remove 4382
Install 4384
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4384
Remove 4384
Install 4386
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4386
Remove 4386
Install 4386
LPG Tank Bracket Alignment Pin, Lift Truck Models GLC40-55VX; GLC55SVX (GLC080-120VX; GLC080-100VXBCS, GLC120SVX; GLC120VXPRS) (E818, F818), GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (F813, G813, H813, J813, K813), and GLC60-70VX (GLC135-155VX) (D879, E879, F879) 4387
Remove 4387
Install 4389
Fuel Filter Unit 4389
Fuel Filter Element 4390
Remove 4390
Clean and Inspect 4390
Install 4391
Fuel Filter Housing with LP Vapor Sensor 4391
Remove 4391
Disassemble 4393
Clean and Inspect 4394
Assemble 4394
Install 4395
Throttle Body 4396
Remove 4396
Clean 4400
Install 4400
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 4401
Remove 4401
Install 4402
Control System 4402
Engine Control Unit (ECU) 4403
Remove 4403
Install 4404
Low Pressure Switch 4404
Remove 4404
Install 4404
Low Fuel Sensor 4405
Remove 4405
Install 4405
LP Converter 4406
Remove and Disassemble 4406
Assemble and Install 4407
LPG Lock-Off 4407
Remove 4408
Install 4409
Exhaust System 4410
Counterweight Exhaust 4410
Remove and Disassemble 4410
Inspect 4412
Assemble and Install 4412
Overhead Exhaust 4413
Remove and Disassemble 4413
Inspect 4415
Assemble and Install 4415
Exhaust Manifold 4415
Remove 4415
Install 4417
Oxygen (HEGO) Sensor 4417
Remove 4417
Install 4417
LPG Fuel Testing 4418
General 4418
Available Fuel Tests 4418
Composition Test (ASTM D-2163) 4418
Ammonia Test (ASTM D-4490) 4418
Basic Nitrogen Test (ASTM UOP269-90) 4418
Residues Test (ASTM D-2158) 4418
Vapor Pressure Test (ASTM D-2598) 4418
Sulfur Compounds Test (ASTM D-5623) 4418
Methanol Test (ASTM D-4864) 4419
Copper Corrosion (ASTM D-1838) 4419
Where To Send LPG Fuel Samples For Testing 4419
550073240 1900YRM1620 (01 2023) US EN 4423
Proper Flushing after Major Hydraulic Repairs 4429
Introduction 4429
The Phases of Wear 4429
Causes of Hydraulic System Failure 4429
Progression of Contaminant Caused Hydraulic System Failure 4430
Hydraulic System Flushing Techniques 4430
Double Oil and Filter Change 4430
Mechanical Cleaning 4431
Cleaning of Components 4431
How to Clean Tubes and Hoses 4431
Filter Caddy 4431
Start-Up Procedure for Cleaned System 4432
Contaminated Oil Coolers 4432
Additional Filter Caddy Functions 4433
How to Handle Different Fluids 4433
Water Removal Filters 4433
Fluid Conditioning and System Flushing Procedures 4434
Operation of the Filter Caddy 4434
Filter Caddy operation 4434
Fluid Conditioning Procedure 4434
Filter Caddy Start-Up 4435
System Flushing Procedure 4435
Component Cleaning Procedure 4436
Reservoir Cleaning Procedure 4436
Cylinder Cleaning Procedure 4436
Hose and Tube Cleaning Procedure 4436
Valve Cleaning Procedure 4437
Front-End Attachment Cleaning Procedure 4438
System Flushing Procedure 4438
Filter Caddy Start-Up 4439
System Start-Up and Flushing 4439
Reservoir Fluid Cleaning Times 4440
Dealing With Different Fluid Types 4441
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4441
Filter Caddy Maintenance 4441
Servicing the Strainer 4441
DC Motor 4441
Hydraulic Oil Sampling Method and Procedure 4442
Hydraulic Oil Sampling Method 4442
Objective 4442
General Guidelines 4442
Synopsis 4443
Hydraulic Oil Analysis Report Guidelines 4444
Sampling Conditions 4444
Equipment 4444
Sampling Procedure 4445
Hydraulic Oil Sampling 4445
Sample Labeling 4445
Results Documentation 4445
550073240 1900YRM1620 (03 2020) UK EN 4447
Proper Flushing after Major Hydraulic Repairs 4451
Introduction 4451
The Phases of Wear 4451
Causes of Hydraulic System Failure 4451
Progression of Contaminant Caused Hydraulic System Failure 4452
Hydraulic System Flushing Techniques 4452
Double Oil and Filter Change 4452
Mechanical Cleaning 4453
Cleaning of Components 4453
How to Clean Tubes and Hoses 4453
Filter Caddy 4453
Start-Up Procedure for Cleaned System 4454
Contaminated Oil Coolers 4454
Additional Filter Caddy Functions 4454
How to Handle Different Fluids 4454
Water Removal Filters 4455
Fluid Conditioning and System Flushing Procedures 4455
Operation of the Filter Caddy 4455
Filter Caddy operation 4455
Fluid Conditioning Procedure 4456
Filter Caddy Start-Up 4456
System Flushing Procedure 4457
Component Cleaning Procedure 4457
Reservoir Cleaning Procedure 4457
Cylinder Cleaning Procedure 4457
Hose and Tube Cleaning Procedure 4458
Valve Cleaning Procedure 4458
Front-End Attachment Cleaning Procedure 4459
System Flushing Procedure 4459
Filter Caddy Start-Up 4460
System Start-Up and Flushing 4460
Reservoir Fluid Cleaning Times 4461
Dealing With Different Fluid Types 4461
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4461
Filter Caddy Maintenance 4462
Servicing the Strainer 4462
DC Motor 4462
Hydraulic Oil Sampling Method and Procedure 4462
Hydraulic Oil Sampling Method 4462
Objective 4462
General Guidelines 4462
Synopsis 4463
Hydraulic Oil Analysis Report Guidelines 4464
Sampling Conditions 4465
Equipment 4465
Sampling Procedure 4465
Hydraulic Oil Sampling 4465
Sample Labeling 4466
Results Documentation 4466