Yale Forklift D878 (GPGLPGDP135 VX, GPGLPGDP155VX) Service Manual PDF

Yale Forklift D878 (GPGLPGDP135 VX, GPGLPGDP155VX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift D878 (GPGLPGDP135 VX, GPGLPGDP155VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4758
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift D878 (GPGLPGDP135 VX, GPGLPGDP155VX) 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
524223780 8000YRM1134 (03 2020) US 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) US 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
524262276 0900YRM1244 (06 2012) US EN 3377
toc 3377
Gasoline Fuel System 3377
Safety Precautions Maintenance and Repair 3378
General 3381
Electronic Throttle Body Repair 3381
Electronic Throttle Body 3381
Remove 3381
Clean/Inspect 3381
Install 3382
Fuel System Repair 3383
Before Repair Procedure 3383
After Repair Procedure 3383
Fuel Leakage Check for Lift Trucks Built Before January, 2010 3383
Fuel Leakage Check for Lift Trucks Built After January, 2010 3384
Fuel Line Pressure Check 3386
Fuel Injector Repair 3387
Remove 3387
Install 3397
Control System 3398
Electronic Control Unit (ECU) 3398
Remove for Lift Trucks Built Before January, 2010 3398
Remove for Lift Trucks Built After January, 2010 3399
Install for Lift Trucks Built Before January, 2010 3400
Install for Lift Trucks Built After January, 2010 3401
Exhaust System Repair 3402
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; ( 3402
Remove for Lift Trucks Built Before January, 2010 3402
Remove for Lift Trucks Built After January, 2010 3404
Inspect 3404
Install for Lift Trucks Built Before January, 2010 3406
Install for Lift Trucks Built After January, 2010 3406
GM 4 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45 3407
Remove for Lift Trucks Built Before January, 2010 3407
Remove for Lift Trucks Built After January, 2010 3409
Inspect 3411
Install for Lift Trucks Built Before January, 2010 3411
Install for Lift Trucks Built After January, 2010 3412
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (G 3413
Remove for Lift Trucks Built Before January, 2010 3413
Remove for Lift Trucks Built After January, 2010 3415
Inspect 3417
Install for Lift Trucks Built Before January, 2010 3417
Install for Lift Trucks Built After January, 2010 3418
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (G 3418
Remove for Lift Trucks Built Before January, 2010 3418
Remove for Lift Trucks Built After January, 2010 3421
Inspect 3421
Install for Lift Trucks Built Before January, 2010 3423
Install for Lift Trucks Built After January, 2010 3423
Oxygen Sensor 3424
Remove 3424
Install 3424
524262279 1800YRM1247 (09 2018) US EN 3427
General 3431
Dry Brake System 3431
Wet Brake System 3432
Service Brakes Repair (Dry Brake) 3436
Remove and Disassemble 3436
Clean 3438
Inspect 3439
Assemble and Install 3439
Adjust 3443
Parking Brake Repair 3443
Dry Brake System 3444
Remove and Disassembly 3444
Assemble and Install 3446
Wet Brake System 3446
Remove and Install 3447
Assemble and Install 3453
Adjust 3453
Dry Brake System 3453
Wet Brake System 3454
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3454
Master Cylinder Repair 3455
Remove 3455
Disassemble 3460
Clean and Inspect 3461
Assemble 3462
Install and Adjust 3462
Accumulator 3464
Pre-Charge Check 3465
Remove 3466
Install 3468
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3468
Remove 3469
Modulating Brake Valve 3470
Disassemble 3470
Clean and Inspect 3472
Assemble 3472
Accumulator Charge Valve 3473
Disassemble 3473
Clean and Inspect 3475
Assemble 3475
Install 3476
Pressure Checks 3477
Accumulator Charge Valve Check 3477
Accumulator Check 3477
Service Brakes Adjustment (Dry Brake) 3478
Service Brakes Adjustment 3478
Brake System Air Removal 3479
Using Pressure Bleed System 3479
Using Brake Pedal Pressure 3480
Lift Truck Models with Master Cylinder 3480
Lift Truck Models with Modulating Brake Valve 3480
Brake Pedal Adjustment 3481
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) 3481
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3482
Free Pedal Adjustment 3484
Torque Specifications 3485
524265342 4000YRM1250 (09 2018) US EN 3489
Safety Procedures When Working Near Mast 3495
Fork Replacement 3497
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3497
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3499
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) 3500
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3501
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3502
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) 3503
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3503
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) 3505
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3505
Fixed Carriage Replacement 3507
Remove, Carriage With Hook Forks 3507
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3516
Install, Carriage With Hook Forks 3517
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3517
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3518
Connecting Attachment Hydraulic Quick Disconnect Hoses 3518
Integral Sideshift Carriage Repair 3519
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) 3519
Disassemble 3519
Clean and Inspect 3522
Assemble 3522
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) 3523
Hang On Sideshift Carriage Repair 3523
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) 3523
Disassemble 3535
Clean and Inspect 3544
Assemble 3545
Install 3546
Bolzoni Hang-On Sideshift Carriage Repair 3548
Remove 3548
Disassemble Carriage 3550
Clean and Inspect 3553
Assemble 3553
Install 3556
Fork Positioner 3558
Two-Stage Mast With Limited Free-Lift Repair 3559
Remove 3559
Disassemble 3563
Clean and Inspect 3566
Assemble 3583
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) 3585
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) 3586
Header Hose Alignment 3598
Two-Stage Mast With Full Free-Lift Repair 3608
Remove 3608
Disassemble 3610
Clean and Inspect 3622
Assemble 3623
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) 3625
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) 3628
Header Hose Installation and Adjustment 3632
Installation 3632
Adjustment 3632
Three-Stage Mast With Full Free-Lift Repair 3633
Remove 3633
Disassemble 3635
Clean and Inspect 3665
Assemble 3666
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) 3670
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) 3675
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) 3682
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) 3688
Mast Operation Check 3692
Tilt Cylinder Adjustment 3692
Lift Chains Adjustment 3693
Mast Adjustments 3694
Load Roller Adjustment 3694
Mast Side Kicking Adjustment 3696
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 3697
Carriage Adjustments 3700
524288194 1300YRM1317 (03 2020) UK EN 3703
Transmission Repair 3707
Remove 3707
Torque Converter, Remove 3707
Disassemble 3708
Clean and Inspect 3757
Housings 3757
Oil Seals and Gaskets 3757
Bearings 3757
Gears and Shafts 3758
Assemble 3758
Torque Converter, Install 3799
Install 3800
Control Valve Repair 3801
Remove 3801
Disassemble 3801
Clean 3803
Inspect 3803
Assemble 3803
Install 3804
Torque Specification 3805
524288194 1300YRM1317 (03 2020) US EN 3807
Transmission Repair 3811
Remove 3811
Torque Converter, Remove 3811
Disassemble 3812
Clean and Inspect 3861
Housings 3861
Oil Seals and Gaskets 3861
Bearings 3861
Gears and Shafts 3862
Assemble 3862
Torque Converter, Install 3903
Install 3904
Control Valve Repair 3905
Remove 3905
Disassemble 3905
Clean 3907
Inspect 3907
Assemble 3907
Install 3908
Torque Specification 3909
524288212 8000YRM1320 (06 2019) US EN 3911
Lift Truck Lifting Capacity 3915
Counterweight Weights 3915
Tire Sizes 3915
Capacities 3916
Electrical System 3923
Transmission Oil Pressures 3924
Hydraulic System Relief Pressures 3928
Steering System 3929
Stall Speeds (in RPM ±100 rpm) 3930
GM 4 3L Gas GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3930
GM 4 3L LPG GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3930
GM 4 3L Gas GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3930
GM 4 3L LPG GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3930
Cummins 4 5L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879) 3931
Cummins QSB 3 3L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879) 3931
Cummins 4 5L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878) 3931
Cummins QSB 3 3L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3931
Mast Speeds 3932
Tilt Angles 3933
Front End Equipment – Mast Creep 3934
Mast Creep 3934
Engine Specifications 3934
Torque Specifications 3936
Frame 3936
Mast, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3936
Mast, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3937
Hang On Sideshift Carriage With Fork Positioner, Lift Truck Models Manufactured After August, 2012GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3937
Steering System 3937
Transmission 3938
Engine – GM 4 3L 3938
Engine – Cummins 4 5L and QSB 3 3L Diesel 3939
524288879 0100YRM1321 (11 2016) US EN 3941
General 3945
Description 3946
Side Covers, Seat, Dash, and Hood Replacement 3947
Side Covers 3947
Remove 3947
Install 3947
Seat and Seat Plate 3948
Remove Seat 3948
Remove Seat Plate 3948
Install Seat Plate 3948
Install Seat 3948
Operator Restraint System 3952
Emergency Locking Retractor (ELR) 3952
Seat Plate and Seat Rail Check 3952
Steering Column, Dash, Kick Panel, and Seal Plate 3952
Remove 3952
Install 3955
Hood Support and Door Assembly 3957
Remove 3957
Install 3957
Hood Door Assembly 3962
Remove 3962
Install 3962
Steering Column 3963
Description 3963
Steering Column Repair 3963
Remove 3963
Disassemble 3964
Clean 3967
Inspect 3967
Assemble 3967
Install 3967
LPG Tank and Bracket Assembly 3967
Counterweight Replacement 3968
Remove 3968
Install 3969
Tow Pin, Remove and Install 3971
Overhead Guard Replacement 3971
Remove 3971
Install 3973
Engine Replacement 3973
Remove Engine 3973
Remove Transmission 3998
Remove Engine and Transmission 4001
Install Engine 4004
Install Transmission 4008
Install Engine and Transmission 4009
Electronic Throttle Replacement 4012
Cummins 4 5L Diesel Engine With Electronic Throttle 4013
Remove 4013
Install 4013
Pull Actuator Linkage Adjustment 4018
Low Idle Adjustment 4018
Throttle Pedal and Cable Adjustment 4018
Cummins 4 5L Diesel Engine 4019
Exhaust System Repair 4020
GM 4 3L Engine for Lift Truck Models GLP60VX, GLP70VX (GP/GLP135VX, GP/GLP155VX) (C878, D878) 4021
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909) 4021
Cummins QSB 3 3L Engine for Lift Truck Models GDP60VX, GDP70VX (GDP135VX, GDP155VX) (C878, D878), GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 4021
Remove 4021
Inspect 4023
Install 4023
Cummins 4 5L Diesel Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 4023
Remove 4023
Inspect 4025
Install 4025
Cooling System 4025
Description 4025
Hydraulic Filter Assembly Repair 4025
Remove 4026
Install 4026
Fuel and Hydraulic Tanks Repair 4028
Inspect 4028
Clean 4028
Steam Method of Cleaning 4028
Chemical Solution Method of Cleaning 4029
Additional Preparations for Repair 4029
Small Leaks, Repair 4030
Large Leaks, Repair 4030
Preparations for Use After Repair 4030
Safety Labels 4030
524288884 8000YRM1322 (12 2018) US EN 4039
General 4045
Serial Number Data 4045
How to Move Disabled Lift Truck 4046
How to Tow Lift Truck 4046
How to Put Lift Truck on Blocks 4047
How to Raise Drive Tires 4047
How to Raise Steering Tires 4047
How to Clean a Lift Truck 4048
Maintenance Schedule 4049
Maintenance Procedures Every 8 Hours or Daily 4070
How to Make Checks With Engine Stopped 4070
Tires and Wheels 4070
Safety Labels 4070
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4071
Operator Restraint System 4071
Emergency Locking Retractor (ELR) 4071
Adjust Seat – Full Suspension 4072
Adjust Seat – Internal Suspension 4074
Seat Plate and Seat Rails 4074
Engine Compartment 4074
Paper Application 4074
Fuel, Oil, and Coolant Leaks, Check 4075
Hydraulic Hoses 4075
Coolant Hoses 4075
Steering Column Gas Cylinder 4075
Transmission 4075
Hydraulic System Oil 4076
Engine Oil 4077
Air Filter 4083
Forks 4083
Remove 4083
Inspect 4083
Install 4084
Adjust 4084
Hang On Sideshift Carriage 4084
How to Make Checks With Engine Running 4086
Indicator Lights, Horn, Fuses, and Relays 4086
Service Brakes 4089
Brake Oil Level 4089
Operation, Check 4089
Parking Brake 4089
Engine Oil Pressure 4090
Cooling System 4090
Steering System 4091
Control Levers and Pedals 4091
Lift System, Operate 4091
Air Filter 4092
Fuel/Water Separator Filter, Cummins 4 5L and QSB 3 3L Diesel Engine 4092
First Service After First 100 Hours of Operation 4092
GM 4 3L Engine Oil and Oil Filter 4092
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 4093
Maintenance Procedures Every 250 Hours or 6 Months 4094
GM 4 3L Engine Oil and Oil Filter Change 4094
Drive Belt 4094
GM 4 3L Engine 4094
Fan and Alternator Drive Belt 4094
Drain Tar From LPG Regulator 4095
Drain Tar From LPG Converter 4096
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine 4097
Maintenance Procedures Every 500 Hours or 6 Months 4098
Hydraulic System Oil 4099
Hydraulic Tank Breather 4102
Inspect 4102
Battery 4102
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 4102
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 4103
Remove 4103
Install 4103
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 4105
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 4106
Controlled Venting 4106
Manual Bleeding 4106
Low Idle Speed Adjustment, Cummins 4 5L Engine Only 4106
Drive Belt 4107
Cummins 4 5L and QSB 3 3L Diesel Engine 4107
Fan and Alternator Drive Belt 4107
Clean Debris From Radiator Core 4108
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 4108
Wet Brake Center Body Oil Level Check 4109
Forks 4111
Mast Lubrication 4112
Header Hose Checks 4116
Lift Chain Lubrication 4116
Tilt Cylinder Lubrication 4116
Master Brake Cylinder Rod End Pin Lubrication 4118
Manual Hydraulic Levers Lubrication 4118
Brake Oil 4118
Tie Rod Lubrication 4119
Parking Brake Adjustment 4120
Maintenance Procedures Every 1000 Hours or 6 Months 4121
Valve Clearance, Check and Adjust 4121
Ignition System 4121
GM 4 3L Engine 4121
LPG Fuel Filter Element Replace, GM 4 3L Engine 4121
Remove 4121
Install 4122
In-Line Filter Replacement, Cummins 4 5L Engine 4122
Remove 4122
Install 4123
Lift Chains Wear Check 4124
Lift Chain Lubrication 4124
Hang On Sideshift Carriage, Check Sliding Surfaces 4125
Steering Axle Spindle Bearings 4128
Control Levers and Pedals 4129
Inspect Engine Electrical System, Connectors 4129
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 4130
Parking Brake Lever Lubrication, Wet Brake Axle 4134
Normal Operating Environment 4134
Heavy Duty or Contaminated Environment 4135
Remove 4135
Clean and Inspect 4136
Install 4136
Maintenance Procedures Every 2000 Hours or Annually 4137
Hydraulic System 4137
Hydraulic Filter Assembly, Replace 4137
Install 4138
Hydraulic Tank Breather, Replace 4139
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 4141
Cooling System Check 4141
Air Filter 4143
Oxygen Sensor, GM 4 3L Engine Equipped With GFI Installed 4144
LPG Regulator Fuel Filter, GM 4 3L Engines with GFI Installed 4145
Remove 4145
Install 4146
Gasoline Fuel Filter 4146
Remove and Replace 4146
LPG Fuel Injector, GM 4 3L Engines with GFI Installed 4147
Gasoline Fuel Injector, GM Engines 4147
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 4147
Forks 4147
Brake Oil (Master Cylinder), Change 4147
Test Regulator PressureLPG/GAS 4148
Check Throttle Shaft for Sticking 4148
Inspect Exhaust Manifold and Piping for Leaks 4148
Transmission Automatic Clutch Calibration 4148
Brake System Accumulator 4148
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 4148
Wheel Bearings 4149
Steer Wheels, Lubrication 4149
Maintenance Procedures Every 4000 Hours or 2 Years 4149
Hydraulic Oil, Replace 4150
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 4152
Safety Procedures When Working Near Mast 4154
Fuel Filter Water Removal 4157
Lift Chain Adjustments 4157
Jump-Starting the Lift Truck 4159
Jump-Starting Using a Battery Charger 4159
Jump-Starting a Lift Truck Using Another Lift Truck 4159
Welding Repairs 4160
Overhead Guard Changes 4160
Wheel and Tire Replacement 4160
General 4160
Pneumatic Tire With Tube, Repair 4160
Remove Wheels From Lift Truck 4160
Remove Tire From Wheel 4161
Install Wheel in Tire 4164
Install Tire on Two-Piece Wheel 4166
Add Air to Pneumatic Tires With Tube 4167
Install the Wheels 4167
Dual Drive Wheels, Install 4168
Pneumatic Tubeless Tire, Repair 4169
Remove Wheels From Lift Truck 4169
Add Air to Pneumatic Tubeless Tire 4174
Wheels, Install 4174
Solid Rubber Tires on Pneumatic Wheels, Change 4174
Adhesives and Sealants 4178
524294878 2100YRM1328 (09 2018) US EN 4181
General 4185
Safety Procedures When Working Near Mast 4185
Tilt Cylinder Repair 4187
Remove 4187
Disassemble 4192
Clean 4194
Inspect 4194
Assemble 4194
Install 4196
Tilt Cylinders, Adjust 4198
Tilt Cylinder Leak Check 4199
Lift Cylinder Repair 4200
Remove 4200
Disassemble 4210
Clean 4213
Inspect 4213
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) 4213
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4213
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) 4214
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4214
Free-Lift Cylinder Repair 4215
Remove 4215
Disassemble 4221
Clean 4223
Inspect 4223
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) 4224
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4224
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) 4224
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4225
Sideshift Cylinder Repair 4226
Remove 4226
Disassemble 4227
Clean 4230
Inspect 4230
Assemble 4231
Install 4232
Bolzoni Sideshift Cylinder Repair 4233
Remove 4233
Disassemble 4233
Clean 4234
Inspect 4234
Assemble 4235
Install 4235
Fork Positioner Cylinder Repair 4235
Remove 4236
Disassemble 4239
Clean 4243
Inspect 4243
Assemble 4244
Install 4245
Lift Cylinder Leak Check 4246
Seal Kit Installation 4246
External Installation (Seal and Back-Up Ring) 4246
Internal Installation (Piston Rod Assembly) 4247
Special Tools 4248
Torque Specifications 4249
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) 4249
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4249
524296605 1400YRM1344 (03 2020) US EN 4253
General 4257
Identification Plate 4257
Drive Axle Removal 4257
Planetary Reduction Gear Repair 4269
Clean and Inspect 4279
Brake Repair 4288
Clean and Inspect 4301
Wet Brake Noise Reduction 4311
General 4311
Adding Additive To Transmission 4312
Differential Repair 4313
Clean and Inspect 4324
Bevel Pinion 4336
Clean and Inspect 4340
Drive Axle Installation 4350
Special Tools 4361
Torque Specifications 4362
524306203 0100YRM1290 (04 2014) US EN 4365
524329117 8000YRM1387 (03 2020) US EN 4469
General Information About Diagrams and Schematics 4473
Symbol Definitions 4473
Diagrams Manual Applications 4474
Diagrams and Schematics 4476
550001092 8000YRM1409 (03 2020) US EN 4541
General Information About Diagrams and Schematics 4545
Symbol Definitions 4545
Diagrams Manual Applications 4546
Diagrams and Schematics 4548
550043871 0900YRM1556 (04 2018) US EN 4629
General 4633
LPG Tank and Bracket 4633
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) 4633
Remove 4633
Install 4641
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) 4642
Remove 4642
Install 4644
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4644
Remove 4644
Install 4646
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4646
Remove 4646
Install 4646
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) 4647
Remove 4647
Install 4649
Fuel Filter Unit 4649
Fuel Filter Element 4650
Remove 4650
Clean and Inspect 4650
Install 4651
Fuel Filter Housing with LP Vapor Sensor 4651
Remove 4651
Disassemble 4653
Clean and Inspect 4654
Assemble 4654
Install 4655
Throttle Body 4656
Remove 4656
Clean 4660
Install 4660
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 4661
Remove 4661
Install 4662
Control System 4662
Engine Control Unit (ECU) 4663
Remove 4663
Install 4664
Low Pressure Switch 4664
Remove 4664
Install 4664
Low Fuel Sensor 4665
Remove 4665
Install 4665
LP Converter 4666
Remove and Disassemble 4666
Assemble and Install 4667
LPG Lock-Off 4667
Remove 4668
Install 4669
Exhaust System 4670
Counterweight Exhaust 4670
Remove and Disassemble 4670
Inspect 4672
Assemble and Install 4672
Overhead Exhaust 4673
Remove and Disassemble 4673
Inspect 4675
Assemble and Install 4675
Exhaust Manifold 4675
Remove 4675
Install 4677
Oxygen (HEGO) Sensor 4677
Remove 4677
Install 4677
LPG Fuel Testing 4678
General 4678
Available Fuel Tests 4678
Composition Test (ASTM D-2163) 4678
Ammonia Test (ASTM D-4490) 4678
Basic Nitrogen Test (ASTM UOP269-90) 4678
Residues Test (ASTM D-2158) 4678
Vapor Pressure Test (ASTM D-2598) 4678
Sulfur Compounds Test (ASTM D-5623) 4678
Methanol Test (ASTM D-4864) 4679
Copper Corrosion (ASTM D-1838) 4679
Where To Send LPG Fuel Samples For Testing 4679
550048401 0900YRM1570 (03 2015) US EN 4683
550073240 1900YRM1620 (01 2023) US EN 4713
Proper Flushing after Major Hydraulic Repairs 4719
Introduction 4719
The Phases of Wear 4719
Causes of Hydraulic System Failure 4719
Progression of Contaminant Caused Hydraulic System Failure 4720
Hydraulic System Flushing Techniques 4720
Double Oil and Filter Change 4720
Mechanical Cleaning 4721
Cleaning of Components 4721
How to Clean Tubes and Hoses 4721
Filter Caddy 4721
Start-Up Procedure for Cleaned System 4722
Contaminated Oil Coolers 4722
Additional Filter Caddy Functions 4723
How to Handle Different Fluids 4723
Water Removal Filters 4723
Fluid Conditioning and System Flushing Procedures 4724
Operation of the Filter Caddy 4724
Filter Caddy operation 4724
Fluid Conditioning Procedure 4724
Filter Caddy Start-Up 4725
System Flushing Procedure 4725
Component Cleaning Procedure 4726
Reservoir Cleaning Procedure 4726
Cylinder Cleaning Procedure 4726
Hose and Tube Cleaning Procedure 4726
Valve Cleaning Procedure 4727
Front-End Attachment Cleaning Procedure 4728
System Flushing Procedure 4728
Filter Caddy Start-Up 4729
System Start-Up and Flushing 4729
Reservoir Fluid Cleaning Times 4730
Dealing With Different Fluid Types 4731
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4731
Filter Caddy Maintenance 4731
Servicing the Strainer 4731
DC Motor 4731
Hydraulic Oil Sampling Method and Procedure 4732
Hydraulic Oil Sampling Method 4732
Objective 4732
General Guidelines 4732
Synopsis 4733
Hydraulic Oil Analysis Report Guidelines 4734
Sampling Conditions 4734
Equipment 4734
Sampling Procedure 4735
Hydraulic Oil Sampling 4735
Sample Labeling 4735
Results Documentation 4735
550073240 1900YRM1620 (03 2020) US EN 4737
Proper Flushing after Major Hydraulic Repairs 4741
Introduction 4741
The Phases of Wear 4741
Causes of Hydraulic System Failure 4741
Progression of Contaminant Caused Hydraulic System Failure 4742
Hydraulic System Flushing Techniques 4742
Double Oil and Filter Change 4742
Mechanical Cleaning 4743
Cleaning of Components 4743
How to Clean Tubes and Hoses 4743
Filter Caddy 4743
Start-Up Procedure for Cleaned System 4744
Contaminated Oil Coolers 4744
Additional Filter Caddy Functions 4744
How to Handle Different Fluids 4744
Water Removal Filters 4745
Fluid Conditioning and System Flushing Procedures 4745
Operation of the Filter Caddy 4745
Filter Caddy operation 4745
Fluid Conditioning Procedure 4746
Filter Caddy Start-Up 4746
System Flushing Procedure 4747
Component Cleaning Procedure 4747
Reservoir Cleaning Procedure 4747
Cylinder Cleaning Procedure 4747
Hose and Tube Cleaning Procedure 4748
Valve Cleaning Procedure 4748
Front-End Attachment Cleaning Procedure 4749
System Flushing Procedure 4749
Filter Caddy Start-Up 4750
System Start-Up and Flushing 4750
Reservoir Fluid Cleaning Times 4751
Dealing With Different Fluid Types 4751
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4751
Filter Caddy Maintenance 4752
Servicing the Strainer 4752
DC Motor 4752
Hydraulic Oil Sampling Method and Procedure 4752
Hydraulic Oil Sampling Method 4752
Objective 4752
General Guidelines 4752
Synopsis 4753
Hydraulic Oil Analysis Report Guidelines 4754
Sampling Conditions 4755
Equipment 4755
Sampling Procedure 4755
Hydraulic Oil Sampling 4755
Sample Labeling 4756
Results Documentation 4756