Yale Forklift E878 (GLP60VX, GLP70VX, GDP60VX, GDP70VX Europe) Service Manual PDF

Yale Forklift E878 (GLP60VX, GLP70VX, GDP60VX, GDP70VX Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift E878 (GLP60VX, GLP70VX, GDP60VX, GDP70VX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5240
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift E878 (GLP60VX, GLP70VX, GDP60VX, GDP70VX 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 (11 2017) UK EN 2259
General 2263
Hydraulic Gear Pump Assembly 2264
Variable Displacement Pump Assembly 2265
Single Gear Pump Assembly Repair 2265
Remove 2265
Disassemble 2272
Clean 2272
Inspect 2274
Assemble 2274
Install 2274
Tandem Gear Pump Assembly 2278
Remove 2279
Disassemble 2281
Clean 2283
Inspect 2283
Assemble 2283
Install 2284
Gear Pump Specifications 2284
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2290
Remove 2290
Disassemble 2300
Clean 2303
Inspect 2303
Assemble 2303
Install 2304
63 0 cc/rev – Variable Displacement Pump Repair 2307
Remove 2307
Disassemble 2310
Clean 2310
Inspect 2310
Assemble 2312
Install 2312
Variable Displacement Pump Checks and Adjustments (Single Pump) 2314
Margin Pressure Check 2314
Flow Compensator Adjustment 2315
Pressure Compensator Adjustment 2315
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2316
Variable Displacement Pump Specifications 2319
Torque Specifications 2320
Hydraulic Gear Pump 2321
Variable Displacement Pump 2322
Special Tools 2322
524223767 2000YRM1137 (01 2017) UK EN 2327
General 2333
Electro-Hydraulic Main Control Valve 2334
Description 2334
Remove 2342
Electro-Hydraulic Control Valve Sections 2347
General 2347
Outlet Control Valve Section 2347
Remove 2347
Disassemble 2348
Clean 2350
Inspect 2350
Assemble 2350
Install 2351
Auxiliary Control Valve Sections 2351
Remove 2351
Disassemble 2358
Clean 2359
Inspect 2360
Assemble 2360
Install 2362
Tilt Control Valve Section 2363
Remove 2363
Disassemble 2363
Clean 2369
Inspect 2369
Assemble 2369
Install 2370
Lift/Lower Control Valve Section 2371
Remove 2371
Disassemble 2371
Clean 2380
Inspect 2380
Assemble 2380
Install 2381
Mid-Inlet Section 2381
Remove 2381
Clean 2382
Inspect 2382
Install 2382
Install 2382
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2387
Lift Pilot Pin 2387
Lower Pilot Pin 2391
Abnormal/Erroneous EHPV Adjustment 2393
Manual Main Control Valve 2394
Description 2394
Remove 2398
OPS Solenoid Assembly 2406
General 2406
Remove 2407
Clean and Inspect 2410
Install 2410
Manual Control Valve Sections 2411
General 2411
Outlet Control Valve Section 2411
Remove 2411
Disassemble 2411
Clean 2414
Inspect 2414
Assemble 2414
Install 2415
Auxiliary Control Valve Sections 2415
Remove 2415
Disassemble 2415
Clean 2418
Inspect 2418
Assemble 2418
Install 2419
Lift/Tilt Control Valve Section 2419
Remove 2419
Disassemble 2419
Clean 2426
Inspect 2426
Assemble 2427
Install 2428
Mid-Inlet Section 2429
Remove 2429
Clean 2429
Inspect 2429
Install 2429
Install 2430
Pressure Relief Valve Check and Adjustment 2436
Primary Relief Valve 2437
Secondary Relief Valve 2441
Steering Control Unit Repair 2448
Steering Control Unit, Remove 2448
Steering Control Unit, Disassemble 2452
Steering Control Unit, Clean 2454
Steering Control Unit, Inspect 2454
Steering Control Unit, Assemble 2454
Relief Valve, Disassemble 2455
Relief Valve, Clean 2455
Relief Valve, Inspect 2456
Relief Valve, Assemble 2456
Steering Control Unit, Install 2456
524223769 2200YRM1128 (01 2023) US EN 2461
Series Code / Model Designation Reference Table 2469
General 2471
Deutsch Crimping Tool 2472
How to Strip a Wire for Use With Deutsch Crimping Tool 2472
How to Crimp With the Deutsch Crimping Tool 2473
Calibration Test for the Deutsch Crimping Tool 2475
Deutsch Connectors 2477
DT, DTM, and DTP Series Connectors 2477
HD Series Connectors 2520
Metri-Pack Connectors 2542
Remove and Install 2542
Micro-Pack Connectors 2545
Weather-Pack Connectors 2546
AMPSEAL Crimping Tools 2548
AMP Hand Crimping Tool With Certi-Crimp 2548
Description 2548
Stripping Wire for Use with AMP Hand Crimping Tool 2549
Insulation Crimp Adjustment 2550
Maintenance and Inspection for AMP Hand Crimping Tool 2550
AMP Hand Crimping Tool 2550
Crimp Height Inspection 2550
How to use AMP Hand Crimping Tool 2551
AMP Pro-Crimper II Tool 2551
Description 2551
Remove and Install Die Set and Locator Assembly 2552
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2552
Contact Support Adjustment 2553
Crimp Height Adjustment 2554
Maintenance and Inspection Procedures 2554
PRO-CRIMPER II Tool 2554
Crimp Height Inspection 2554
How to Use AMP PRO-CRIMPER II Tool 2555
AMPSEAL Connector Assemblies 2556
Description for Plug Connector Assembly 2556
Seal Plug 2557
Contact Crimping 2557
Description for Plug Connector and Header Assembly 2562
Voltage Reading 2565
Seal Plug 2565
Contact Crimping 2565
AMP Superseal 1 5 Crimping Tools 2572
Mini Mic Receptacle and Tab Contacts 2572
Description 2572
Crimping Conditions and Measurements 2572
Insertion of Rubber Seal on Cable 2574
AMP Hand Application Tool 2579
Description 2579
Maintenance and Inspection 2579
Crimp Height Inspection 2579
Crimp Height Adjustment 2580
How to Use AMP Hand Application Tool 2580
AMP Pro-Crimper II Tool 2581
Description 2581
Remove and Install Die Set and Locator Assembly 2581
Adjustments 2582
Contact Support 2582
Crimp Height 2583
Inspections and Maintenance 2584
Crimp Height Inspection 2584
Visual Inspection 2584
Maintenance 2585
How to Use Pro-Crimper II Tool 2585
AMP Superseal 1 5 Connector Assemblies 2586
Description 2586
Repair and Maintenance 2593
Panel Mount Option 2593
AMP Fastin-Faston Hand Tools 2594
Description – AMP Double Action Hand Tool 2594
Maintenance and Inspection Procedures 2594
Daily Maintenance 2594
Periodic Tool Inspection 2595
Lubrication 2595
Visual Inspection 2595
Crimp Height Inspection 2595
Certi-Crimp Ratchet Inspection 2596
How to Use AMP Double Action Hand Tool 2597
Description – AMP Extraction Tool 2598
Maintenance and Inspection 2599
How to Use AMP Extraction Tool 2599
AMP Fastin-Faston Receptacles and Housings 2601
Description 2601
Wire Repair 2609
Wire Splicing Requirements 2609
Deutsch Jiffy Splice 2610
Twisted/Shielded Cable and Leads Repair 2616
Special Tools 2618
524223769 2200YRM1128 (07 2020) UK EN 2627
Series Code / Model Designation Reference Table 2633
General 2636
Deutsch Crimping Tool 2636
How to Strip a Wire for Use With Deutsch Crimping Tool 2636
How to Crimp With the Deutsch Crimping Tool 2637
Calibration Test for the Deutsch Crimping Tool 2639
Deutsch Connectors 2641
DT, DTM, and DTP Series Connectors 2641
HD Series Connectors 2683
Metri-Pack Connectors 2706
Remove and Install 2706
Micro-Pack Connectors 2708
Weather-Pack Connectors 2709
AMPSEAL Crimping Tools 2711
AMP Hand Crimping Tool With Certi-Crimp 2711
Description 2711
Stripping Wire for Use with AMP Hand Crimping Tool 2711
Insulation Crimp Adjustment 2712
Maintenance and Inspection for AMP Hand Crimping Tool 2712
AMP Hand Crimping Tool 2712
Crimp Height Inspection 2712
How to use AMP Hand Crimping Tool 2713
AMP Pro-Crimper II Tool 2713
Description 2713
Remove and Install Die Set and Locator Assembly 2714
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2715
Contact Support Adjustment 2715
Crimp Height Adjustment 2716
Maintenance and Inspection Procedures 2716
PRO-CRIMPER II Tool 2716
Crimp Height Inspection 2716
How to Use AMP PRO-CRIMPER II Tool 2717
AMPSEAL Connector Assemblies 2718
Description for Plug Connector Assembly 2718
Seal Plug 2719
Contact Crimping 2719
Description for Plug Connector and Header Assembly 2724
Voltage Reading 2726
Seal Plug 2726
Contact Crimping 2726
AMP Superseal 1 5 Crimping Tools 2733
Mini Mic Receptacle and Tab Contacts 2733
Description 2733
Crimping Conditions and Measurements 2733
Insertion of Rubber Seal on Cable 2735
AMP Hand Application Tool 2740
Description 2740
Maintenance and Inspection 2740
Crimp Height Inspection 2740
Crimp Height Adjustment 2741
How to Use AMP Hand Application Tool 2741
AMP Pro-Crimper II Tool 2742
Description 2742
Remove and Install Die Set and Locator Assembly 2743
Adjustments 2743
Contact Support 2743
Crimp Height 2744
Inspections and Maintenance 2745
Crimp Height Inspection 2745
Visual Inspection 2745
Maintenance 2746
How to Use Pro-Crimper II Tool 2746
AMP Superseal 1 5 Connector Assemblies 2747
Description 2747
Repair and Maintenance 2754
Panel Mount Option 2754
AMP Fastin-Faston Hand Tools 2755
Description – AMP Double Action Hand Tool 2755
Maintenance and Inspection Procedures 2755
Daily Maintenance 2755
Periodic Tool Inspection 2756
Lubrication 2756
Visual Inspection 2756
Crimp Height Inspection 2756
Certi-Crimp Ratchet Inspection 2757
How to Use AMP Double Action Hand Tool 2758
Description – AMP Extraction Tool 2759
Maintenance and Inspection 2759
How to Use AMP Extraction Tool 2760
AMP Fastin-Faston Receptacles and Housings 2761
Description 2761
Wire Repair 2768
Wire Splicing Requirements 2768
Deutsch Jiffy Splice 2769
Twisted/Shielded Cable and Leads Repair 2774
Special Tools 2777
524223770 2200YRM1130 (03 2020) UK EN 2785
General 2789
Description 2789
Dash Display Menu Access 2789
Menu Navigation 2790
Standard Display 2790
Main Menu 2790
Passwords Menu 2791
Password Administration 2791
Add Password 2791
Delete Password 2792
Edit Password 2792
Other Password Functions 2793
Operator Passwords – Enable/Disable 2793
Password Time-Out Delay 2793
Passwords – Number Wrong to Disable 2794
Lockout Reset Password 2794
View Password Log 2795
View Versions 2796
VSM Versions 2796
Dash Display Versions 2797
Engine Controller Version 2798
Transmission (Xmsn) Controller Version 2799
Truck Serial Number 2800
Diagnostics 2801
View Fault Log 2801
Set Travel and Braking 2802
Speed Limit 2802
Acceleration Rate 2803
Auto-Deceleration Rate 2803
Set Power Reversal Rate 2804
Set Inching/Brake Overlap 2805
Setup Display Menu 2806
Set Operator Language 2806
Set Units 2807
Set Time Format (12/24 Hour) 2807
Set Daylight Saving Time 2807
Set Time 2810
Set Date Format 2811
Set Date 2811
Setup Hydraulics 2812
Return to Set Tilt Delay/On/Off 2812
Setup General Items 2813
Light Shutdown Time-Out 2813
Impact Sensor – Enable/Disable 2814
Impact Sensor – Soft Impact Settings 2815
Impact Sensor – Hard Impact Settings 2816
Adjust Impact Sensor Settings 2816
Initial Adjustment of Soft and Hard Impact Settings 2818
Readjustment of Soft and Hard Impact Settings 2818
Impact Sensor – Impact Alarm/Shutdown Reset 2819
Impact Sensor – Alarm Time Duration and Deactivation 2820
Impact Sensor – View Impact Event Log 2821
Engine Mode Indicator 2822
Generation 1 (ECO-eLo ONLY) 2822
Generation 2 2823
Operator Checklist 2824
Operator Checklist Off-On Mode 2824
Edit Operator Checklist 2824
Set Operator Checklist Expiration 2825
View Checklist Log 2825
Clear Operator Checklist Log 2826
Clear Operator Checklist Fault 2826
Calibrations 2827
Set Tilt Stop Point 2827
Calibrate Loaded Weight 2827
524223771 2200YRM1131 (03 2020) UK EN 2829
Series Code / Model Designation Reference Table 2835
General 2837
Description 2837
Dash Display Menu Access 2837
Menu Navigation 2838
Main Menu 2838
Passwords 2839
Adding Passwords 2839
Hourmeters 2841
View Versions 2842
VSM Versions 2842
Dash Display Versions 2843
Engine Controller Version 2844
Transmission (Xmsn) Controller Version 2845
Truck Serial Number 2846
Truck Configuration 2847
Diagnostics 2848
Clear Fault Log 2848
View Fault Log 2849
No-Run Data Display 2850
Engine Accelerator and Throttle Data Display 2850
Engine Speeds and Governor Data Display 2851
Engine Fuel and Emissions Data Display 2852
Engine General Data Display 2854
XMSN/Brake Data Display 2855
Hydraulic Data Display 2858
General Truck Data Display 2860
Set Travel and Braking 2861
Speed Limit 2861
Acceleration Rate 2862
Auto-Deceleration Rate 2863
Set Power Reversal Rate 2863
Set Inching/Brake Overlap 2864
Setup Hydraulics 2864
Lift Maximum Speed 2865
Lower Maximum Speed 2865
Tilt Maximum Speed 2866
Auxiliary Function One, Direction A, Maximum Speed 2868
Auxiliary Function One, Direction B, Maximum Speed 2870
Auxiliary Function Two, Direction A, Maximum Speed 2870
Auxiliary Function Two, Direction B, Maximum Speed 2871
Auxiliary Function Three, Direction A, Maximum Speed 2872
Auxiliary Function Three, Direction B, Maximum Speed 2872
Lift/Lower Ramp Rate 2873
Hydraulic Auxiliary Ramp Rate 2873
Return to Set Tilt Delay/On/Off 2874
Hydraulic Input Device 2875
Auxiliary Solenoid 2875
Dual Function 2876
Setup Display 2877
Set Service Language 2877
Setup General Items 2877
Motion Alarm Activation Type 2878
Light Shutdown Time-Out 2879
Restore Default Settings 2879
Restore Engine Controller Default Calibration 2880
Impact Sensor – Enable/Disable 2880
Impact Sensor – Soft Impact Settings 2881
Impact Sensor – Hard Impact Settings 2882
Adjust Impact Sensor Settings 2883
Initial Adjustment of Soft and Hard Impact Settings 2885
Readjustment of Soft and Hard Impact Settings 2885
Impact Sensor – Impact Alarm/Shutdown Reset 2886
Impact Sensor – Alarm Time Duration and Deactivation 2887
Impact Sensor – View Impact Event Log 2888
Engine Mode Indicator 2888
Generation 1 (ECO-eLo ONLY) 2888
Generation 2 2889
Diesel Particulate Filter (DPF) Display 2890
General Description 2890
Passive Regeneration Only 2890
Regeneration Level 0 2890
Auto/Active Regeneration Inhibited 2891
Auto/Active Regeneration 2891
Regeneration Level 1 2891
Parked Regeneration Request 2892
Regeneration Level 2 2892
Warning Level 2892
Regeneration Level 3 2892
Service Level 2893
Regeneration Level 4 2893
Display, Diesel Particulate Filter (DPF), Revised 2893
Operator Interface 2893
Refer to Operator Manual 2893
CAN Communication Lost 2894
Passive Regeneration Only 2894
Regeneration Level 0 2894
Auto/Active Regeneration Inhibited 2894
Auto/Active Regeneration 2895
Regeneration Level 1 2895
Idle-up Auto/Active Regeneration 2895
Parked Regeneration Request 2895
Regeneration Level 2 2895
Warning Level 2897
Regeneration Level 3 2897
Service Level 2897
Regeneration Level 4 2897
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2897
Display, Diesel Particulate Filter (DPF), Stage V Engine 2897
Operator Interface 2898
Refer to Operator Manual 2898
CAN Communication Lost 2898
Passive Regeneration Only 2898
Regeneration Level 0 2898
Auto/Active Regeneration Inhibited 2899
Auto/Active Regeneration 2899
Regeneration Level 1 2899
Idle-up Auto/Active Regeneration 2900
Parked Regeneration Request 2900
Regeneration Level 2 2900
Warning Level 2901
Regeneration Level 3 2901
Service Level 2902
Regeneration Level 4 2902
Stage V Content 2902
Emissions System Malfunction 2902
Ash Load 2902
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2903
Operator Interface 2903
Refer to Operator Manual 2903
CAN Communication Lost 2904
Passive Regeneration Only 2904
Regeneration Level 0 2904
Auto/Active Regeneration Inhibited 2904
Auto/Active Regeneration 2905
Regeneration Level 1 2905
Idle-up Auto/Active Regeneration 2905
Parked Regeneration Request 2905
Regeneration Level 2 2905
Warning Level 2907
Regeneration Level 3 2907
Service Level 2907
Regeneration Level 4 2907
Calibrations 2908
Calibrate Transmission Valve 2910
Set Tilt Stop Point 2910
Calibrate Loaded Weight 2910
Calibrate Travel Speed Sensor 2911
Calibrate Mazda LP and Gas Accelerator Pedal 2911
524223772 2200YRM1142 (01 2020) UK EN 2913
General 2923
Display Switch Cluster 2926
Remove 2926
Install 2929
Direction Control and Turn Signal Levers 2929
Remove 2929
Install 2931
Key Switch 2931
Remove 2931
Install 2932
Display Switch Cluster Panel Bezel and Overlay 2932
Remove 2932
Install 2932
Steering Column Repair 2932
Remove 2932
Disassemble 2935
Assemble 2935
Install 2935
Sensors and Switches 2936
General 2936
Dash and Kick Panel, Remove and Install 2936
Remove 2936
Install 2937
Accelerator Pedal Position Sensor 2938
Remove 2938
Install 2941
Brake Fluid Level Switch 2942
Remove 2942
Install 2944
Service Brake Pedal Position Sensor 2945
Remove 2945
Install 2948
Parking Brake Sensor 2949
Remove 2949
Install 2950
Service Brake Pressure Sensor 2951
Remove 2951
Install 2953
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2954
Remove 2954
Install 2954
Sensor Microswitch (Foot Directional Control Pedal) 2955
Remove 2955
Install 2958
Low Coolant Level Sensor 2959
Remove 2959
Install 2962
Fuel Level Sensor, Gas and Diesel Engines Only 2963
Remove 2963
Install 2964
Armrest Switch 2964
Remove 2964
Install 2966
Seat Sensor (Operator Presence System) 2966
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) 2966
Remove 2966
Install 2967
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 2967
Remove 2967
Install 2968
Full Suspension Seats; All Lift Truck Models 2968
Remove 2968
Install 2968
Hood Shut Off Switch 2968
Remove 2968
Install 2971
Remote Key Switch 2972
Remove 2972
Install 2972
Hydraulic Filter Pressure Switch 2973
Remove 2973
Install 2975
Transmission Speed Sensor 2975
Remove 2975
Install 2978
Transmission Pressure Sensors 2979
Remove 2979
Install 2981
Transmission Temperature Sensor 2982
Remove 2982
Install 2984
Engine Speed Sensor 2986
Remove 2986
Install 2986
Intermediate Speed Sensor 2987
Remove 2987
Install 2987
Return to Set Tilt (Tilt Angle) Sensor 2987
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) 2987
Remove 2987
Install 2988
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) 2989
Remove 2989
Install 2990
Rear Horn Button Switch 2990
Remove 2990
Install 2991
Impact Sensor 2992
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) 2992
Remove 2992
Install 2995
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) 2995
Remove 2995
Install 2996
Load Weight Sensor 2997
Remove 2997
Install 2998
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 2999
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 2999
Crankshaft Position (CKP) Sensor 2999
Camshaft Position (CMP) Sensor 2999
Oil Pressure Sensor 2999
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 2999
Engine Coolant Temperature (ECT) Sensor 3000
Air Flow Restriction Switch 3000
Remove for GM 2 4L Gas and LPG Trucks 3000
Install for GM 2 4L Gas and LPG Trucks 3000
Oxygen Sensor 3001
Remove 3001
Install 3004
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3005
Crankshaft Position (CKP) Sensor 3005
Camshaft Position (CMP) Sensor 3005
Oil Pressure Sensor 3005
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3005
Engine Coolant Temperature (ECT) Sensor 3005
Air Flow Restriction Switch 3005
Oxygen Sensor 3005
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3005
Low LPG Pressure Switch 3005
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3006
Air Filter Restriction Switch 3006
Remove 3006
Install 3006
Oil Pressure Sensor 3006
Remove 3006
Install 3006
Engine Speed Sensor 3006
Remove 3006
Install 3006
Engine Coolant Temperature (ECT) Sensor 3006
Remove 3006
Install 3006
Throttle Position Sensor (TPS) 3009
Remove 3009
Install 3010
Fuel/Water Separator Sensor 3010
Remove 3010
Install 3010
Glow Plug Relay 3011
Remove 3011
Install 3013
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3013
Air Filter Restriction Switch 3013
Remove 3013
Install 3013
Engine Oil Pressure Sensor 3018
Remove 3018
Install 3018
Engine Speed Sensor 3018
Remove 3018
Install 3019
Engine Coolant Temperature (ECT) Sensor 3019
Remove 3019
Install 3020
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3021
Remove 3021
Install 3021
Fuel/Water Separator Sensor 3022
Remove 3022
Install 3022
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3023
Intake Air Temperature Sensor 3023
Remove 3023
Install 3024
Intake Air Pressure Sensor 3024
Remove 3024
Install 3024
Air Inlet Heater 3024
Remove 3024
Install 3025
Engine Oil Pressure Sensor 3025
Remove 3025
Install 3025
Engine Coolant Temperature (ECT) Sensor 3025
Remove 3025
Install 3025
Crankshaft Position Sensor 3026
Remove 3026
Install 3026
Adjust Shim Procedure 3027
Camshaft Position Sensor 3028
Remove 3028
Install 3028
Air Flow Restriction Sensor 3029
Remove 3029
Install 3029
Fuel/Water Separator 3029
Remove 3029
Install 3030
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3030
Intake Air Temperature Sensor 3034
Remove 3034
Install 3035
Boost Sensor 3035
Remove 3035
Install 3036
Throttle Valve Assembly and Air Intake Heater 3036
Remove 3036
Install 3036
Engine Coolant Temperature (ECT) Sensor 3037
Remove 3037
Install 3037
Engine Oil Pressure Sensor 3037
Remove 3037
Install 3038
Crankshaft Position Sensor 3038
Remove 3038
Install 3038
Adjust Shim Procedure 3039
Camshaft Position Sensor 3040
Remove 3040
Install 3041
Differential Pressure Sensor 3041
Remove 3041
Install 3041
Mass Air Flow Sensor 3042
Remove 3042
Install 3043
Fuel/Water Separator 3043
Remove 3043
Install 3044
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3044
Engine Coolant Temperature (ECT) Sensor 3045
Remove 3045
Install 3045
Throttle Position Sensor 3046
Engine Oil Pressure Sensor 3046
Remove 3046
Install 3046
Engine Speed Sensor 3046
Remove 3046
Install 3046
Fuel Shut Off Solenoid 3046
Remove 3046
Install 3046
Vehicle System Manager (VSM) 3047
General 3047
VSM Replacement 3047
Remove 3047
Install 3049
Programming a New VSM and/or Display Switch Cluster 3049
General 3049
PC Service Tool Software 3050
Data Transferring 3050
New VSM 3050
New (Blank) Display Switch Cluster 3050
Used (Non-Blank) Display Switch Cluster 3050
Power Distribution Module (PDM) and Component Parts 3052
Remove 3052
PDM as a Unit 3052
Install 3056
PDM as a Unit 3056
Remove and Install 3057
PDM Component Parts 3057
Transmission Control Unit 3057
Remove 3057
Install 3061
Battery 3063
Remove 3063
Install 3063
Lights 3064
Work Lights (Front and Rear) 3064
Remove 3064
Install 3064
Strobe Light 3065
Remove 3065
Install 3065
LED Tail, Backup, and Brake Lights 3066
Remove 3066
Install 3067
Front Marker/Turn Signal Lights 3068
Replacing Whole Front Marker/Turn Signal Light Assembly 3068
Remove 3068
Install 3068
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3069
Remove 3069
Install 3069
Diesel Particulate Filter (DPF) Display 3069
Remove 3069
Clean and Inspect 3070
Install 3070
Electronic-Hydraulic Controls – Generation 1 3071
E-Hydraulic Controls – Test 3071
Mini-Levers 3071
Full Stroke Test 3071
Function Returns to Neutral Test 3071
Push Button Switch 3071
General 3072
Mini-Lever Replacement 3072
Remove 3072
Clean and Inspect 3073
Install 3073
Push Button Switch Replacement 3074
Remove 3074
Install 3076
Mini-Lever Module (MLM) 3076
Remove 3076
Install 3076
Joystick 3077
Remove and Disassemble 3077
Inspect 3077
Assemble and Install 3077
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3078
General 3078
Mini-levers, Remove and Install 3078
Armrest Assembly 3079
Remove 3079
Install 3082
Horn Button 3082
Remove 3082
Install 3082
Direction Control Switch 3083
Remove 3083
Install 3083
push (override) buttons and Toggle Switch 3083
Remove 3084
Install 3085
Joystick 3086
Remove and Disassemble 3086
Inspect 3086
Assemble and Install 3086
Joystick Armrest Slider Assembly 3087
Remove 3087
Install 3088
Electronic-Hydraulic Controls, After January, 2020 3088
E-Hydraulic Controls – TEST 3088
Mini-Levers 3088
Full Stroke Test 3088
Function Returns to Neutral Test 3088
Push (Override) Button 3089
General 3089
Mini-levers, Remove and Install 3089
Armrest Assembly 3090
Remove 3090
Install 3093
Horn Button 3093
Remove 3093
Install 3093
Direction Control Switch 3093
Remove 3093
Install 3094
Push (Override) buttons and Toggle Switch 3094
Remove 3095
Install 3097
Special Tools 3098
524223780 8000YRM1134 (03 2020) UK EN 3101
Series Code / Model Designation Reference Table 3107
Description 3109
Proc_Cal_001: Service Password Entry 3111
When to Perform 3111
Why Perform 3111
How to Perform 3111
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3112
When to Perform 3112
Calibration Order 3112
Why Perform 3112
How to Perform 3113
Proc_Cal_003: Save and Exit 3114
When to Perform 3114
Why Perform 3114
How to Perform 3114
Proc_Cal_004: Lift Valve Output Threshold 3115
When to Perform 3115
Calibration Order 3115
Why Perform 3115
How to Perform 3116
Proc_Cal_005: Lower Valve Output Threshold 3118
When to Perform 3118
Calibration Order 3118
Why Perform 3118
How to Perform 3118
Proc_Cal_006: Tilt Back Valve Output Threshold 3121
When to Perform 3121
Calibration Order 3121
Why Perform 3121
How to Perform 3121
Proc_Cal_007: Tilt Forward Valve Output Threshold 3124
When to Perform 3124
Calibration Order 3124
Why Perform 3124
How to Perform 3124
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3127
When to Perform 3127
Calibration Order 3127
Why Perform 3127
How to Perform 3127
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3130
When to Perform 3130
Calibration Order 3130
Why Perform 3130
How to Perform 3130
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3133
When to Perform 3133
Calibration Order 3133
Why Perform 3133
How to Perform 3133
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3136
When to Perform 3136
Calibration Order 3136
Why Perform 3136
How to Perform 3136
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3139
When to Perform 3139
Calibration Order 3139
Why Perform 3139
How to Perform 3139
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3142
When to Perform 3142
Calibration Order 3142
Why Perform 3142
How to Perform 3142
Proc_Cal_014: Load Weight Zero Point 3146
When to Perform 3146
Calibration Order 3146
Why Perform 3146
How to Perform 3146
Proc_Cal_015: Loaded Weight Calibration 3148
When to Perform 3148
Calibration Order 3148
Why Perform 3148
How to Perform 3148
Proc_Cal_016: Transmission Valve Calibration 3151
Applicable System/Option 3151
When to Perform 3151
Calibration Order 3151
Why Perform 3151
How to Perform 3151
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3153
Applicable System/Option 3153
When to Perform 3153
Calibration Order 3153
Why Perform 3153
How to Perform 3153
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3155
Applicable System/Option 3155
When to Perform 3155
Calibration Order 3155
Why Perform 3155
How to Perform 3156
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3157
Required Tools 3157
When to Perform 3157
Calibration Order 3157
Why Perform 3158
How to Perform 3158
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3159
When to Perform 3159
Why Perform 3159
How to Perform 3159
Proc_Cal_026: Travel Speed Calibration 3161
When to Perform 3161
Calibration Order 3161
Why Perform 3161
How to Perform 3161
524223780 8000YRM1134 (05 2022) US EN 3165
Series Code / Model Designation Reference Table 3171
Description 3174
Proc_Cal_001: Service Password Entry 3176
When to Perform 3176
Why Perform 3176
How to Perform 3176
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3177
When to Perform 3177
Calibration Order 3177
Why Perform 3177
How to Perform 3177
Proc_Cal_003: Save and Exit 3179
When to Perform 3179
Why Perform 3179
How to Perform 3179
Proc_Cal_004: Lift Valve Output Threshold 3180
When to Perform 3180
Calibration Order 3180
Why Perform 3180
How to Perform 3180
Proc_Cal_005: Lower Valve Output Threshold 3183
When to Perform 3183
Calibration Order 3183
Why Perform 3183
How to Perform 3183
Proc_Cal_006: Tilt Back Valve Output Threshold 3186
When to Perform 3186
Calibration Order 3186
Why Perform 3186
How to Perform 3186
Proc_Cal_007: Tilt Forward Valve Output Threshold 3189
When to Perform 3189
Calibration Order 3189
Why Perform 3189
How to Perform 3189
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3192
When to Perform 3192
Calibration Order 3192
Why Perform 3192
How to Perform 3192
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3195
When to Perform 3195
Calibration Order 3195
Why Perform 3195
How to Perform 3195
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3198
When to Perform 3198
Calibration Order 3198
Why Perform 3198
How to Perform 3198
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3201
When to Perform 3201
Calibration Order 3201
Why Perform 3201
How to Perform 3201
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3204
When to Perform 3204
Calibration Order 3204
Why Perform 3204
How to Perform 3204
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3207
When to Perform 3207
Calibration Order 3207
Why Perform 3207
How to Perform 3207
Proc_Cal_014: Load Weight Zero Point 3210
When to Perform 3210
Calibration Order 3210
Why Perform 3210
How to Perform 3210
Proc_Cal_015: Loaded Weight Calibration 3212
When to Perform 3212
Calibration Order 3212
Why Perform 3212
How to Perform 3212
Proc_Cal_016: Transmission Valve Calibration 3215
Applicable System/Option 3215
When to Perform 3215
Calibration Order 3215
Why Perform 3215
How to Perform 3215
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3217
Applicable System/Option 3217
When to Perform 3217
Calibration Order 3217
Why Perform 3217
How to Perform 3217
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3220
Applicable System/Option 3220
When to Perform 3220
Calibration Order 3220
Why Perform 3220
How to Perform 3220
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3223
Required Tools 3223
When to Perform 3223
Calibration Order 3223
Why Perform 3223
How to Perform 3223
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3225
When to Perform 3225
Why Perform 3225
How to Perform 3225
Proc_Cal_026: Travel Speed Calibration 3227
When to Perform 3227
Calibration Order 3227
Why Perform 3227
How to Perform 3227
524262279 1800YRM1247 (09 2018) UK EN 3231
General 3235
Dry Brake System 3235
Wet Brake System 3236
Service Brakes Repair (Dry Brake) 3240
Remove and Disassemble 3240
Clean 3242
Inspect 3243
Assemble and Install 3243
Adjust 3247
Parking Brake Repair 3247
Dry Brake System 3248
Remove and Disassembly 3248
Assemble and Install 3250
Wet Brake System 3250
Remove and Install 3251
Assemble and Install 3257
Adjust 3257
Dry Brake System 3257
Wet Brake System 3258
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3258
Master Cylinder Repair 3259
Remove 3259
Disassemble 3264
Clean and Inspect 3265
Assemble 3266
Install and Adjust 3266
Accumulator 3268
Pre-Charge Check 3269
Remove 3270
Install 3272
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3272
Remove 3273
Modulating Brake Valve 3274
Disassemble 3274
Clean and Inspect 3276
Assemble 3276
Accumulator Charge Valve 3277
Disassemble 3277
Clean and Inspect 3279
Assemble 3279
Install 3280
Pressure Checks 3281
Accumulator Charge Valve Check 3281
Accumulator Check 3281
Service Brakes Adjustment (Dry Brake) 3282
Service Brakes Adjustment 3282
Brake System Air Removal 3283
Using Pressure Bleed System 3283
Using Brake Pedal Pressure 3284
Lift Truck Models with Master Cylinder 3284
Lift Truck Models with Modulating Brake Valve 3284
Brake Pedal Adjustment 3285
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) 3285
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3286
Free Pedal Adjustment 3288
Torque Specifications 3289
524265337 0600YRM1251 (09 2015) UK EN 3293
General 3299
Engine Removal and Installation 3299
Cylinder Head Repair 3299
Remove and Disassemble 3299
Clean and Inspect 3301
Valve Oil Seals 3304
Remove and Disassemble 3304
Cylinder Leak Down Test 3304
Clean and Inspect 3305
Assemble and Install 3305
Valve Guides and Seats, Repairs 3307
Valves, Repair 3307
Valve Seats, Repair 3308
Valve Springs 3309
Assemble and Install 3310
Engine Block Cleaning and Inspection 3313
Clean and Inspect 3314
Piston Bore Preparation 3316
Engine Mounts Installation 3316
Remove 3316
Clean and Inspect 3317
Install 3317
Lubrication System Repair 3318
Oil Pump, Remove and Disassemble 3318
Clean and Inspect 3319
Oil Pump, Assemble and Install 3320
Oil Pan, Install 3322
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 3324
Timing Cover 3324
Remove 3324
Install 3326
Timing Sprockets 3326
Remove 3326
Install 3326
Camshaft 3326
Remove 3326
Inspect 3327
Install 3327
Balance Shaft 3328
Remove 3328
Install 3329
Valve Lifters 3330
Remove 3330
Clean and Inspect 3330
Install 3331
Crankshaft Repair 3331
Remove 3332
Inspect and Repair 3332
How to Check Clearance Between Main Bearings and Their Journals 3333
Install 3334
Piston and Connecting Rod Assemblies Repair 3336
Connecting Rod Bearings, Replace 3336
Piston and Connecting Rod Assemblies, Remove 3337
Disassemble 3337
Piston, Clean and Inspect 3338
Cylinder Bores, Inspect and Repair 3338
Piston Rings 3339
Assemble 3340
Piston and Connecting Rod Assemblies, Install 3340
Flywheel and Flywheel Housing Repair 3340
Flywheel, Remove 3341
Clean 3341
Inspect 3341
Flywheel, Install 3342
Coolant Pump Repair 3342
Remove 3342
Clean and Inspect 3343
Install 3343
Thermostat Replacement 3343
Remove 3344
Thermostat Operation Check 3344
Install 3344
Starter Replacement 3345
3345
Remove 3345
Install 3348
Fan Assembly Replacement 3349
Remove 3349
Inspect 3351
Install 3351
Drive Belt Installation 3352
Remove 3352
Clean 3352
Inspect 3352
Installation 3353
Compression Check 3354
Engine Specifications 3354
Engine Data 3354
Cylinder Head 3354
Hydraulic Valve Lifter 3355
Camshaft 3355
Pistons 3355
Crankshaft 3356
Connecting Rods 3356
Balance Shaft 3357
Cooling System 3357
Lubrication System 3357
Torque Specifications 3358
524265342 4000YRM1250 (09 2018) UK EN 3363
Safety Procedures When Working Near Mast 3369
Fork Replacement 3371
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3371
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3373
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) 3374
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3375
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3376
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) 3377
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3377
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) 3379
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3379
Fixed Carriage Replacement 3381
Remove, Carriage With Hook Forks 3381
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3390
Install, Carriage With Hook Forks 3391
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3391
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3392
Connecting Attachment Hydraulic Quick Disconnect Hoses 3392
Integral Sideshift Carriage Repair 3393
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) 3393
Disassemble 3393
Clean and Inspect 3396
Assemble 3396
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) 3397
Hang On Sideshift Carriage Repair 3397
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) 3397
Disassemble 3409
Clean and Inspect 3418
Assemble 3419
Install 3420
Bolzoni Hang-On Sideshift Carriage Repair 3422
Remove 3422
Disassemble Carriage 3424
Clean and Inspect 3427
Assemble 3427
Install 3430
Fork Positioner 3432
Two-Stage Mast With Limited Free-Lift Repair 3433
Remove 3433
Disassemble 3437
Clean and Inspect 3440
Assemble 3457
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) 3459
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) 3460
Header Hose Alignment 3472
Two-Stage Mast With Full Free-Lift Repair 3482
Remove 3482
Disassemble 3484
Clean and Inspect 3496
Assemble 3497
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) 3499
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) 3502
Header Hose Installation and Adjustment 3506
Installation 3506
Adjustment 3506
Three-Stage Mast With Full Free-Lift Repair 3507
Remove 3507
Disassemble 3509
Clean and Inspect 3539
Assemble 3540
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) 3544
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) 3549
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) 3556
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) 3562
Mast Operation Check 3566
Tilt Cylinder Adjustment 3566
Lift Chains Adjustment 3567
Mast Adjustments 3568
Load Roller Adjustment 3568
Mast Side Kicking Adjustment 3570
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 3571
Carriage Adjustments 3574
524288194 1300YRM1317 (03 2020) UK EN 3577
Transmission Repair 3581
Remove 3581
Torque Converter, Remove 3581
Disassemble 3582
Clean and Inspect 3631
Housings 3631
Oil Seals and Gaskets 3631
Bearings 3631
Gears and Shafts 3632
Assemble 3632
Torque Converter, Install 3673
Install 3674
Control Valve Repair 3675
Remove 3675
Disassemble 3675
Clean 3677
Inspect 3677
Assemble 3677
Install 3678
Torque Specification 3679
524294873 1300YRM1343 (11 2019) UK EN 3681
Transmission Repair 3685
Remove 3685
Torque Converter, Remove 3685
Disassemble 3686
Clean and Inspect 3726
Housings 3726
Oil Seals and Gaskets 3726
Bearings 3727
Gears and Shafts 3727
Assemble 3727
Torque Converter, Install 3765
Install 3766
Control Valve Repair 3767
Remove 3767
Disassemble 3767
Control Valve Assembly 3767
Control Valve Body 3767
Clean 3770
Inspect 3770
Assemble 3770
Control Valve Body 3770
Control Valve Assembly 3770
Install 3771
Torque Specification 3773
524294878 2100YRM1328 (09 2018) UK EN 3775
General 3779
Safety Procedures When Working Near Mast 3779
Tilt Cylinder Repair 3781
Remove 3781
Disassemble 3786
Clean 3788
Inspect 3788
Assemble 3788
Install 3790
Tilt Cylinders, Adjust 3792
Tilt Cylinder Leak Check 3793
Lift Cylinder Repair 3794
Remove 3794
Disassemble 3804
Clean 3807
Inspect 3807
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) 3807
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3807
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) 3808
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3808
Free-Lift Cylinder Repair 3809
Remove 3809
Disassemble 3815
Clean 3817
Inspect 3817
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) 3818
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3818
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) 3818
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3819
Sideshift Cylinder Repair 3820
Remove 3820
Disassemble 3821
Clean 3824
Inspect 3824
Assemble 3825
Install 3826
Bolzoni Sideshift Cylinder Repair 3827
Remove 3827
Disassemble 3827
Clean 3828
Inspect 3828
Assemble 3829
Install 3829
Fork Positioner Cylinder Repair 3829
Remove 3830
Disassemble 3833
Clean 3837
Inspect 3837
Assemble 3838
Install 3839
Lift Cylinder Leak Check 3840
Seal Kit Installation 3840
External Installation (Seal and Back-Up Ring) 3840
Internal Installation (Piston Rod Assembly) 3841
Special Tools 3842
Torque Specifications 3843
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) 3843
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3843
524296605 1400YRM1344 (03 2020) UK EN 3847
General 3851
Identification Plate 3851
Drive Axle Removal 3851
Planetary Reduction Gear Repair 3863
Clean and Inspect 3873
Brake Repair 3882
Clean and Inspect 3895
Wet Brake Noise Reduction 3905
General 3905
Adding Additive To Transmission 3906
Differential Repair 3907
Clean and Inspect 3918
Bevel Pinion 3930
Clean and Inspect 3934
Drive Axle Installation 3944
Special Tools 3955
Torque Specifications 3956
524306203 0100YRM1290 (04 2014) UK EN 3959
550043871 0900YRM1556 (04 2018) UK EN 4063
General 4067
LPG Tank and Bracket 4067
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) 4067
Remove 4067
Install 4075
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) 4076
Remove 4076
Install 4078
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4078
Remove 4078
Install 4080
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4080
Remove 4080
Install 4080
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) 4081
Remove 4081
Install 4083
Fuel Filter Unit 4083
Fuel Filter Element 4084
Remove 4084
Clean and Inspect 4084
Install 4085
Fuel Filter Housing with LP Vapor Sensor 4085
Remove 4085
Disassemble 4087
Clean and Inspect 4088
Assemble 4088
Install 4089
Throttle Body 4090
Remove 4090
Clean 4094
Install 4094
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 4095
Remove 4095
Install 4096
Control System 4096
Engine Control Unit (ECU) 4097
Remove 4097
Install 4098
Low Pressure Switch 4098
Remove 4098
Install 4098
Low Fuel Sensor 4099
Remove 4099
Install 4099
LP Converter 4100
Remove and Disassemble 4100
Assemble and Install 4101
LPG Lock-Off 4101
Remove 4102
Install 4103
Exhaust System 4104
Counterweight Exhaust 4104
Remove and Disassemble 4104
Inspect 4106
Assemble and Install 4106
Overhead Exhaust 4107
Remove and Disassemble 4107
Inspect 4109
Assemble and Install 4109
Exhaust Manifold 4109
Remove 4109
Install 4111
Oxygen (HEGO) Sensor 4111
Remove 4111
Install 4111
LPG Fuel Testing 4112
General 4112
Available Fuel Tests 4112
Composition Test (ASTM D-2163) 4112
Ammonia Test (ASTM D-4490) 4112
Basic Nitrogen Test (ASTM UOP269-90) 4112
Residues Test (ASTM D-2158) 4112
Vapor Pressure Test (ASTM D-2598) 4112
Sulfur Compounds Test (ASTM D-5623) 4112
Methanol Test (ASTM D-4864) 4113
Copper Corrosion (ASTM D-1838) 4113
Where To Send LPG Fuel Samples For Testing 4113
550055278 0100YRM1581 (05 2017) UK EN 4117
General 4121
Description 4122
Side Covers, Seat, Dash, and Hood Replacement 4123
Side Covers 4123
Remove 4123
Install 4123
Seat and Seat Plate 4123
Remove Seat 4123
Remove Seat Plate 4123
Install Seat Plate 4127
Install Seat 4127
Operator Restraint System 4128
Emergency Locking Retractor (ELR) 4128
Seat Plate and Seat Rail Check 4128
Steering Column, Dash, Kick Panel, and Seal Plate 4128
Remove 4128
Install 4128
Hood Support and Door Assembly 4133
Remove 4133
Install 4133
Hood Door Assembly 4138
Remove 4138
Install 4138
Steering Column 4138
Description 4139
Steering Column Repair 4139
Remove 4139
Disassemble 4141
Clean 4142
Inspect 4142
Assemble 4142
Install 4142
LPG Tank and Bracket Assembly 4142
Counterweight Replacement 4142
Remove 4143
Install 4146
Tow Pin, Remove and Install 4146
Overhead Guard Replacement 4147
Remove 4147
Install 4147
Engine Replacement 4148
Remove Engine 4149
Remove Transmission 4171
Remove Engine and Transmission 4175
Install Engine 4178
Install Transmission 4182
Install Engine and Transmission 4184
Throttle Pedal and Cable Adjustment 4187
Exhaust System Repair 4188
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4188
GM 5 7L Engine for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909) 4188
Kubota 3 8L Diesel Engine for Lift Truck Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878, B909) 4188
Remove 4188
Inspect 4190
Install 4190
Kubota 3 6L Diesel Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4191
Remove 4191
Inspect 4191
Install 4191
Cummins QSB 3 3L Engine for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909) 4193
Remove 4193
Inspect 4193
Install 4193
4195
Diesel Particulate Filter 4195
Disassemble 4195
Clean and Inspect 4196
Differential Pressure Pipes and Hoses 4197
Assemble 4197
Cooling System 4198
Description 4198
Hydraulic Filter Assembly Repair 4198
Remove 4198
Install 4198
Fuel and Hydraulic Tanks Repair 4200
Inspect 4200
Clean 4200
Steam Method of Cleaning 4201
Chemical Solution Method of Cleaning 4201
Additional Preparations for Repair 4201
Small Leaks, Repair 4202
Large Leaks, Repair 4202
Preparations for Use After Repair 4202
Safety Labels 4202
550055279 0600YRM1579 (11 2019) UK EN 4211
General 4217
Engine Identification 4217
Major Engine Component Identification 4217
Location of Labels 4217
Crankcase Description 4218
Engine Removal and Installation 4219
Cylinder Head Assembly Repair 4219
Valve Covers and Fuel Injectors 4219
Remove 4219
Clean and Inspect 4223
Install 4224
Rocker Arm Assembly 4225
Remove 4225
Disassemble 4227
Clean and Inspect 4227
Push Rods 4227
Rocker Arm Assembly 4227
Assemble 4228
Install 4228
Valve Clearance Adjustments 4228
Cylinder Head Assembly 4229
Remove 4229
Disassemble 4237
Valves and Valve Springs, Remove 4237
Valve Guides, Remove 4239
Clean and Inspect 4239
Cylinder Head 4240
Valve Guides 4240
Valves 4240
Valve Sink 4241
Valve Seat 4241
Valve Springs 4241
Assemble 4242
Valve Guides, Install 4242
Valves and Valve Springs, Install 4242
Install 4243
Timing Gear Case and Timing Gears Repair 4248
Timing Gear Case Cover 4248
Remove 4248
Clean and Inspect 4248
Install 4249
Timing Gears 4250
Crankshaft Gear 4250
Remove 4250
Install 4250
Idler Gear 4250
Remove 4250
Inspect 4251
Install 4251
Camshaft Gear 4251
Remove 4251
Install 4252
Timing Gear Case 4252
Remove 4252
Clean and Inspect 4253
Install 4253
Drive Train, Camshaft, and Cylinder Block Repair 4253
Remove 4253
Disassemble 4254
Pistons and Connecting Rods 4254
Crankshaft 4255
Camshaft 4257
Clean and Inspect 4258
Cylinder Block 4259
Honing and Boring 4261
Cylinder Correction (Oversize) 4262
Pistons 4262
Piston Pin 4263
Connecting Rod 4263
Tappets 4263
Crankshaft 4264
Camshaft 4266
Camshaft Bushing 4267
Assemble 4267
Camshaft 4267
Crankshaft 4267
Pistons and Connecting Rods 4267
Install 4269
Lubrication System Repair 4270
Engine Oil and Oil Filter Change 4270
Oil Pan 4271
Remove 4271
Install 4272
Oil Suction Tube 4272
Remove 4272
Clean 4273
Install 4273
Oil Pump 4273
Remove 4273
Clean and Inspect 4273
Outer Rotor Outside Clearance 4274
Outer Rotor to Inner Rotor Tip Clearance 4274
Outer Rotor Side Clearance 4274
Rotor Shaft Clearance 4275
Install 4275
Fuel System Repair 4276
Fuel Injectors 4276
Remove 4276
Inspect 4276
Clean 4276
Replace 4276
Install 4276
Electronic Throttle System 4276
Remove 4276
Throttle Position Sensor Proceedures After September 2018 GDP60-70VX (GDP135-155VX) (F878), GDP60VX, GDP70VX, GP70VXS6 (GDP135VX GDP155VX, GP155VXS) (G878), and GP080VX, GP090VX, GP100VX, GP100VX, GP120VX, (GDP40VX5, GDP40VX6, GDP45VX6, GDP45SVX5, GDP50VX, GDP55VX) (K813) 4280
Bearing Replacement 4280
Install 4281
Adjustment 4282
Fuel Injection Pump 4282
Remove 4282
Disassemble 4286
Clean and Inspect 4288
Assemble 4288
Install 4289
Cooling System Repair 4290
Serpentine Belt 4290
Remove 4290
Inspect 4290
Install 4290
Serpentine Belt, Adjustment 4290
Water Pump 4291
Remove 4291
Install 4293
Thermostat 4294
Remove 4294
Inspect 4295
Install 4295
Flywheel and Flywheel Housing 4296
Flywheel 4296
Remove 4296
Install 4297
Flywheel Housing 4297
Remove 4297
Install 4297
Electrical Equipment Repair 4297
Alternator 4297
Remove 4297
Install 4298
Starter 4299
Remove 4299
Install 4299
Engine Specifications 4301
Engine Data 4301
Engine Tuning 4302
Cylinder Head 4302
Intake/Exhaust Valve and Guide 4303
Valve Spring 4303
Rocker Arm and Shaft 4303
Push Rod 4303
Gear Train and Camshaft 4304
Camshaft 4304
Idle Gear Shaft and Bushing 4304
Backlash of Each Gear 4304
Cylinder Block 4304
Crankshaft 4304
Piston 4305
Piston Ring 4305
Connecting Rod 4305
Rod Small End 4305
Tappet 4306
Oil Pump 4306
Engine Oil Pressure 4306
Outer Rotor Outside Clearance 4306
Outer Rotor Side Clearance 4306
Inner Rotor to Cover 4306
Standard Torque Specifications 4307
Standard Torque Chart 4307
Special Torque Specifications 4307
Special Tools 4309
550055282 8000YRM1584 (06 2019) UK EN 4319
Lift Truck Lifting Capacity 4323
Counterweight Weights 4323
Tire Sizes 4323
Capacities 4323
Electrical System 4327
Transmission Oil Pressures 4328
Hydraulic System Relief Pressures 4329
Steering System 4330
Stall Speeds (in RPM ±100 rpm) 4330
GM 4 3L Gas GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4330
GM/PSI 4 3L LPG GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4330
Kubota 3 6L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4331
Kubota 3 8L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4331
Mast Speeds 4331
Tilt Angles 4332
Front End Equipment – Mast Creep 4332
Mast Creep 4332
Engine Specifications 4333
Diesel Fuel Cleanliness Levels 4335
Torque Specifications 4335
Frame 4335
Mast, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4335
Hang On Sideshift Carriage With Fork Positioner, Lift Truck Models Manufactured After August, 2012GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4336
Steering System 4336
Transmission 4336
Engine – GM/PSI 4 3L 4336
Engine – Kubota 3 6L Diesel 4337
Engine – Kubota 3 8L Diesel 4338
550055283 8000YRM1585 (07 2020) UK EN 4341
General Information About Diagrams and Schematics 4345
Symbol Definitions 4345
Diagrams Manual Applications 4346
Diagrams and Schematics 4348
550055296 8000YRM1583 (05 2019) UK EN 4437
General 4443
Serial Number Data 4443
How to Move Disabled Lift Truck 4443
How to Tow Lift Truck 4443
How to Put Lift Truck on Blocks 4444
How to Raise Drive Tires 4444
How to Raise Steering Tires 4445
How to Clean a Lift Truck 4446
Maintenance Schedule 4446
Maintenance Procedures Every 8 Hours or Daily 4459
How to Make Checks With Engine Stopped 4459
Tires and Wheels 4460
Safety Labels 4460
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4460
Operator Restraint System 4461
Emergency Locking Retractor (ELR) 4461
Adjust Seat – Full Suspension 4461
Adjust Seat – Internal Suspension 4462
Seat Plate and Seat Rails 4464
Engine Compartment 4464
Paper Application 4464
Fuel, Oil, and Coolant Leaks, Check 4465
Hydraulic Hoses 4465
Coolant Hoses 4465
Steering Column Gas Cylinder 4465
Transmission 4465
Hydraulic System Oil 4466
Engine Oil 4467
Air Filter 4470
Forks 4470
Remove 4470
Inspect 4471
Install 4471
Adjust 4472
Hang On Sideshift Carriage 4472
How to Make Checks With Engine Running 4473
Indicator Lights, Horn, Fuses, and Relays 4473
Service Brakes 4476
Brake Oil Level 4476
Operation, Check 4476
Parking Brake 4476
Engine Oil Pressure 4477
Cooling System 4477
Steering System 4478
Control Levers and Pedals 4478
Lift System, Operate 4478
Air Filter 4479
Fuel/Water Separator Filter, Kubota Diesel Engine 4479
First Service After First 100 Hours of Operation 4479
4 3L Engine Oil and Oil Filter 4479
Kubota Diesel Engine Oil and Oil Filter 4480
Maintenance Procedures Every 500 Hours or 1 Year 4481
Hydraulic System Oil 4481
Hydraulic Tank Breather 4482
Inspect 4482
Battery 4483
4 3L Engine Oil and Oil Filter Change 4483
Kubota Diesel Engine Oil and Oil Filter 4484
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 4485
Remove 4485
Install 4485
Priming the Fuel System (Kubota 3 8L Engine) 4486
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 4487
Remove 4487
Install 4487
Priming the Fuel System (Kubota 3 6L Engine) 4488
Drive Belt 4488
4 3L Engine 4488
Fan and Alternator Drive Belt 4488
Drive Belt 4489
Kubota Diesel Engine 4489
Fan and Alternator Drive Belt 4489
Drain Tar From LPG Converter 4490
Clean Debris From Radiator Core 4491
Transmission Oil Breather/Dipstick 4491
Differential and Drive Axle Oil Level Check 4492
Forks 4494
Mast Lubrication 4495
Header Hose Checks 4499
Lift Chain Lubrication 4499
Tilt Cylinder Lubrication 4499
Master Brake Cylinder Rod End Pin Lubrication 4500
Manual Hydraulic Levers Lubrication 4501
Brake Oil 4501
Tie Rod Lubrication 4502
Parking Brake Adjustment 4503
Maintenance Procedures Every 1000 Hours or 1 year 4504
Valve Clearance, Check and Adjust 4504
Valve Clearance, Check and Adjust, Kubota 3 6L Engine 4504
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 4504
Ignition System 4504
4 3L Engine 4504
LPG Fuel Filter Element Replace, 4 3L Engine 4504
Remove 4504
Install 4505
In-Line Strainer Replacement, Kubota Diesel Engine 4505
Remove 4505
Install 4505
Lift Chains Wear Check 4506
Lift Chain Lubrication 4507
Hang On Sideshift Carriage, Check Sliding Surfaces 4507
Steering Axle Spindle Bearings 4509
Control Levers and Pedals 4510
Inspect Engine Electrical System, Connectors 4510
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 4510
Parking Brake Lever Lubrication, Wet Brake Axle 4514
Normal Operating Environment 4514
Heavy Duty or Contaminated Environment 4515
Remove 4515
Clean and Inspect 4516
Install 4516
Crankcase Breather Element, Kubota 3 8L Diesel 4517
Remove 4517
Clean and Inspect 4517
Install 4517
Maintenance Procedures Every 2000 Hours or Annually 4518
Hydraulic System 4518
Hydraulic Filter Assembly, Replace 4518
Install 4519
Hydraulic Tank Breather, Replace 4520
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 4521
Cooling System Check 4521
Air Filter 4522
Fuel Injector, Kubota 3 8L Engine 4524
Fuel Injector, Kubota 3 6L Engine 4524
Forks 4524
Brake Oil (Master Cylinder), Change 4524
Check Throttle Shaft for Sticking 4525
Inspect Exhaust Manifold and Piping for Leaks 4525
Transmission Automatic Clutch Calibration 4526
Wheel Bearings 4526
Steer Wheels, Lubrication 4526
Maintenance Procedure Every 3000 Hours 4526
Diesel Particulate Filter 4526
Remove 4526
Disassemble 4528
Servicing the Diesel Particulate Filter 4529
Assemble 4529
Install 4530
Maintenance Procedures Every 4000 Hours or 2 Years 4530
Hydraulic Oil, Replace 4531
Safety Procedures When Working Near Mast 4532
Fuel Filter Water Removal 4535
Kubota Diesel Engine 4535
3 8L Diesel Engine 4535
3 6L Diesel Engine 4536
Lift Chain Adjustments 4537
Jump-Starting the Lift Truck 4538
Jump-Starting Using a Battery Charger 4538
Jump-Starting a Lift Truck Using Another Lift Truck 4539
Welding Repairs 4539
Overhead Guard Changes 4539
Wheel and Tire Replacement 4540
General 4540
Pneumatic Tire With Tube, Repair 4540
Remove Wheels From Lift Truck 4540
Remove Tire From Wheel 4540
Install Wheel in Tire 4543
Install Tire on Two-Piece Wheel 4545
Snap-On-Tire, Change 4546
Easy Mounting Style Solid Rubber Tires on Pneumatic Wheels, Change 4549
Adhesives and Sealants 4554
550059479 0600YRM1590 (07 2019) UK EN 4557
General 4563
Engine Identification 4563
Major Engine Component Identification 4563
Location of Labels 4564
Crankcase Description 4564
Precautions Before Beginning Repair 4565
Exhaust System and DPF 4566
Engine Removal and Installation 4566
Cylinder Head Assembly Repair 4567
Valve Covers and Fuel Injectors 4567
Remove 4567
Clean and Inspect 4570
Install 4570
Rocker Arm Assembly 4571
Remove 4571
Disassemble 4572
Clean and Inspect 4572
Push Rods 4572
Rocker Arm Assembly 4572
Assemble 4573
Install 4573
Valve Clearance Adjustments 4573
Cylinder Head Assembly 4574
Remove 4574
Disassemble 4583
Valves and Valve Springs, Remove 4583
Valve Guides, Remove 4584
Clean and Inspect 4584
Cylinder Head 4585
Valve Guides 4585
Valves 4585
Valve Sink 4586
Valve Seat 4586
Valve Springs 4587
Assemble 4587
Valve Guides, Install 4587
Valves and Valve Springs, Install 4588
Install 4589
Timing Gear Case and Timing Gears Repair 4591
Timing Gear Case Cover 4591
Remove 4591
Clean and Inspect 4592
Install 4592
Timing Gears 4593
Crankshaft Gear 4594
Remove 4594
Install 4594
Idler Gear 4594
Remove 4594
Inspect 4595
Install 4596
Camshaft Gear 4596
Remove 4596
Install 4596
Drive Train, Camshaft, and Cylinder Block Repair 4596
Remove 4596
Disassemble 4597
Pistons and Connecting Rods 4597
Crankshaft 4598
Camshaft 4600
Clean and Inspect 4602
Cylinder Block 4602
Honing and Boring 4604
Cylinder Correction (Oversize) 4605
Pistons 4605
Piston Pin 4606
Connecting Rod 4606
Tappets 4607
Crankshaft 4607
Camshaft 4609
Camshaft Bushing 4610
Assemble 4610
Camshaft 4610
Crankshaft 4610
Pistons and Connecting Rods 4611
Install 4613
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 4613
Lubrication System Repair 4616
Engine Oil and Oil Filter Change 4616
Oil Pan 4617
Remove 4617
Install 4618
Oil Suction Tube 4619
Remove 4619
Clean 4619
Install 4619
Oil Pump 4619
Remove 4619
Clean and Inspect 4620
Outer Rotor Outside Clearance 4621
Outer Rotor to Inner Rotor Tip Clearance 4621
Outer Rotor Side Clearance 4621
Rotor Shaft Clearance 4622
Install 4622
Fuel System Repair 4623
Fuel Injectors 4623
Remove 4623
Inspect 4623
Clean 4623
Replace 4623
Install 4623
Test 4623
Fuel Injection Pump 4624
Remove 4624
Clean and Inspect 4625
Install 4625
Cooling System Repair 4626
Serpentine Belt 4626
Remove 4626
Inspect 4627
Install 4627
Adjust 4627
Water Pump 4628
Remove 4628
Install 4629
Thermostat 4630
Remove 4630
Inspect 4631
Install 4631
Flywheel and Flywheel Housing 4632
Flywheel 4632
Remove 4632
Install 4633
Flywheel Housing 4633
Remove 4633
Install 4633
Electrical Equipment Repair 4634
Alternator 4634
Remove 4634
Install 4635
Starter 4636
Remove 4636
Install 4636
Engine Specifications 4638
Engine Data 4638
Engine Tuning 4642
Cylinder Head 4642
Intake/Exhaust Valve and Guide 4642
Valve Spring 4643
Rocker Arm and Shaft 4643
Push Rod 4643
Gear Train and Camshaft 4643
Camshaft 4643
Idle Gear Shaft and Bushing 4643
Backlash of Each Gear 4644
Cylinder Block 4644
Crankshaft 4644
Piston 4644
Piston Ring 4645
Connecting Rod 4645
Rod Small End 4645
Tappet 4645
Oil Pump 4646
Engine Oil Pressure 4646
Outer Rotor Outside Clearance 4646
Outer Rotor Side Clearance 4646
Inner Rotor to Cover 4646
Standard Torque Specifications 4647
Standard Torque Chart 4647
Special Torque Specifications 4647
Special Tools 4649
550073240 1900YRM1620 (01 2023) US EN 4663
Proper Flushing after Major Hydraulic Repairs 4669
Introduction 4669
The Phases of Wear 4669
Causes of Hydraulic System Failure 4669
Progression of Contaminant Caused Hydraulic System Failure 4670
Hydraulic System Flushing Techniques 4670
Double Oil and Filter Change 4670
Mechanical Cleaning 4671
Cleaning of Components 4671
How to Clean Tubes and Hoses 4671
Filter Caddy 4671
Start-Up Procedure for Cleaned System 4672
Contaminated Oil Coolers 4672
Additional Filter Caddy Functions 4673
How to Handle Different Fluids 4673
Water Removal Filters 4673
Fluid Conditioning and System Flushing Procedures 4674
Operation of the Filter Caddy 4674
Filter Caddy operation 4674
Fluid Conditioning Procedure 4674
Filter Caddy Start-Up 4675
System Flushing Procedure 4675
Component Cleaning Procedure 4676
Reservoir Cleaning Procedure 4676
Cylinder Cleaning Procedure 4676
Hose and Tube Cleaning Procedure 4676
Valve Cleaning Procedure 4677
Front-End Attachment Cleaning Procedure 4678
System Flushing Procedure 4678
Filter Caddy Start-Up 4679
System Start-Up and Flushing 4679
Reservoir Fluid Cleaning Times 4680
Dealing With Different Fluid Types 4681
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4681
Filter Caddy Maintenance 4681
Servicing the Strainer 4681
DC Motor 4681
Hydraulic Oil Sampling Method and Procedure 4682
Hydraulic Oil Sampling Method 4682
Objective 4682
General Guidelines 4682
Synopsis 4683
Hydraulic Oil Analysis Report Guidelines 4684
Sampling Conditions 4684
Equipment 4684
Sampling Procedure 4685
Hydraulic Oil Sampling 4685
Sample Labeling 4685
Results Documentation 4685
550073240 1900YRM1620 (03 2020) UK EN 4687
Proper Flushing after Major Hydraulic Repairs 4691
Introduction 4691
The Phases of Wear 4691
Causes of Hydraulic System Failure 4691
Progression of Contaminant Caused Hydraulic System Failure 4692
Hydraulic System Flushing Techniques 4692
Double Oil and Filter Change 4692
Mechanical Cleaning 4693
Cleaning of Components 4693
How to Clean Tubes and Hoses 4693
Filter Caddy 4693
Start-Up Procedure for Cleaned System 4694
Contaminated Oil Coolers 4694
Additional Filter Caddy Functions 4694
How to Handle Different Fluids 4694
Water Removal Filters 4695
Fluid Conditioning and System Flushing Procedures 4695
Operation of the Filter Caddy 4695
Filter Caddy operation 4695
Fluid Conditioning Procedure 4696
Filter Caddy Start-Up 4696
System Flushing Procedure 4697
Component Cleaning Procedure 4697
Reservoir Cleaning Procedure 4697
Cylinder Cleaning Procedure 4697
Hose and Tube Cleaning Procedure 4698
Valve Cleaning Procedure 4698
Front-End Attachment Cleaning Procedure 4699
System Flushing Procedure 4699
Filter Caddy Start-Up 4700
System Start-Up and Flushing 4700
Reservoir Fluid Cleaning Times 4701
Dealing With Different Fluid Types 4701
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4701
Filter Caddy Maintenance 4702
Servicing the Strainer 4702
DC Motor 4702
Hydraulic Oil Sampling Method and Procedure 4702
Hydraulic Oil Sampling Method 4702
Objective 4702
General Guidelines 4702
Synopsis 4703
Hydraulic Oil Analysis Report Guidelines 4704
Sampling Conditions 4705
Equipment 4705
Sampling Procedure 4705
Hydraulic Oil Sampling 4705
Sample Labeling 4706
Results Documentation 4706
550096331 8000YRM1689 (03 2020) UK EN 4709
General Information About Diagrams and Schematics 4713
Symbol Definitions 4713
Diagrams Manual Applications 4714
Diagrams and Schematics 4716
550118420 8000YRM1904 (05 2022) US EN 4819
General Information About Diagrams and Schematics 4825
Symbol Definitions 4825
Diagrams Manual Applications 4826
Diagrams and Schematics 4828
550118420 8000YRM1904 (10 2020) UK EN 4937
General Information About Diagrams and Schematics 4941
Symbol Definitions 4942
Diagrams Manual Applications 4943
Diagrams and Schematics 4945
550148125 9000YRM2010 (05 2016) UK EN 5055
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 5061
Group 05 – Operational Checkout 5063
SECTION 9020 ENGINE 5069
Group 10 – Principles of Operation 5071
Group 03 – General Maintenance and Diagnostic Data 5081
Group 30 – Observed Symptoms 5085
SECTION 9030 ELECTRICAL SYSTEM 5091
Group 03 – General Maintenance and Diagnostic Data 5095
Group 10 – Principles of Operation 5101
Group 20 – Diagnostic Trouble Codes 5109
SECTION 9080 SUPPLEMENTARY DATA 5171
Group 50 – Abbreviations and Acronyms 5173
Group 60 – Special Tools List 5181
Group 70 – Fault Mode Indicator Reference 5183
550152439 0900YRM1951 (11 2019) UK EN 5187
General 5193
LPG Tank and Bracket 5193
LPG Tank, Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080-120VX) (K813) and GLC60-70VX (GLC135-155VX) (F879) 5193
Remove 5193
Install 5198
LPG Tank Bracket, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813), and GLC60-70VX (GLC135-155VX) (F879) 5199
Remove 5199
Install 5200
LPG Tank, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878) and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 5201
Remove 5201
Install 5203
LPG Tank Bracket, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 5203
Remove 5203
Install 5203
LPG Tank Bracket Alignment Pin, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813) and GLC60-70VX (GLC135-155VX) (F879) 5204
Remove 5204
Install 5205
Fuel Filter Unit 5206
Fuel Filter Element 5206
Remove 5206
Clean and Inspect 5207
Install 5207
Fuel Filter Housing, Lift Truck Models GLP60-70VX (GLP135-155VX) (F878), GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878), GLC60-70VX (GLC135-155VX) (F879), and GLP40VX5, GLP40-45VX6, GLP45SVX5, GLP50-55VX (GLP80-120VX) (K813) 5208
Remove 5208
Disassemble 5209
Clean and Inspect 5209
Assemble 5210
Install 5210
Fuel Filter Housing, Lift Truck Models GLP60-70VX (E878) 5210
Remove 5210
Disassemble 5212
Clean and Inspect 5213
Assemble 5213
Install 5214
Throttle Body 5214
Remove 5214
Clean 5216
Install 5216
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 5217
Remove 5217
Install 5218
Control System 5219
Engine Control Unit (ECU) 5219
Remove 5219
Install 5220
Low Pressure Switch 5220
Remove 5220
Install 5221
Low Fuel Sensor 5221
Remove 5221
Install 5222
LP Converter 5222
Remove and Disassemble 5222
Assemble and Install 5224
LPG Lock-Off 5225
Remove 5225
Install 5226
Exhaust System 5226
Counterweight Exhaust 5226
Remove and Disassemble Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 5226
Inspect 5228
Assemble and Install Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 5229
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 5229
Inspect 5230
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 5230
Overhead Exhaust 5231
Remove and Disassemble Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 5231
Inspect 5232
Assemble and Install Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 5233
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 5233
Inspect 5235
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 5235
Exhaust Manifold 5235
Remove 5235
Install 5236
Oxygen (HEGO) Sensor 5237
Remove 5237
Install 5237
LPG Fuel Testing 5237
General 5237
Available Fuel Tests 5238
Composition Test (ASTM D-2163) 5238
Ammonia Test (ASTM D-4490) 5238
Basic Nitrogen Test (ASTM UOP269-90) 5238
Residues Test (ASTM D-2158) 5238
Vapor Pressure Test (ASTM D-2598) 5238
Sulfur Compounds Test (ASTM D-5623) 5238
Methanol Test (ASTM D-4864) 5238
Copper Corrosion (ASTM D-1838) 5238
Where To Send LPG Fuel Samples For Testing 5238