Yale Forklift E878 (GPGLPGDP135VX, GPGLPGDP155VX) Service Manual PDF

Yale Forklift E878 (GPGLPGDP135VX, GPGLPGDP155VX) Service Manual – PDF DOWNLOAD

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Yale Forklift E878 (GPGLPGDP135VX, GPGLPGDP155VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5270
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift E878 (GPGLPGDP135VX, 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 (11 2017) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US EN 3959
550043871 0900YRM1556 (04 2018) US 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
550048401 0900YRM1570 (03 2015) US EN 4117
550055278 0100YRM1581 (05 2017) US EN 4147
General 4151
Description 4152
Side Covers, Seat, Dash, and Hood Replacement 4153
Side Covers 4153
Remove 4153
Install 4153
Seat and Seat Plate 4153
Remove Seat 4153
Remove Seat Plate 4153
Install Seat Plate 4157
Install Seat 4157
Operator Restraint System 4158
Emergency Locking Retractor (ELR) 4158
Seat Plate and Seat Rail Check 4158
Steering Column, Dash, Kick Panel, and Seal Plate 4158
Remove 4158
Install 4158
Hood Support and Door Assembly 4163
Remove 4163
Install 4163
Hood Door Assembly 4168
Remove 4168
Install 4168
Steering Column 4168
Description 4169
Steering Column Repair 4169
Remove 4169
Disassemble 4171
Clean 4172
Inspect 4172
Assemble 4172
Install 4172
LPG Tank and Bracket Assembly 4172
Counterweight Replacement 4172
Remove 4173
Install 4176
Tow Pin, Remove and Install 4176
Overhead Guard Replacement 4177
Remove 4177
Install 4177
Engine Replacement 4178
Remove Engine 4179
Remove Transmission 4201
Remove Engine and Transmission 4205
Install Engine 4208
Install Transmission 4212
Install Engine and Transmission 4214
Throttle Pedal and Cable Adjustment 4217
Exhaust System Repair 4218
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4218
GM 5 7L Engine for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909) 4218
Kubota 3 8L Diesel Engine for Lift Truck Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878, B909) 4218
Remove 4218
Inspect 4220
Install 4220
Kubota 3 6L Diesel Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4221
Remove 4221
Inspect 4221
Install 4221
Cummins QSB 3 3L Engine for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909) 4223
Remove 4223
Inspect 4223
Install 4223
4225
Diesel Particulate Filter 4225
Disassemble 4225
Clean and Inspect 4226
Differential Pressure Pipes and Hoses 4227
Assemble 4227
Cooling System 4228
Description 4228
Hydraulic Filter Assembly Repair 4228
Remove 4228
Install 4228
Fuel and Hydraulic Tanks Repair 4230
Inspect 4230
Clean 4230
Steam Method of Cleaning 4231
Chemical Solution Method of Cleaning 4231
Additional Preparations for Repair 4231
Small Leaks, Repair 4232
Large Leaks, Repair 4232
Preparations for Use After Repair 4232
Safety Labels 4232
550055279 0600YRM1579 (11 2019) US EN 4241
General 4247
Engine Identification 4247
Major Engine Component Identification 4247
Location of Labels 4247
Crankcase Description 4248
Engine Removal and Installation 4249
Cylinder Head Assembly Repair 4249
Valve Covers and Fuel Injectors 4249
Remove 4249
Clean and Inspect 4253
Install 4254
Rocker Arm Assembly 4255
Remove 4255
Disassemble 4257
Clean and Inspect 4257
Push Rods 4257
Rocker Arm Assembly 4257
Assemble 4258
Install 4258
Valve Clearance Adjustments 4258
Cylinder Head Assembly 4259
Remove 4259
Disassemble 4267
Valves and Valve Springs, Remove 4267
Valve Guides, Remove 4269
Clean and Inspect 4269
Cylinder Head 4270
Valve Guides 4270
Valves 4270
Valve Sink 4271
Valve Seat 4271
Valve Springs 4271
Assemble 4272
Valve Guides, Install 4272
Valves and Valve Springs, Install 4272
Install 4273
Timing Gear Case and Timing Gears Repair 4278
Timing Gear Case Cover 4278
Remove 4278
Clean and Inspect 4278
Install 4279
Timing Gears 4280
Crankshaft Gear 4280
Remove 4280
Install 4280
Idler Gear 4280
Remove 4280
Inspect 4281
Install 4281
Camshaft Gear 4281
Remove 4281
Install 4282
Timing Gear Case 4282
Remove 4282
Clean and Inspect 4283
Install 4283
Drive Train, Camshaft, and Cylinder Block Repair 4283
Remove 4283
Disassemble 4284
Pistons and Connecting Rods 4284
Crankshaft 4285
Camshaft 4287
Clean and Inspect 4288
Cylinder Block 4289
Honing and Boring 4291
Cylinder Correction (Oversize) 4292
Pistons 4292
Piston Pin 4293
Connecting Rod 4293
Tappets 4293
Crankshaft 4294
Camshaft 4296
Camshaft Bushing 4297
Assemble 4297
Camshaft 4297
Crankshaft 4297
Pistons and Connecting Rods 4297
Install 4299
Lubrication System Repair 4300
Engine Oil and Oil Filter Change 4300
Oil Pan 4301
Remove 4301
Install 4302
Oil Suction Tube 4302
Remove 4302
Clean 4303
Install 4303
Oil Pump 4303
Remove 4303
Clean and Inspect 4303
Outer Rotor Outside Clearance 4304
Outer Rotor to Inner Rotor Tip Clearance 4304
Outer Rotor Side Clearance 4304
Rotor Shaft Clearance 4305
Install 4305
Fuel System Repair 4306
Fuel Injectors 4306
Remove 4306
Inspect 4306
Clean 4306
Replace 4306
Install 4306
Electronic Throttle System 4306
Remove 4306
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) 4310
Bearing Replacement 4310
Install 4311
Adjustment 4312
Fuel Injection Pump 4312
Remove 4312
Disassemble 4316
Clean and Inspect 4318
Assemble 4318
Install 4319
Cooling System Repair 4320
Serpentine Belt 4320
Remove 4320
Inspect 4320
Install 4320
Serpentine Belt, Adjustment 4320
Water Pump 4321
Remove 4321
Install 4323
Thermostat 4324
Remove 4324
Inspect 4325
Install 4325
Flywheel and Flywheel Housing 4326
Flywheel 4326
Remove 4326
Install 4327
Flywheel Housing 4327
Remove 4327
Install 4327
Electrical Equipment Repair 4327
Alternator 4327
Remove 4327
Install 4328
Starter 4329
Remove 4329
Install 4329
Engine Specifications 4331
Engine Data 4331
Engine Tuning 4332
Cylinder Head 4332
Intake/Exhaust Valve and Guide 4333
Valve Spring 4333
Rocker Arm and Shaft 4333
Push Rod 4333
Gear Train and Camshaft 4334
Camshaft 4334
Idle Gear Shaft and Bushing 4334
Backlash of Each Gear 4334
Cylinder Block 4334
Crankshaft 4334
Piston 4335
Piston Ring 4335
Connecting Rod 4335
Rod Small End 4335
Tappet 4336
Oil Pump 4336
Engine Oil Pressure 4336
Outer Rotor Outside Clearance 4336
Outer Rotor Side Clearance 4336
Inner Rotor to Cover 4336
Standard Torque Specifications 4337
Standard Torque Chart 4337
Special Torque Specifications 4337
Special Tools 4339
550055281 8000YRM1583 (12 2018) US EN 4349
General 4355
Serial Number Data 4355
How to Move Disabled Lift Truck 4356
How to Tow Lift Truck 4356
How to Put Lift Truck on Blocks 4357
How to Raise Drive Tires 4357
How to Raise Steering Tires 4357
How to Clean a Lift Truck 4358
Maintenance Schedule 4359
Maintenance Procedures Every 8 Hours or Daily 4373
How to Make Checks With Engine Stopped 4374
Tires and Wheels 4374
Safety Labels 4374
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4374
Operator Restraint System 4375
Emergency Locking Retractor (ELR) 4375
Adjust Seat – Full Suspension 4376
Adjust Seat – Internal Suspension 4378
Seat Plate and Seat Rails 4378
Engine Compartment 4379
Paper Application 4379
Fuel, Oil, and Coolant Leaks, Check 4380
Hydraulic Hoses 4380
Coolant Hoses 4380
Steering Column Gas Cylinder 4380
Transmission 4380
Hydraulic System Oil 4380
Engine Oil 4381
Air Filter 4385
Forks 4385
Remove 4386
Inspect 4386
Install 4387
Adjust 4387
Hang On Sideshift Carriage 4387
How to Make Checks With Engine Running 4388
Indicator Lights, Horn, Fuses, and Relays 4388
Service Brakes 4391
Brake Oil Level 4391
Operation, Check 4391
Parking Brake 4391
Engine Oil Pressure 4392
Cooling System 4392
Steering System 4393
Control Levers and Pedals 4393
Lift System, Operate 4393
Air Filter 4394
Fuel/Water Separator Filter, Kubota Diesel Engine 4394
First Service After First 100 Hours of Operation 4394
4 3L Engine Oil and Oil Filter 4394
Kubota Diesel Engine Oil and Oil Filter 4395
Maintenance Procedures Every 250 Hours or 6 Months 4396
GM 4 3L Engine Oil and Oil Filter Change 4396
Kubota 3 6L Diesel Engine Oil and Oil Filter 4397
Drive Belt 4397
GM 4 3L Engine 4397
Fan and Alternator Drive Belt 4397
Drain Tar From LPG Converter 4398
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine With PSI Installed 4399
Maintenance Procedures Every 500 Hours or 6 Months 4400
Hydraulic System Oil 4401
Hydraulic Tank Breather 4402
Inspect 4402
Battery 4403
Kubota Diesel Engine Oil and Oil Filter 4403
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 4404
Remove 4404
Install 4404
Priming the Fuel System (Kubota 3 8L Engine) 4405
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 4406
Remove 4406
Install 4406
Priming the Fuel System (Kubota 3 6L Engine) 4407
Drive Belt 4407
Kubota Diesel Engine 4407
Fan and Alternator Drive Belt 4407
Clean Debris From Radiator Core 4408
Transmission Oil Breather/Dipstick 4408
Differential and Drive Axle Oil Level Check 4409
Forks 4411
Mast Lubrication 4412
Header Hose Checks 4416
Lift Chain Lubrication 4416
Tilt Cylinder Lubrication 4416
Master Brake Cylinder Rod End Pin Lubrication 4418
Manual Hydraulic Levers Lubrication 4418
Brake Oil 4418
Tie Rod Lubrication 4419
Parking Brake Adjustment 4420
Maintenance Procedures Every 1000 Hours or 6 Months 4421
Valve Clearance, Check and Adjust 4421
Valve Clearance, Check and Adjust, Kubota 3 6L Engine 4421
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 4421
Ignition System 4421
GM 4 3L Engine 4421
LPG Fuel Filter Element Replace, GM 4 3L Engine 4421
Remove 4421
Install 4422
In-Line Strainer Replacement, Kubota Diesel Engine 4422
Remove 4422
Install 4422
Lift Chains Wear Check 4424
Lift Chain Lubrication 4424
Hang On Sideshift Carriage, Check Sliding Surfaces 4424
Steering Axle Spindle Bearings 4427
Control Levers and Pedals 4428
Inspect Engine Electrical System, Connectors 4428
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 4428
Parking Brake Lever Lubrication, Wet Brake Axle 4432
Normal Operating Environment 4432
Heavy Duty or Contaminated Environment 4433
Remove 4433
Clean and Inspect 4434
Install 4434
Crankcase Breather Element, Kubota 3 8L Diesel 4435
Remove 4435
Clean and Inspect 4435
Install 4435
Maintenance Procedures Every 2000 Hours or Annually 4436
Hydraulic System 4436
Hydraulic Filter Assembly, Replace 4436
Install 4437
Hydraulic Tank Breather, Replace 4438
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 4440
Cooling System Check 4440
Air Filter 4441
Gasoline Fuel Filter 4443
Remove and Replace 4443
Gasoline Fuel Injector, GM Engines 4443
Fuel Injector, Kubota 3 8L Engine 4443
Fuel Injector, Kubota 3 6L Engine 4443
Forks 4444
Brake Oil (Master Cylinder), Change 4444
Check Throttle Shaft for Sticking 4445
Inspect Exhaust Manifold and Piping for Leaks 4445
Transmission Automatic Clutch Calibration 4445
Wheel Bearings 4445
Steer Wheels, Lubrication 4445
Maintenance Procedure Every 3000 Hours 4446
Diesel Particulate Filter 4446
Remove 4446
Disassemble 4448
Servicing the Diesel Particulate Filter 4449
Assemble 4449
Install 4450
Maintenance Procedures Every 4000 Hours or 2 Years 4450
Hydraulic Oil, Replace 4451
Safety Procedures When Working Near Mast 4452
Fuel Filter Water Removal 4455
Kubota Diesel Engine 4455
3 8L Diesel Engine 4455
3 6L Diesel Engine 4456
Lift Chain Adjustments 4457
Jump-Starting the Lift Truck 4458
Jump-Starting Using a Battery Charger 4458
Jump-Starting a Lift Truck Using Another Lift Truck 4459
Welding Repairs 4459
Overhead Guard Changes 4459
Wheel and Tire Replacement 4460
General 4460
Pneumatic Tire With Tube, Repair 4460
Remove Wheels From Lift Truck 4460
Remove Tire From Wheel 4460
Install Wheel in Tire 4463
Install Tire on Two-Piece Wheel 4465
Adhesives and Sealants 4466
550055282 8000YRM1584 (06 2019) US EN 4469
Lift Truck Lifting Capacity 4473
Counterweight Weights 4473
Tire Sizes 4473
Capacities 4473
Electrical System 4477
Transmission Oil Pressures 4478
Hydraulic System Relief Pressures 4479
Steering System 4480
Stall Speeds (in RPM ±100 rpm) 4480
GM 4 3L Gas GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4480
GM/PSI 4 3L LPG GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4480
Kubota 3 6L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4481
Kubota 3 8L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4481
Mast Speeds 4481
Tilt Angles 4482
Front End Equipment – Mast Creep 4482
Mast Creep 4482
Engine Specifications 4483
Diesel Fuel Cleanliness Levels 4485
Torque Specifications 4485
Frame 4485
Mast, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4485
Hang On Sideshift Carriage With Fork Positioner, Lift Truck Models Manufactured After August, 2012GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 4486
Steering System 4486
Transmission 4486
Engine – GM/PSI 4 3L 4486
Engine – Kubota 3 6L Diesel 4487
Engine – Kubota 3 8L Diesel 4488
550055283 8000YRM1585 (07 2020) US EN 4491
General Information About Diagrams and Schematics 4495
Symbol Definitions 4495
Diagrams Manual Applications 4496
Diagrams and Schematics 4498
550059479 0600YRM1590 (07 2019) US EN 4587
General 4593
Engine Identification 4593
Major Engine Component Identification 4593
Location of Labels 4594
Crankcase Description 4594
Precautions Before Beginning Repair 4595
Exhaust System and DPF 4596
Engine Removal and Installation 4596
Cylinder Head Assembly Repair 4597
Valve Covers and Fuel Injectors 4597
Remove 4597
Clean and Inspect 4600
Install 4600
Rocker Arm Assembly 4601
Remove 4601
Disassemble 4602
Clean and Inspect 4602
Push Rods 4602
Rocker Arm Assembly 4602
Assemble 4603
Install 4603
Valve Clearance Adjustments 4603
Cylinder Head Assembly 4604
Remove 4604
Disassemble 4613
Valves and Valve Springs, Remove 4613
Valve Guides, Remove 4614
Clean and Inspect 4614
Cylinder Head 4615
Valve Guides 4615
Valves 4615
Valve Sink 4616
Valve Seat 4616
Valve Springs 4617
Assemble 4617
Valve Guides, Install 4617
Valves and Valve Springs, Install 4618
Install 4619
Timing Gear Case and Timing Gears Repair 4621
Timing Gear Case Cover 4621
Remove 4621
Clean and Inspect 4622
Install 4622
Timing Gears 4623
Crankshaft Gear 4624
Remove 4624
Install 4624
Idler Gear 4624
Remove 4624
Inspect 4625
Install 4626
Camshaft Gear 4626
Remove 4626
Install 4626
Drive Train, Camshaft, and Cylinder Block Repair 4626
Remove 4626
Disassemble 4627
Pistons and Connecting Rods 4627
Crankshaft 4628
Camshaft 4630
Clean and Inspect 4632
Cylinder Block 4632
Honing and Boring 4634
Cylinder Correction (Oversize) 4635
Pistons 4635
Piston Pin 4636
Connecting Rod 4636
Tappets 4637
Crankshaft 4637
Camshaft 4639
Camshaft Bushing 4640
Assemble 4640
Camshaft 4640
Crankshaft 4640
Pistons and Connecting Rods 4641
Install 4643
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 4643
Lubrication System Repair 4646
Engine Oil and Oil Filter Change 4646
Oil Pan 4647
Remove 4647
Install 4648
Oil Suction Tube 4649
Remove 4649
Clean 4649
Install 4649
Oil Pump 4649
Remove 4649
Clean and Inspect 4650
Outer Rotor Outside Clearance 4651
Outer Rotor to Inner Rotor Tip Clearance 4651
Outer Rotor Side Clearance 4651
Rotor Shaft Clearance 4652
Install 4652
Fuel System Repair 4653
Fuel Injectors 4653
Remove 4653
Inspect 4653
Clean 4653
Replace 4653
Install 4653
Test 4653
Fuel Injection Pump 4654
Remove 4654
Clean and Inspect 4655
Install 4655
Cooling System Repair 4656
Serpentine Belt 4656
Remove 4656
Inspect 4657
Install 4657
Adjust 4657
Water Pump 4658
Remove 4658
Install 4659
Thermostat 4660
Remove 4660
Inspect 4661
Install 4661
Flywheel and Flywheel Housing 4662
Flywheel 4662
Remove 4662
Install 4663
Flywheel Housing 4663
Remove 4663
Install 4663
Electrical Equipment Repair 4664
Alternator 4664
Remove 4664
Install 4665
Starter 4666
Remove 4666
Install 4666
Engine Specifications 4668
Engine Data 4668
Engine Tuning 4672
Cylinder Head 4672
Intake/Exhaust Valve and Guide 4672
Valve Spring 4673
Rocker Arm and Shaft 4673
Push Rod 4673
Gear Train and Camshaft 4673
Camshaft 4673
Idle Gear Shaft and Bushing 4673
Backlash of Each Gear 4674
Cylinder Block 4674
Crankshaft 4674
Piston 4674
Piston Ring 4675
Connecting Rod 4675
Rod Small End 4675
Tappet 4675
Oil Pump 4676
Engine Oil Pressure 4676
Outer Rotor Outside Clearance 4676
Outer Rotor Side Clearance 4676
Inner Rotor to Cover 4676
Standard Torque Specifications 4677
Standard Torque Chart 4677
Special Torque Specifications 4677
Special Tools 4679
550073240 1900YRM1620 (01 2023) US EN 4693
Proper Flushing after Major Hydraulic Repairs 4699
Introduction 4699
The Phases of Wear 4699
Causes of Hydraulic System Failure 4699
Progression of Contaminant Caused Hydraulic System Failure 4700
Hydraulic System Flushing Techniques 4700
Double Oil and Filter Change 4700
Mechanical Cleaning 4701
Cleaning of Components 4701
How to Clean Tubes and Hoses 4701
Filter Caddy 4701
Start-Up Procedure for Cleaned System 4702
Contaminated Oil Coolers 4702
Additional Filter Caddy Functions 4703
How to Handle Different Fluids 4703
Water Removal Filters 4703
Fluid Conditioning and System Flushing Procedures 4704
Operation of the Filter Caddy 4704
Filter Caddy operation 4704
Fluid Conditioning Procedure 4704
Filter Caddy Start-Up 4705
System Flushing Procedure 4705
Component Cleaning Procedure 4706
Reservoir Cleaning Procedure 4706
Cylinder Cleaning Procedure 4706
Hose and Tube Cleaning Procedure 4706
Valve Cleaning Procedure 4707
Front-End Attachment Cleaning Procedure 4708
System Flushing Procedure 4708
Filter Caddy Start-Up 4709
System Start-Up and Flushing 4709
Reservoir Fluid Cleaning Times 4710
Dealing With Different Fluid Types 4711
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4711
Filter Caddy Maintenance 4711
Servicing the Strainer 4711
DC Motor 4711
Hydraulic Oil Sampling Method and Procedure 4712
Hydraulic Oil Sampling Method 4712
Objective 4712
General Guidelines 4712
Synopsis 4713
Hydraulic Oil Analysis Report Guidelines 4714
Sampling Conditions 4714
Equipment 4714
Sampling Procedure 4715
Hydraulic Oil Sampling 4715
Sample Labeling 4715
Results Documentation 4715
550073240 1900YRM1620 (03 2020) US EN 4717
Proper Flushing after Major Hydraulic Repairs 4721
Introduction 4721
The Phases of Wear 4721
Causes of Hydraulic System Failure 4721
Progression of Contaminant Caused Hydraulic System Failure 4722
Hydraulic System Flushing Techniques 4722
Double Oil and Filter Change 4722
Mechanical Cleaning 4723
Cleaning of Components 4723
How to Clean Tubes and Hoses 4723
Filter Caddy 4723
Start-Up Procedure for Cleaned System 4724
Contaminated Oil Coolers 4724
Additional Filter Caddy Functions 4724
How to Handle Different Fluids 4724
Water Removal Filters 4725
Fluid Conditioning and System Flushing Procedures 4725
Operation of the Filter Caddy 4725
Filter Caddy operation 4725
Fluid Conditioning Procedure 4726
Filter Caddy Start-Up 4726
System Flushing Procedure 4727
Component Cleaning Procedure 4727
Reservoir Cleaning Procedure 4727
Cylinder Cleaning Procedure 4727
Hose and Tube Cleaning Procedure 4728
Valve Cleaning Procedure 4728
Front-End Attachment Cleaning Procedure 4729
System Flushing Procedure 4729
Filter Caddy Start-Up 4730
System Start-Up and Flushing 4730
Reservoir Fluid Cleaning Times 4731
Dealing With Different Fluid Types 4731
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4731
Filter Caddy Maintenance 4732
Servicing the Strainer 4732
DC Motor 4732
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 4735
Equipment 4735
Sampling Procedure 4735
Hydraulic Oil Sampling 4735
Sample Labeling 4736
Results Documentation 4736
550096331 8000YRM1689 (03 2020) US EN 4739
General Information About Diagrams and Schematics 4743
Symbol Definitions 4743
Diagrams Manual Applications 4744
Diagrams and Schematics 4746
550118420 8000YRM1904 (05 2022) US EN 4849
General Information About Diagrams and Schematics 4855
Symbol Definitions 4855
Diagrams Manual Applications 4856
Diagrams and Schematics 4858
550118420 8000YRM1904 (10 2020) US EN 4967
General Information About Diagrams and Schematics 4971
Symbol Definitions 4972
Diagrams Manual Applications 4973
Diagrams and Schematics 4975
550148125 9000YRM2010 (05 2016) US EN 5085
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 5091
Group 05 – Operational Checkout 5093
SECTION 9020 ENGINE 5099
Group 10 – Principles of Operation 5101
Group 03 – General Maintenance and Diagnostic Data 5111
Group 30 – Observed Symptoms 5115
SECTION 9030 ELECTRICAL SYSTEM 5121
Group 03 – General Maintenance and Diagnostic Data 5125
Group 10 – Principles of Operation 5131
Group 20 – Diagnostic Trouble Codes 5139
SECTION 9080 SUPPLEMENTARY DATA 5201
Group 50 – Abbreviations and Acronyms 5203
Group 60 – Special Tools List 5211
Group 70 – Fault Mode Indicator Reference 5213
550152439 0900YRM1951 (11 2019) US EN 5217
General 5223
LPG Tank and Bracket 5223
LPG Tank, Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080-120VX) (K813) and GLC60-70VX (GLC135-155VX) (F879) 5223
Remove 5223
Install 5228
LPG Tank Bracket, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813), and GLC60-70VX (GLC135-155VX) (F879) 5229
Remove 5229
Install 5230
LPG Tank, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878) and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 5231
Remove 5231
Install 5233
LPG Tank Bracket, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 5233
Remove 5233
Install 5233
LPG Tank Bracket Alignment Pin, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813) and GLC60-70VX (GLC135-155VX) (F879) 5234
Remove 5234
Install 5235
Fuel Filter Unit 5236
Fuel Filter Element 5236
Remove 5236
Clean and Inspect 5237
Install 5237
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) 5238
Remove 5238
Disassemble 5239
Clean and Inspect 5239
Assemble 5240
Install 5240
Fuel Filter Housing, Lift Truck Models GLP60-70VX (E878) 5240
Remove 5240
Disassemble 5242
Clean and Inspect 5243
Assemble 5243
Install 5244
Throttle Body 5244
Remove 5244
Clean 5246
Install 5246
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 5247
Remove 5247
Install 5248
Control System 5249
Engine Control Unit (ECU) 5249
Remove 5249
Install 5250
Low Pressure Switch 5250
Remove 5250
Install 5251
Low Fuel Sensor 5251
Remove 5251
Install 5252
LP Converter 5252
Remove and Disassemble 5252
Assemble and Install 5254
LPG Lock-Off 5255
Remove 5255
Install 5256
Exhaust System 5256
Counterweight Exhaust 5256
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) 5256
Inspect 5258
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) 5259
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 5259
Inspect 5260
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 5260
Overhead Exhaust 5261
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) 5261
Inspect 5262
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) 5263
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 5263
Inspect 5265
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 5265
Exhaust Manifold 5265
Remove 5265
Install 5266
Oxygen (HEGO) Sensor 5267
Remove 5267
Install 5267
LPG Fuel Testing 5267
General 5267
Available Fuel Tests 5268
Composition Test (ASTM D-2163) 5268
Ammonia Test (ASTM D-4490) 5268
Basic Nitrogen Test (ASTM UOP269-90) 5268
Residues Test (ASTM D-2158) 5268
Vapor Pressure Test (ASTM D-2598) 5268
Sulfur Compounds Test (ASTM D-5623) 5268
Methanol Test (ASTM D-4864) 5268
Copper Corrosion (ASTM D-1838) 5268
Where To Send LPG Fuel Samples For Testing 5268